Document r6pjVMzK9oB3zjvzmZjEBg67e

(jBiiERAL SAFELY INSTRUCTIONS APPLYING TO ALL EQUIPMENT 4"ifteen General Safety Instruction Sheets cite the hazards that ^ ,in the operation and maintenance of equipment and give recommenda- oiding hazards and for inspections and tests, ' j|t three sheets apply generally to all equipment,, jHai hazards and recommendations that-are peculiar to a class or type 7are given on the following sheets (4 to 15) applying to the more im- .tifications of equipment, lliarly significant or unusual hazards, recommendations, inspections or I*~ to a specific item of equipment should be given on the Safety In set made out for that particular item, . \ HAZARDS llisral hazards to be considered in the operation of all process plant include: . 1 j, j>g condition due to defects existing 'in equipment as built or as re- ffii, ' Injure or unsafe condition of equipment due to operation at pressure, 1n|>erature, speed, minimum thickness, or other condition in excess of Jbbstablished safe limits, . *- -- - - fife condition resulting from corrosion (internal or external) reduo- fijthickness below the minimum allowable limit. This may.occur from Ifflfct attack or result from failure of protective linings, jacking or deterioration caused by caustic embrittlement, hydrogen atlaStf intergranular corrosion, or stress-corrosion, fligue failures occasioned'by vibration or repeated stress. pfttotion of strength, of ductility, or of impact resistance, and/or the lifting up of high residual stress as a result of improper welding or |<||ti:ng operations, i|asafe condition or failure due to thermal stresses occasioned by exceed-] " ' established limiting rates of temperature change - during heating, l&ijling, or operating cycles. jA . . JMessivs strain or failure at rigid connections due to heating of lines H^equipment above design temperatures for which expansion provision is ~de, ir 8"afe condition or failure of reoiprooating or rotating machines, or btors due to operation at speeds or overloads in excess of design lim~ Ms. iP- , jgSllure, .inadequacy or blocking-off of excess pressure relieving equip- or other automatic safety devices, * .,,,-.??ssive pressure caused by thermal expansion of liquid in filled lines,| j|?sels, pumps, containers, etc. - "sun pressure". age to equipment caused by testing at pressures in excess of estab- limits, testing at too low temperatures, or from excess loading |||ue to weight of testing medium, . Release of flammable, poisonous, or corrosive gases or liquids due to ||ilure of equipment from any cause. PLAINTIFF'S EXHIBIT CHV-509 '8 Q CO ::s t s GENERAL SAFETY INSTRUCTION SHEET Applying To All Equipment ME-5102 Sheet 1 _--~ fl s4 /* /- IPIeHBRAL SAFETY INSTRUCTIONS APPLYING-TO ALL EQUtPMENI- ' HAZARDS (Coat'd.) ' .. - He at threaded or gasketed joints,-or at packing glands of pumps, fl'ssors, valves, level controls 'and instruments. . ||^. 0f relief valves that are not equipped with, discharge conduits at a safe location, Jr -/ ftive mixtures in equipment caused by the failure of control valves, ^operated..valves, cyole timers, etc. JgTgtS^ * Iggpee of towers, columns, stacks, tanks, etc,, under wind or earth ilfloading due. to corrosion below minimdm safe thickness or deterio- pEof foundations, supports,- or guys. ||se of equipment due to external pressure loading- in exoess of de limits of pressure, thickness or roundness. ' , if. RECOMsENDAIIONS FOR AVOIDING HAZARDS ' :exceed the safe limits for ary equipment in operation, cleaning lintenance as given in: Je)Safety Instruction Sheets, iterating Standards and applicable Standing Orders. 'inery and Engineering Instructions. Iles and Standards authorized for refinery use, and itory State Safety Orders, -the Engineering Division - Design Engineer, Maintenance Foreman, puipment Inspector as the case may require, whenever there, is any |ion as to the safety of equipment, or danger of exceeding estab- 3d- safe limits. Khe inspection of all critical repairs and new equipment installa- _g:the mechanical condition and functioning of instruments and control >|ment at regular intervals as required to assure dependable and safe ||ion. -. gajl'b the Engineering Division, before changing any established safe |gs`for the operation of equipment. ' SHr' . INSPECTIONS !|j|ain adequate periodic inspection of equipment i:a accordance with: J& Equipment Inspection Schedule for the plant; or in lieu |||.such schedule, as recommended in the Safety Instruction Sheets, 1|L - M}^irments of State Safety Orders for periodic inspection fli0ilers, air pressure tanks, elevators and mechanical IRipment. CHEV GENERAL SAFETY INSTRUCTION SHEET Applying To All Equipment ME-5102 Sheet 2 - .... S-45 GENERAL SAFETY INSTRUCT I OHS. APPLYING TO ALL EQUIPMENT INSPECTIONS (Conk'd.) ' mm' |See that adequate maintenance schedules are established and followed ff0T the servicing and inspection of: . ' ' . , ! ' l Electrical equipment - motors and controls; power'circuits; lighting service* control systems*, and signals and alarms, pf. Mechanical equipment - pumps, turbines, compressors, etc., * and their governors and protective devices. Po, Instruments and control equipment, particularly those which ' are vital to controlling operation within established safe limits. , ' ' Hjuring initial operation of equipment maintain close inspection of; Effects of thermal expansion on line systems, and lines stairs and ladders connecting to hot vessels for re stricted movement, interference, or. evidence of exy cessive strain, gb;.- Bearings, shaft packing, and governors on mechanical ' . equipment. > Electrical equipment for overloads, heating, sources of ignition, and for proper functioning of controls, alarms, js:, and protective' devices, .i . TESTS ' Jest all equipment after any major repair affecting the strength of Ithe equipment, pest certain equipment, as fired heater coils, at specified intervals as polled for in the Equipment Inspeotion Schedules or as specifically refo'ommended in the Safety Instruction Sheets. W~'' H,Ke test pressure for routine field tests of equipment shall be as given In;,the Safety Instruction Sheets, . war^ud> rostatic testing procedure shall conform to Engineering Instruction 500 and SOI or as given on speoial Hydrostatic Test Schedules prepared Sfbr particular installations. |pnsult the Engineering Division before applying apy pneumatic test,. . |Aotual tests applied during shop fabrication or field construction are p-iven. on the Safety Instruction Sheets or on Hydrostatic Test Schedules Tjwepared to cover initial testing, iS|B0Ts> tost and reset safety or relief valves protecting the equipment *:-frequenoies given in the Equipment Inspeotion Schedule for the plant, l-3-eu I&eeta, such a sohedule as reoommended on the Safety Instruction . GENERAL SAFETY INSTRUCTION SHEET Pi Applying To 'All Equipment ME-S102 Sheet 3 S-45. ______________ 'jj$pr ipM: &K.VV illffe GENERAL SAFETY INSTRUCTIONS APPLYING TO PROCESS .LINES HAZARDS The hazards that are particularly to be oonsid&red in the operation of lines include: .' 1 - rCt' ''1**: CD Those hazards listed in the General .Safety Instructions Applying to All ||; Equipment which apply to piping systems. ft It Hydraulic shock from rapid closing of valves, jTv Excessive vibration or repeated strain leading to fatigue failure. if Exceeding design limits for expansion or anchorage of lines or alteration! of supports, anchors, tie rods, hangar adjustments, initial "cold pull", etc. . J; Failure of gaskets or packing due to deterioration, corrosion or exceed|{1ihg pressure or temperature limits for the paoking material. wM' -V IlffLeakage or failure due to external oorrosion - both general and localized conditions, and particularly buried lines - electrolysis and soil corro sion. .' ' I'Breakage of threaded piping especially small sizes due to mechanical ^strains, thermal expansion, operating valves, etc. !(V. . - .Excessive stress in welded piping at supports, mitre welds, tee Inter sections, etc. leading .to opening of cracks. Particularly important in ilin.es: with high internal pressure; subject to severe thermal expansion ^strains- in low temperature service; hot caustic service; or of alloy J|steel materials. * (internal combustion or explosions in lines. IfifFire hazard from ignition, of flammable materials (timber, paper insula tion sheathing, etc.) located too close to high temperature lines. JjV -- JRelease of flammable, poisonous or corrosive liquids or vapors due to relaxation of flange bolts at high temperatures or sudden temperature change) 'of_flanged joints, or oorrosion or erosion of pyrometer or thermometer !*rells in lines. RECOS3NDAIIONS FOR AVOIDING HAZARDS pote recommendations in the General Instructions Applying to All Equipggent. parm up lines gradually and avoid sudden temperature change except in an Igliergency. ii^^ain supports, anchorages, spring hangars, tie rods, etc, in proper ig^gdition and with specified adjustments. Consult Engineering Division ;01>s altering supports or adjustments, I GENERAL SAFETY INSTRUCTION SHEET Process Lines --.S-45 ME-5102 Sheet 4 CHEV B8 6420 ^ SAFETY INSTRUCTIONS APPLYING TO PROCESS LiEEo HEcOITSljLAIIONS FOR AVOIDING HAZARDS (Coat'd.) S- , Mock off sections full of liquid without venting or draining, S^ct dead ends or idle lines against, freezing by insulating, draining |||Sy maintaining flew. , Race installed pipe and fittings in kind, o^in accordance with pllrials Standard No, 319, or per recommendations of the engineering |||iislon before reconnecting dead or idle lines, particularly if buried. Kect lines against mechanical strains during maintenance operations, fairw: ' ^'act 18-8 Cr. Ni. and 18-8-3 Cr. Ni. Mo. material against intergranu- |pcorrosion during idle periods. Refer to Recommended Practice No.124.| ^erwe all precautions given in Engineering Instructions on maintenanc ^^'installation practice including: No, 800 - Bolting Up Practice? ice |p-gj_0 - Fitting"Up Fabricated Pipe* No, 506 - Installing Gaskets? |||4'656 - Breaking Lines. iirve all precautions given in Engineering_ Instructions covering weld- fie* practice and requirements for stress relief, annealing or heat treat-! welded piping - both steel and alloy. E. otherwise stated, maximum, allowable operating pressures and tem- IIrIatpuarertsicufolar rnecwlaslisneosf fsihtotiunldg caonndforsmertvoice.M. atTehriealsratSintagnsdagrdiveNno.th3e19refinor ff-tased on the A.S.A. Standards and Piping Code. Si-L- .I Mre not specifically given, the minimum safe thicknesses for steel pipe g^Wercial sizes of A.S.A. steel fittings, can be determined from I th ic- kness c-har-ts: --MF-4 0*2-3, s'tee'l lines? MF-4639, steal fittings. >4640 low alloy fittings; and MF-4S41, 18-8 Cr, Ni. fittings. ' jp INSPECTIONS AND TESTS |,, ... jifer to General Safety Instructions Applying to All Equipment iless otherwise specified, the test pressures for separable pipin g seo- tbhs shall be in conformance with the A.S.A, Pressure Piping Code? Er. ip 150 lb, steel fitted lines shall, be tested at 350 psl, A' 300 lb, steal fitted lines shall be tested at 750 psl, ' jSafe test pressures for lines may be limited by reduoed thickness....:^ v (corrosion), special fittings (as control valves, expansion joints, .stc,)s and pressure test limits for oonnected equipment where lineSyi; cannot be isolated. Refer to sheet on Hydrostatic Tost Pressures ^supplementing Engineering Instruction No, 300, ?eult Engineering Division for proper test pressure and prooedure .fj|j ^ of any question. ft"' f GENERAL SAFETY INSTRUCTION SHEET V. Process Lines GENERAL SAFETY INSTRUCTIONS FOR FIRED .HEATERS HAZARDS / - ........ m ;jhe hazards to fired heater installations in operation, includes Pie general hazards listed in the General' Safety Instructions Applying *All Equipment which apply to fired heater installations. Illssirs tube temperatures resulting in damage to /or failure of, tubes passive temperatures may be caused by coke or other deposits, by ex- ffsive firing rates or by uneven heat distribution, HAS '' icessive pressures caused by stoppage or restricted flow due to obstruc tions or coke formation in the heating element or transfer lines. Cores psed liners, pass or outlet control valves, may cause restricted rcw, ' Icessive pressures due to failure, plugging or coking of relief valves, Jure or loosening of rolled joints or of tube seal welds due to re tted cycles of temperature change, or to sudden changes in temperature |to improper use of dissimilar metals in rolled joints or in' adjacent lube positions, ' . * akage or opening of header plugs due to damaged seats, or to breakage, jjggs of strength or excessive wear of screws and holding members, or to Securely seated plugs, , Age or actual rupture of parts involved in flashes from leakage of Ills or plugs. J|losions in firebox from ignition of explosive fuel-air mixtures or aterruDtion of gas fuel flow. r Bructural failure from overheating or deterioration of tube supports, Igupporting steel structure?, breechings, stacks, internal insulation, etnj (fet* mage to tubes, particularly alloy tubes, by abuse in cleaning, by oon- |aued service at exoessive temperatures or by too rapid oooling, . M- , *>orroBion or oxidation of exterior tube surfaoes by furnaces gases in Iteration} and corrosion - inside or outside - by residual salts and ' during idle periods, including' intergranular corrosion of 18-8 Ni, material, , shell stills: overheating of fire sheet, exoessive vacuum, corrosion _ still bottom, deterioration of still supports, or exoessive pressure lor.^bumping'1 from water in still. GENERAL SAFETY INSTRUCTION SHEET Fired Heaters ME5102 Sheet 6 S-4S CHEV B8 6422 GSSBKAL SAFBY INSTRUCT IOftS FOR. HEAT TRANSFER EQUIPlffiffj' jRjjfif-'' . . HAZARDS ||||jhe hazards to heat exchange equipment in operation include. %, ' iKose general hazards listed in the General Safety Instruction HjjfcAll Equipment which apply to heat exchange units, `s APplyi llj'dssive pressures on tube or shell side, as from: v , ^Fouling or plugging of tubes, of shell passe's, or of relief ,, ^Leakage from high pressure into low pressure side, Failure of cooling medium circulation or of heating medium ^Jlhetmal expansion of liquid if closed off when filled, due jing from opposite side, or to "sun pressure." * 0 ke-?-2 lljpmperatures in excess of limits set' by: cast iron construct! tli|x-aus tube bundles, packed or gasketed joints, shells prots a: ifcreernal insulation. ': > ' uoe*d Excessive temperature difference or excessive rate of temperat Rising high stresses, deformation of tube bundle or loosonins-111^ 0-l <li||i?ubes. These niay occur from interruption or failure of oooli T3jm flow, heating without cooling medium circulation, or loss oT Sekel where bundles are designed to operate immersed. ' r essive pressures or temperatures caused by failure of automat; tL equipment. . sf df|?' 'S pcessive corrosion by the fluids handled and particularly in the Si gpSxcessive salt water temperatures (above 120F.) with brass jgl(admiralty) tubes, ,,,, iffOxygen or carbon dioxide released in steam reboilers or proheata^ gfesiectrolytic corrosion' at contacts of dissimilar meta.ls, inoludfi llcnjetal 'gaskets* . ^Effects of neutralizing or treating agents, ammonia, caustic, .oj$ |'rine, etc,, on non-ferrous materials. ..\J pfCaustic embrittlement of steel, hydrogen attack in steel at hig "^temperatures, intergranular and stress corrosion of 18-8 Cr, Nit? i1,.. .t'&M gJCorrosive influences must be considered not only during operates ff&lso while units are shutdown and during chemioal cleaning, rsB ifs . ' ' f Szards occasioned-by internal leakage such as: contamination of^ g|of treated cooling water; chemical reactions between hot andj^l bids, if mixed; entrance of water into dry feed stocks to highjf gjfrature equipment; or the release of flammable or poisonous vapor g|ses through the water conduits to cooling towers or sewers, li&e&te 0f hydrogen sulfide gas in chemical cleaning operations.^ >! GENERAL SAFETY INSTRUCTION SHEET ME-6102! fc- . Heat Transfer Equipment - -m Esgt**.. 4~W GENERAL SAFETY INSTRUCTIONS FOR HEAT TRANSFER EQUIPMENT sjrrtr^su.*.- - RECOMMENDATIONS FOR AVOIDING HAZARDS M Observe recommendations on sheet - General Safety Instructions Applying V'-'A-ll Equipment. ' 9 .' K ji initial operation check closely for free expansion at supports, ex- Jiision joints and connected piping, -- SsS'.u. 1 * "Britain close watch on instruments and controls regulating operating tuitions, ~iT . ' Ve cold medium circulating before starting hot side flow, ibid excessive rates of temperature change or thermal "shock", "Af, Jfht unprotected units when idle and closed off. intain requisite pH control on cooling tower water, steam reboiler V heater condensate, and on overhead streams to' check neutralizing. ' fjb water outlet temperatures should not exceed 1H0F, for brass fSdmiralty metal) tubes, jisan, flush, or neutralise shutdown unit's as necessary to prevent Inge when steaming out or standing idle. Whenever possible salt ,-Ter cooled units should be flushed with freshwater before steaming pu%", to prevent rapid dezincification, INSPECTIONS AND TESTS '" `fgs-general recommendations given on sheet - General Safety Instructions plying to All Equipment. .. ate inspections for corrosion of all exposed parts whenever tube head Hf'shell cover (and floating head) are opened, j- - _ J&ke complete inspection of unit, including gage measurements of shell l&'cknsss - if required, whenever a unit is retubed, l-tv , ply specified test pressure after repairs to tube bundle or shell, ply at least water system pressure test to bundle after replacing JSating head to check fit and gaskets before replacing shell cover "tad. t: Jisult Engineering Division for proper test pressure and prooedure in vent of any question on pressure testing. GENERAL SAFETY INSTRUCTION SHEET Heat Transfer Equipment HB-51D2 Sheet 9 SP3SL GENERAL SAFETY INSTRUCTIONS FOR PRESSURE VESSELS ' HAZARDS h Hie hazards to pressure vassal equipment include: `i PSThose general hazards listed in the General Safety Instructions Applying -|0 All Equipment which apply in the case of pressure vessels, tpiilure, plugging, isolation from, or too high settings of pressure refeief valves, resulting in excessive pressure. Sf' gfailure of regulating or control equipment, resulting in excessive presisure or temperature, mineral reduction below minimum safe shell thickness, or local penetra%.on, or weakening of internal bracing or structures due to: normal pro Kves odrrosion or localized or accelerated attack; failure of internal or.otactive linings; inadequate neutralizing of corrosive media; or cor rosion caused by opening, purging, washing or chemical cleaning, Weakening or failure of supports due to: wind or earth shock loads in ||xcess of design provisions: fire exposure; corrosive leakage; temperIraires in excess of design limits for strength or for free expansion; lEL.tinding or restraint of special support elements, Ipllapse due to: external pressure in excess of design limits; corrosion ipTshell or internal bracing below safe minimum thickness for external assure loading; or out-of-roundness in excess of safe limits for ex- Strual pressure. Also damage to internal linings, especially lead lin ings, due to external pressure loading, |f|ease of hot, flammable, corrosive, or poisonous liquids or gases in jrsttfc of rupture or cracking; or leakage from fitted or packed joints, jjiveted joints, gage glass breakage; or in draining or opening vessels, IBermal stresses at localized points caused by too rapid rates of ternttgrature ohange, or too great temperature differences, especially in ' dick wall vessels, glass or brick lined, or packed vessels, jrV poking or deformation at supports, at line connections; or at shell gptaohments. caused by: repeated loading or vibration; differential ex^Ssion of connected lines or structures* or by over-loading davits or |okets. , Hi: K|k loading: as by sudden stoppage of flow through filled vessels Jg|(lraulic shock); or by internal explosions; or by exfaarnal impact SgSis - particularly in the cases of vessels in low temperature service pfif oasb iron construction, expansion of contents if closed off too full; or freezing of ||rcained water, especially in drains and connections. mi Sit ' CHEV B8 6426 GENERAL SAFETY INSTRUCTION SHEET Pressuro Vessels - Columns and Drums ME-5102 Sheet 10 S~4d GENERAL SAFETY INSTRUCTIONS FOR PRESSURE VESSELS -HAZARDS (Corrfc'd.) rfission of water or trapping or pocketing of water in hot equipment In'sing violent pressure surges as "Blows" in columns, \I ilure of internal insulating linings,or of. 'Vapor stops" in insulationj ^sing excessive shell temperature and/or corrosion, f, | Iferittlament and crackings as by hydrogen attack if metal temperatures ^oeed safe limits; or by caustic embrittlement,especially if not less-relieved. ijmical reactions - inherent in process or accidental - causing exces- ye pressures, temperatures, or corrosion, . 'aeking, embrittlement, or residual stress caused by unauthorised heat- "or welding, particularly on high tensile or alloy steel or stress- Slieved vessels, ' .. ' . RECOMMENDAIIONS FOR AVOIDING HAZARDS serve general recommendations on sheet - General Safety Instructions pplylng to All Equipment. aspect hot vessels during initial warm-up, for restricted movement or Syidence of strain particularly at supports and connected lines or struc tures. -'intain close observation of instruments and controls regulating opera ting conditions and those indicating shell metal temperatures. Take additional temperature readings in critical areas where there is any ^er of exceeding safe temperature limits. bserve all precautions necessary to safeguard against accidental block ing of safety or relief valves or of blow-off lines from relief valves, especially where three-way valves, locked-open valves, or bursting discs are installed under relief valves. M-void excessive external pressure in operation; or in steaming out, in ^mptying contents, or in testing, Observe all precautions given in Engineering Instructions on vessel eon- fbruction, maintenance,'and repair including those covering: Design, '^Iteration, Repairs, and Inspections of Vessels (No, 103); Installing P-loy Linings (No, 501); Handling Compressed Gas Cylinders (No, 404); `Impair Welds in. Vessel Shells (No, 650); Cleaning Vessels (No, 663); Bolting'Up Praotice (No, 800); and all those covering Welding, Heat treatment and Stress-Relieving Praotice for both steel and special alloy Materials. f, ' Consult the Engineering Division in regard to any repairs or alterations to. pressure vessel equipment. GENERAL SAFETY INSTRUCTION SHEET Pressure Vessels - Columns and Drums ME-5102 Sheet 11 S-45 v?>-V; 'Vv>j%r#' ssp GENERAL SAFETY INSTRUCTIONS FOR PRESSURE VESSELS INSPECTIONS AND TESTS . ggj? ' ' . p;general recommendations given on sheet - General Safety Instructions flying to Ali Equipment, _' ' ,__er- regular periodic inspection of 'all- pressure Vessels in the manner ffporibed in the Equipment Inspection Manual and at frequencies as |fn in the Equipment Inspection Schedule for the plant, or in lieu |such a schedule as recommended on the Safety Instruction Sheets. ^Pressure Tanks in California must he inspected biennially under the Site Safety Orders. - > ' ... : . |e special inspections for possible damage after any instance of fires s, overheating or exoessive pressure, . |||t vessels to routine test pressures given .on the 'Data Sheets, after y|major repair or welding affecting the strength of the equipment, fprve precautions given in Engineering Instruction No. 300 - Hydrolitid Testing, including supplementary sheet on hydrostatic Test 3BEUT6S, insult Engineering Division for proper test pressure emd procedure: "l|ht of any question on pressure testing* in any case of pneumatic Isting; and in any case of test of spheres or spheroids. . in GENERAL SAFETY INSTRUCTION SHEET Pressure Vessels - Columns and Drums ME-5102 Sheet 12 5-45 CHEV B8 6428 GENERAL SAFETY INSTRUCTIONS FOR MECHANICAL EQUIPMENT lltJiS ' HAZARDS . hazards to mechanical-equipmenfc in operation* include: Hi general hazards given in the General Instructions Applying to All lament which apply to the type of mechanical equipment considered* li'sive pressures; in pumps caused hy discharge shut-off, excessive lion pressure, or excessive speed, particularly in series operation pumps, or in testing; in compressor cylinders caused by discharge jjjfeoff, excessive intake pressure or blocked-off jacket water circulion* and in turbine cases caused by- a closed exhaust* Hr * Sic and/or excessive pressure: in reciprocating pumps or engines due to fsteam or failure to drain in starting, particularly in flywheel en~ ||s; and in compressors from liquid entering cylinders with the gas* Urtion or failure of part's and damage to bearings caused by overload- P?as due to operation of machines or motors in excess of design capagfor speed; or to abnormal variation of compressor intake pressure* fjga.to turbine or compressor blading caused by: water in steam; erosion jpotids in the fluids; excessive temperatures; and by corrosion during Spdowh periods. . ||sive speeds caused by malfunctioning or failure of governors speed Rollers or overspeed trips or failure of couplings resulting in run- *|aiid "explosion" of driver, flywheel, or driven machine, . kL' |ffive vibration leading to fatigue failure of parts and of connected especially small threaded connections - oaused by improper founda- is^'.poor alignment, or improper balancing of rotating elements* 1%-J Issive temperatures of steam or fluids handled causing: distortion or Slpre of cases or parts due to reduced strength of the material above jp|esign temperature limit; reduced clearances or running fits leading IJeoessive wear or seizing; irregular expansion and misalignment loading Miration, interference, bearing or packing failure, or shearing of Sl&fLor anchor bolts; deterioration and excessive scaling in water pts and cooling systems* Steaming out equipment which normally oper- ||at lower temperature may cause expansion strains on pump flanges. m^'castings, etc* , resulting in failure or misalignment* gj|>ive temperatures not due to process heat, caused by: mechanical IPUnities such as interference of loose parts or misalignment; overbearings; presence of foreign material; failure of cooling Jgsj and loss or contamination of lubricant to bearings* |||al shocks leading to cracking of case parts - particularly irregular^glapea castings and cast iron parts - due to sudden temperature changes, |too rapid starting from cold or in cutting-in standby units, or too changes* : GENERAL SAFETY INSTRUCTION SHEET A&nioal Equipment - Pumps, Compressors, and Drivers ME5X02 Shoot IS $ 45 i CHEV B8 6429 GENERAL SAFETY INSTRUCTIONS FOR MECHANICAL EQUIPMENT HAZARDS (Cont'd.) . . - . .. Overheating and scoring or seizing of close clearance parts in centri,. glugal or rotary pumps if operated -on other, than the designated fluid o at low throughput due to shutoff or bypassing.to the suction, 0r flcessive temperatures in motors leading to damage to windings and pog title fire hazard caused by improper bearing adjustment or lubrication" ^erloads, shorting, or obstruction of .ventilation. Motor overloads ' gy result from pumps designed for low gravity oils being operated on Sgher gravity stocks or water. Jporrosion or damage to insulation and shorting of motor windings by Hoisture, chemical leakage, dirt, or excessive lubrication. ffiSpfS' . ., . * gDirect release of hot, flammable, corrosive or poisonous liquids or gages in the event of gasket, thread, or packing leakage, or actual failure of case or connections, ` '? SgKrr ' Sburce of ignition hazards such as dragging gland followers on pumps Electrostatic charges on belts, defective gas engine exhausts- and ex,, fjfoison hazards in gas engine crank cases and starting air systems, " RECOMMENDATION FOR AVOIDING HAZARDS . Dserve recommendations on sheet to All Equipment, General Safety Instructions Applying Erovide for adequate "running in% and lose observation in initial one pion for strains, vibration, misalignment, bearing temperature, pacti^" _,Jgland adjustment, functioning of sealing, cooling and lubricating system ^flnd of governors and ovarspeed trips, ' Take precautions against foreign aterial entering wearing parts and bearings. Observe precautions in Sineering Instruction No, 600 - Installing Pumps, feintain close attention in service to.functioning and condition of all Instruments, regulating equipment, governors, automatic outouts, protec tive devices, and relief valves which serve to control operating condi," ions within safe limits, ' A ' llp'qid losing suction or sudden shutoff against' pumps, particularly pos^ gije displacement types, Cheok series or tandem combinations to pre?ent Sxoessive pressure.on the seoond pump, in -- ' ^leed steam supply lines and drains on pumps, engines, and turbines and pppen exhaust valves before admitting live steam. Warn up any hot serri. flguipment slowly when putting it in operation. . ' 00 GENERAL SAFETY INSTRUCTION SHEET Jfechanical Equipment - Pumps, Compressors, and Driyers ME-5102 Sheet 14 5-45 CHEV B8 Up: general safety instructions for mechanical equipment RECOMMENDATIONS FOR AVOIDING HAZARDS (Cont'd.) safe practices for operation and lubrication of equipment as |gji in the Operating Standards including 9091 Lubricants for Refinery ipment, 9421 - Operation of Reciprocating Pumps, and 9422 - Operation jentrifugal Pumps and in the Manufacturers' Instruction Manuals for |oifi units. ^particular attention to gland adjustment, cooling water or oil cir~ fation to glands and bearings, Duraseals, jacket water circulation, and luring lubrication systems. Observe precautions in Engineering Instruch No. 500 - Installing Packing in Pumps and Compressors. Hlg oooling air passages in motors clean and free from obstructions. Do operate motors without specified fuses or overload protection devices over standby units at regular intervals as specified in Operating "aldards. Check functioning of traps in steam to standby units fre- rtntly, Sfiferve requirements of State Safety Orders for Engines and Mechanical Her Transmission relative to guarding, clearances, aooees and ventila- Eon in pump and compressor rooms, INSPECTIONS AND TESTS ^ct general recommendations given in the General Safety Instructions plying to All Equipment, glular periodic tests and inspections of all protective devices includ^test and resetting of relief valves. Relief valve set pressures to |||given on the Data and Operating Limits Sheets. BjjHylar inspection and servicing by machine and electric shops in. ac- jJorcLance with departmental or district maintenance schedules. Have UK'otrical Inspector check any esplosion-proof motor that is opened be~ jora dosing the case. ' 5l`, Bpection of critical units for corrosion, or materials by Equipment Inifb'otors whenever opened for maintenance, or as specifically called for nsthe Safety Instruction Sheets or the Equipment Inspection Schedule for J|: plant. feat equipment to test pressure given on the Safety Instruction-Sheets |per any major repair affecting the strength of the equipment. ' ponsult the Engineering Division for proper test pressure and procedure eT0Qk any question on pressure testing. GENERAL SAFETY INSTRUCTION SHEET , lohanioal Equipment - Pumps, Compressors, and. Drivers ____ ME-5102 Sheet 15 S-4S. CHEV B8 6431