Document jgwkjN9YdN8bOdD69XpJLJ3by

IfetiH lM Ki SGP-EDC-GHC-VC-L/T STG WRITTEN 3Y: PULLEM QAT APPROVED 3Y: DKP DATE: 01/13/92 This SOP is a uniform procedure used throughout Derivatives to ensure that the appropriate steps are taken prior to removing from service or bypassing an alarm, instrument, o_ shut down system automatic valve. This SOP provides a., effective way of communicating the status of these instruments to others and makes sure that the necessary steps are taken to correct the problem. This procedure applies to all pressure, temperature, flow, level, analyze-., etc. instrumentation and the associated control valves. This SOP is modified for VCM-II. ACTION STEPS (Capital letters) and Comments (Small letters)1 2 1. IF AN ALARM, INSTRUMENT, OR SHUT DOWN SYSTEM MALFUNCTIONS, THE OPERATOR'S FIRST RESPONSE SHOULD BE AN ATTEMPT TO FIX.IT. In every circumstance, the first response should be a reasonable effort toward correcting the cause of the problem. Operating without alarms, instrumentation, or down system valves introduces a level of risk that _s desirable. shat 2. CHECK TO MAKE CERTAIN WHAT PRIORITY THE ALARM, INSTRUMENT, OR CONTROL VALVE FALLS INTO: Check the list of alarms attached in the unit SOP manual determine what the priority of the alarm is. The pi. .. system description follows: Priority - Critical instruments whose failure would c_wh_cause or fail to inform of situations causing accideara; fire, explosion, uncontrolled release of dangerous materials, reportable environmental releases, or major' property or production loss. These alarms induce iru; which have been mandated by outside agencies (RCRA, EF'A, DEQ, Consent Decree), also Operations Review Committey (ORC) reliability alarms, and alarms deemed critical byoperations supervision. All of these alarms are on id prooftesting schedule. Priority 2 - Critical instruments whose failure could- = _ : cause or fail to inform of serious conditions involvi... recordable environmental releases, property or produe!...... losses, or other non-life threatening situations. Thes^ are slightly lower priority alarms which are also oh ----- V* proof testing schedule. `-`Du::: '`o f >1 v t, CONFinF.NTlAI.: Subject to l'rot vet: i. 'r. order of 14th Judicial District Court No. 91-1149 SL 003586 U ft) P `r* \> '> ^ ^ 7. ^ ** ^ ** *-** u^ k*1 y r* 'V; * r; o f U) o * Priority 3. - Al 1 other alarms, which are not on the proof testing schedule. For VCM-II, priority 3 includes control valves which are not tied directly into a 52S. Note: Operations will treat priority 1 and 2 alarms m identical fashion. The only reason that these are differentiated is for the sake of the prooftesting program. an IF THE ALARM, INSTRUMENT, OR CONTROL VALVE IS PRIORITY 1 OR 2, GO TO STEP #5. IF THE ALARM IS PRIORITY 3, GO TO STEP #3. 3- RESPONSE TO PRIORITY 3 ALARMS AND BYPASSED CONTROL VALVES. LEAD OPERATORS SHOULD USE THEIR KNOWLEDGE OF THE UNIT TO EVALUATE EACH SITUATION AND DECIDE WHETHER THE INSTRUMENT OR CONTROL VALVE CAN BE BYPASSED SAFELY. If there is any doubt about the choice, consult supervision. These alarms and instrumentation are not considered cntioa. under normal conditions. 4. THE LEAD OPERATOR SHOULD FILL OUT A YELLOW OUT-OF-SERVICE TAG FOR BYPASSED CONTROL VALVES ONLY. A TAG DOES NOT HAVE TO BE FILLED OUT FOR PRIORITY 3 ALARMS. Immediate action is ta .be. taken., to initiate, repairs, on instrumentation. This means at least a note in the maint. logbook so that the problem will not be forgotten. STOP HERE FOR PRIORITY 3 ITEMS. 5. RESPONSE TO PRIORITY 1 OR 2 ALARMS. RCRA, EPA, CONSENT DECREE, OR CRITICAL ALARMS, INSTRUMENTATION OR SHUT DOWN SYSTEM AUTOMATIC VALVES. NOTIFY YOUR LEAD OPERATOR OF THE SITUATION. No one except the unit lead operator or supervisor has the authority to approve taking an alarm out of service. THE LEAD OPERATOR WILL DECIDE IF IT IS SAFE TO TAKE THE INSTRUMENT OUT OF SERVICE. IF IT IS SAFE TO DO SO, THE LEAD OPERATOR WILL COMPLETE AN "OUT-OF-SERVICE" TAG AND MOUNT IT ON THE CONTROL PANEL. HE WILL ALSO MAKE NOTE IN THE OPERATIONS LOGBOOK TO EXPLAIN THE DETAILS OF WHAT HAS BEEN DONE AND WHY IT WAS NECESSARY. IF, IN THE LEAD OPERATOR'S OPINION, IT IS NOT SAFE TO DO SO, SUPERVISION SHOULD BE CONSULTED. The out-of-service tag is intended to be a communications tool for notifying other people that Priority 1 or 2 alaims are out of service or a control valve is bypassed. These tags should be affixed to the instrument on the control panel or, if this is not possible, in another prominent place on the control panel. These out-of-service tags will remain on the board until the situation is corrected. There are circumstances during routine operations when son of these alarms or valves need to be taken out of service for short P.eriods of time to perform short term routine woik on the system. Some examples of this include the following. (1). Pulling alarm cards at EDC I to look for a "mystery alarm". (2). Taking alarms out of service on the computer at VCH II long enough to identify them on the CRT display. (3). When an operator and log book instrument man yt outside to look at a shut down system valve that sticking. (4). When GKC analyzers are bypassed for preventive , maintenance work. Under these and other similar circumstances it would not normally be worth.the effort to complete an out-of-servi tag. For these short-term situations it will be accap.ab^ practice for the alarm, instrument, or control valve tv taken out of service provided that both of the following criteria are met: i) The lead operator is informed of the situation and gives approval. 2} The operator gives undivided attention to this probiem. If both of these cannot be met, then the out-of-service tag must be used regardless of the length of time required for the work to be done. The out-of-service tags are not a substitute for performing maintenance. The out-of-service tags serve only to communicate the status of instruments, in need of, repair. 8. TAKE IMMEDIATE ACTION TO INITIATE REPAIRS ON THE OUT-OFSERVICE INSTRUMENT. 003587 After a priority 1 or 2 alarm, instrument, or control valve has been properly taken out-of-service or bypassed, it should not be forgotten. On day shift this may require redirecting the maintenance logbook priorities, or notifying supervision so an "Emergency" work order can be written. In the back shifts and during holidays, this may mean notifying the shift supervisor to get shift mechanics or call out instrument mechanics so that the repairs can be made in a timely fashion. In either case it is strongly recummendcc ( that repairs be started as soon as practical. . ) Ordering "Out-of-Service" tags. These tags are set up in our reproduction department with a form number (59A-6) so., that day shift operators can reorder these by telephone. * 9. WHEN THE REPAIRS ARE SUCCESSFULLY COMPLETED AND THE ALARM., , INSTRUMENT, OR CONTROL VALVE IS PUT BACK INTO SERVICE, THE ' LEAD OPERATOR WILL REMOVE THE OUT-OF-SERVICE TAG FROM THE BOARD, TAPE IT INTO THE LOGBOOK, AND COMPLETE THE BOTTOM SECTION OF THE OUT-OF-SERVICE TAG. ,i .10. A "WEEKLY OUT-OF-SERVICE TAGGING CHECKLIST" WILL BE COMPLETLL BY EACH UNIT ON MONDAY MORNING GRAVEYARD SHIFT TO CONFIRM THAT THE PANEL ALARMS AND LIGHTS ARE IN WORKING ORDER.AND THAT ALL OF THE OUT-OF-SERVICE ALARMS, INSTRUMENTATION ,* AND CONTROL VALVES HAVE BEEN PROPERLY TAGGED ACCORDING TO . THIS SOP. THE UNIT FOREMAN FILES THESE CHECKLISTS FOR 3 YEARS TO MAINTAIN A RECORD*IN THE EVENT OF AUDITS BY ENVIRONMENTAL AGENCIES. ' CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court . No. 91-1145 The objective of the weekly checklist is to routinely take an inventory of the out-of'service tagging which has ceer. done and to correct all tagging deficiencies on the spot. Each individual unit will make up a detailed checklist whil^P will be entitled "Weekly Out-of-Service Tagging Checklist". During this weekly inventory, the audible and visual alarms -should be proven to be in working order. A check of all of the out-of-service tags on the panel will be made to insure that they all have been done correctly. Also a cross-check in the field will be made to insure that no bypassed SDS automatic valve has been overlooked. All tagging discrepancies which are found should be corrected on the spot by following step #11 below. 11. IF A PROBLEM IS IDENTIFIED DURING THE WEEKLY CHECKLIST WHICH HAS NOT BEEN PROPERLY "OUT-OF-SERVICE" TAGGED, THE DEFICIENCY MUST BE CORRECTED IMMEDIATELY. RETURN TO STEP #1 ABOVE AND FOLLOW THIS SOP TO INSURE THAT EACH ITEM IS PROPERLY OUT-OF-SERVICE TAGGED. 12. THESE CHECKLISTS WILL BE REVIEWED BY THE UNIT SUPERVISORS AND AREA SUPERVISOR, INITIALLED, AND FILED FOR 3 YEARS. SL 003588 CONF1DEHTIAL: Subject to Protective Order ct Court of l*th judicial Dr&tr- No. 91-H*5