首次打開作業(yè)課件

杜邦管線開封程序管線的安全開封指引Copyright?2002E.I.duPontdeNemoursandCompany.Allrightsreserved.學(xué)習(xí)目標(biāo)在結(jié)束之際，你將：了解杜邦S27G內(nèi)的9個管線開封安全的要素明白管線開封的定義，了解何時需要執(zhí)行管線開封和執(zhí)行9個步驟來安全地進(jìn)行管線開封.為管線開封做安全準(zhǔn)備如果你被要求作管線開封，你一定能做好準(zhǔn)備工作

管線開封安全的9個關(guān)鍵要素1.新建項目和項目改造2.培訓(xùn)3.工作計劃4.系統(tǒng)準(zhǔn)備5.上鎖/隔離6.作業(yè)的移交7.PPE:選擇和使用8.執(zhí)行9.事故調(diào)查

圖示管道開封1. 開啟法蘭2. 從法蘭上移調(diào)一個以上的螺絲

圖示管道開封（續(xù)）3. 開啟放空閥門4. 移調(diào)閥門帽或止逆閥門帽ValvebonnetCheckvalve

圖示管道開封（續(xù)）5. 轉(zhuǎn)動雙孔版6. 斷開管線連接點

圖示管道開封（續(xù)）7. 移調(diào)盲板，盲法蘭，封頭、塞子等8. 斷開管線U型接口彎頭

圖示管道開封（續(xù)）11. 開啟觀察孔12. 進(jìn)行設(shè)備的微調(diào)(如,更換閥門的填料)

管線安全開封的9個關(guān)鍵要素

培訓(xùn)工廠應(yīng)制定符合S27G要求的管道開封程序并向所有從事危害工藝和系統(tǒng)作業(yè)的人員（包括計劃和執(zhí)行人員）提供培訓(xùn)。培訓(xùn)應(yīng)包括杜邦管線開封指引內(nèi)的內(nèi)容

培訓(xùn)的對象包括

生產(chǎn)操作人員，包括生產(chǎn)管理層

維修和施工人員,包括管理層

合同工和合同工管理人員

計劃制定人員

管線隔離作業(yè)的申請人員和批準(zhǔn)人員

復(fù)訓(xùn)的周期不應(yīng)大于3年

培訓(xùn)記錄應(yīng)按照杜邦S21A的要求進(jìn)行保管

現(xiàn)場的第一方審核應(yīng)作為驗證培訓(xùn)效果的手段之一

作業(yè)計劃一份書面的計劃來確保管線隔離作業(yè)能被怎樣地安全執(zhí)行，其中包括系統(tǒng)內(nèi)的危害因素的識別、清掃或控制。這份計劃的的制定人應(yīng)該明白這項具體作業(yè)所具有的危害，且這份計劃應(yīng)被每個參與管線隔離作業(yè)的人員回顧。首選的管道開封計劃請參照杜邦管線隔離手冊內(nèi)的管道隔離許可證。

作業(yè)計劃，續(xù)作業(yè)計劃的內(nèi)容包括:危害識別隔離、清潔和沖洗計劃關(guān)于PPE使用的描述（何時使用PPE和何時去掉PPE）明確監(jiān)護(hù)人的職責(zé)如果使用單一的隔離措施或人員沒有恰當(dāng)?shù)谋Ｗo(hù)措施/和環(huán)境有可能受到污染，應(yīng)額外建立應(yīng)急計劃對管道隔離的作業(yè)區(qū)采取隔離措施

作業(yè)計劃，續(xù)對于一些常規(guī)的管道開封作業(yè)，書面作業(yè)計劃可以是書面的、經(jīng)批準(zhǔn)的常規(guī)管道開封作業(yè)程序，包括對管道開封的安全準(zhǔn)備工作。如果使用上述程序,額外作業(yè)流程應(yīng)包括以下要素:

參照S27G的標(biāo)準(zhǔn)，定期回顧已經(jīng)制定的程序?qū)δ切﹨⑴c從事常規(guī)管道隔離作業(yè)人員進(jìn)行培訓(xùn)和復(fù)訓(xùn)，定期復(fù)核他們的培訓(xùn)記錄無論使用何種書面的作業(yè)準(zhǔn)備，其目的是要保證管道開封工作獲得了合適的安全準(zhǔn)備并得到授權(quán)人的批準(zhǔn)在開始管道開封前，對開啟點所在系統(tǒng)的安全準(zhǔn)備必須已經(jīng)完成

系統(tǒng)準(zhǔn)備的關(guān)鍵要素包括:

系統(tǒng)準(zhǔn)備化學(xué)品的危害應(yīng)被徹底排除。如果系統(tǒng)內(nèi)的化學(xué)危害不能被證實已經(jīng)獲得清理，應(yīng)準(zhǔn)備額外的化學(xué)危害排除或控制程序。如果清理工作無法達(dá)到期望的結(jié)果，作業(yè)計劃應(yīng)被中止并執(zhí)行以下步驟：重新計劃、記錄、授權(quán)和溝通。系統(tǒng)的清潔程度應(yīng)被確定和驗證.注意: 能冷凝成固體的熱液體會產(chǎn)生特殊的問題,如果氣體和熱液體截留在固化了的兩段塞子之間,那末它們可能會"流出"來。

管道隔離的陷阱（續(xù)）4.Backfeed(heatexchangers,jacketedlines,etc.)5.Threadfailures(pipe,flange,bolts,plugs,etc.)6.Potentialenergy管道的狀態(tài)示例1: 隔離,泄壓,放空和排盡示例2: 隔離,泄壓,排盡，但沒有放空

注意:系統(tǒng)內(nèi)沒有放空點，所以很難排盡.ClosedClosedOpenOpenClosedOpenClosed上鎖/隔離所有的管道開封作業(yè)都應(yīng)按照S14G的要求進(jìn)行隔離

合適的系統(tǒng)隔離包括以下要素:

在現(xiàn)場有一套文件(如:上鎖清單,P&ID圖)來用于識別和說明作業(yè)范圍內(nèi)的閥門、法蘭、盲法蘭位置.法蘭和盲法蘭應(yīng)被掛牌所有在隔離系統(tǒng)內(nèi)的閥門應(yīng)被保持在開啟狀態(tài)，管道應(yīng)被清理，以避免出現(xiàn)物料積聚在管線或設(shè)備內(nèi)部將辨識隔離所有初級和次級（蒸汽伴隨和電熱伴隨）能源的特定步驟。這對于用凍結(jié)(即凝固)來隔離它們的聚合物和熔融系統(tǒng)，以及對于那些如果先冷卻然后再加熱可能蒸發(fā)的酸類是尤為重要的。

上鎖/隔離（續(xù)）有很多隔離系統(tǒng)或設(shè)備內(nèi)危害因素的方法，優(yōu)先秩序依次為：

1.

雙重隔斷閥門加排盡閥門2.隔斷閥門和盲板加盲法蘭3.雙重隔斷閥門4.單一隔斷閥門5.工程工藝塞(如：固化工藝介質(zhì))示例：

管道隔離示例（續(xù)）如果我們不能采用第一種隔離方法，我們應(yīng)采用關(guān)閉隔離閥門再加盲板的做法

注意:隔離的盲板或盲法蘭的使用必須符合管道原有設(shè)計的規(guī)格（溫度壓力），具體參照P9E和ANSI/ASMEStandardB16.5.

設(shè)置盲板和盲法蘭可以被視為管道隔離.

移調(diào)上述隔離措施應(yīng)被視為管道開封.

SlipblankBlindflangeBlindflangewithaventvalve/drainFlowLocked/ClosedSlip-BlankBlockandBlankWorkarea不銹鋼盲板的厚度注意: Iftemperaturesexceedthe100F(38C)maximumtemperature,contactsiteengineeringforthecorrectthicknessblankstobeused.Theseblanksshouldbemarkedwiththepressureandtemperatureforwhichtheyaredesigned.Linesize

(inches)Flangeclas81/81/81-1/21/83/163/1621/83/161/433/161/43/841/45/167/1665/161/211/1683/85/87/8101/23/41-1/16129/167/81-1/4145/811-3/81611/161-1/81-9/161813/161-1/41-3/4207/81-3/82241-1/161-11/162-3/8

碳鋼盲板厚度能否在單一隔離點前尋找管道斷開點在單一隔離點和作業(yè)位置間是否有排盡或放空點管道隔離示例（續(xù)）以下的信息可以作為制定只能進(jìn)行單一隔離的管道系統(tǒng)的作業(yè)準(zhǔn)備參考注意: 記住,對采用單一隔離措施的管道進(jìn)行明火作業(yè)時，每個班次必須進(jìn)行爆炸性氣體測試工作。

管道隔離示例（續(xù)）4.當(dāng)啟封涉及危險工藝的系統(tǒng)和/或設(shè)備時,如要脫下PPE，在初始管道啟封已完成后的全部工作應(yīng)當(dāng)在雙倍隔離后進(jìn)行。5.如果采用自動控制閥門進(jìn)行管道隔離，工廠必須制定特殊的程序來確保隔離的效果

作業(yè)的移交對于有危害物質(zhì)的管道作業(yè)的準(zhǔn)備、開封和移交給業(yè)主的過程進(jìn)行作業(yè)范圍和計劃的回顧?；仡櫣ぷ鲬?yīng)在作業(yè)開始前或作業(yè)結(jié)束后進(jìn)行，并且，參與工作準(zhǔn)備的人員、維修的人員或設(shè)備的操作人員應(yīng)共同進(jìn)行回顧?；仡櫣ぷ鲬?yīng)包涵安全、健康和環(huán)保的內(nèi)容.

作業(yè)移交的關(guān)鍵回顧要素包括:

提供管道隔離位置、清潔和效果驗證的方法、設(shè)備的狀態(tài)的信息在作業(yè)開始前，與維修人員或合同作業(yè)人員進(jìn)行作業(yè)狀態(tài)的溝通，溝通并明了殘留在設(shè)備物質(zhì)的危害特性如果作業(yè)的延續(xù)已經(jīng)超過一個班次，提供交接班的記錄在開始作業(yè)前，驗證系統(tǒng)或設(shè)備是可以繼續(xù)安全地作業(yè)的所有涉及作業(yè)的人員應(yīng)在交接班的文件上進(jìn)行確認(rèn)PPE對每件有可能暴露于某種危險的工作任務(wù),無論系統(tǒng)已為管道啟封作好如何徹底的準(zhǔn)備，都將基于正常系統(tǒng)的操作條件，指定和準(zhǔn)備好以及使用PPE。

每個工廠將有一個系統(tǒng),準(zhǔn)備好適用而干凈的PPE供隨時使用。人員將就該如何使用特定的PPE及其有何使用限制接受培訓(xùn)。

PPE的選擇對于工廠中每個潛在的暴露，將選擇工作時既給予保護(hù)又方便實用的PPE。

選擇PPE的關(guān)鍵要素包括下列各項:

應(yīng)有跨部門知識廣博的人員，包括使用PPE的人員參與選擇。任何一種PPE，在采用前，應(yīng)當(dāng)由使用它的人員在現(xiàn)場測試其實用性。

工廠已批準(zhǔn)使用的PPE清單，按危險分類別，將對所有員工是現(xiàn)成可取的。

PPE的使用PPE使用的要點使用那種PPE何時使用PPE.何時去掉PPE作業(yè)的執(zhí)行管道開封工作應(yīng)嚴(yán)格按照S27G的要求進(jìn)行關(guān)鍵點：明確地知道斷開點的位置現(xiàn)場采取隔離措施，避免應(yīng)突然泄放的危害物質(zhì)而造成對周邊的人員的傷害。作業(yè)的執(zhí)行（續(xù)）當(dāng)作業(yè)不能象期望的SHE條件進(jìn)行（如，排盡閥門堵塞或管線不能被清理干凈），作業(yè)應(yīng)被中止。重新進(jìn)行作業(yè)安全評估或制定新的作業(yè)計劃。處理意外情況的關(guān)鍵要素將包括下列各項:

任務(wù)將以與評估初始工作計劃相同深度進(jìn)行再評估。

批準(zhǔn)新的工作計劃至少要與批準(zhǔn)初始工作計劃相同級別。

進(jìn)行工作任務(wù)的人員將了解工作計劃和予料情況以使他們能認(rèn)識到何時會出現(xiàn)意外情況。

事故調(diào)查所有管道開封的事故應(yīng)按照S3Y標(biāo)準(zhǔn)進(jìn)行調(diào)查.使用事故原因樹來分析

SupplementalInformation

GeneralSafePracticesShieldingshouldbeconsideredonlinebreaksifandwhenpractical.

Employeesperforminglinebreaksshouldpositionthemselvesontheupwindsideof—andasfarawayaspossiblefrom—anypotentialmaterialrelease.

Whenbreakingintolineswithoutanexistingbreakapparatus(e.g.,vent,drain,flange,tubingfitting),makethebreakusingacuttingordrillingdevice.

Thisdevicemustbenonelectricalandproducenosparks(e.g.,anair-operateddrillmotororhacksaw).D. Whenbreakingintoaflange,loosentheboltnutsontheloweroppositesideawayfromtheworkerfirst,keepingtheboltnutsnearesttheworkerundercontrol.Thisallowsthelinetoseparateinawaythatcausesanymaterialreleasedtobeawayfromtheworker.

Aftertheflangeisopenedawayfromtheworker—ensuringnomaterialisreleased—loosentheremainingboltsandspreadtheflangesapart.Removethegasket,positionitthroughtheflangeboltcircle,orpositionitinawaytovisuallydetectalinebreakhasbeenmade.(Ensurethegasketisnotblockingthecreatedopening.)

GeneralSafePractices,continuedNote: Ifflangeboltsareseverelycorroded,theymayneedtobereplacedbeforeproceeding!Looseningand/orremovalofcorrodedboltsshouldbeconsideredalinebreak,necessitatingfollowingofthelinebreakprocedureandwearingtheproperPPEfortheservice.

GeneralSafePractices,continuedE. Whenavalvebonnetmustberemoved,thepipelinemustbedrainedandthevalveplacedintheopenpositionbeforethebonnetboltsareloosened.

Ballandplugvalvesmayhaveliquidsorpressureinthecavityunderthestempackingandbonnetregardlessofthevalvepositionorpressureinadjacentlines.

Ballandplugvalvesthataretoberemovedmustbeopened,closed,andreopenedafterthesystemisdrained,toensuretrappedliquidorpressurehasbeenrelieved.GeneralSafePractices,continuedF. Whenbreakingapipeunion,loosenithalfwayandcheckfortrappedpressureorliquidbypushingthepipeawayfromtheworker.

G. Whenbreakingatubingfitting,loosenitaquartertohalfwayandcheckfortrappedpressureorliquidbygentlypullingitapartandflexingthefitting.

SpecialprecautionmustbeexercisedwhenbreakingaGrayloc*-typefitting,becauseofthedifficultyincontrollingaleak.Ifthisbecomestheonlypossiblebreakpoint,shieldingmustbeconsidered.*GraylocisaregisteredtrademarkofYellowstoneEnergyProducts.GeneralSafePractices,continuedI. Abarricadeorproperlycordoned-offareashouldbeconsideredtoadequatelyprotectpeoplenotinvolvedinthelinebreakfromasuddenunexpectedreleaseofthehazardousmaterial.

J. Whenthelinebreakconsistsofremovingavesselflangeorhead,alwaysbackalltheboltsoffthreeorfourturns,inanormalpattern,beforeremovinganybolts.Thiswillallowtheflange/coverorheadtobackoffthegasketandallowanycontainedpressure(gas/liquid)toleakoutofthejoint,indicatingthepotentialpresenceofpressure.Thistechniquewillensurethattheflange/coverorheadremainscaptiveinplaceuntilanypressurehasventedoff.HazardsPipingsystemcomplexities(e.g.,multi-floorroutes,loops,pockets,turns)cancreateaninabilitytoensureasystemisemptyandpressure-freeevenafterlinebreaksarecompleted.Thevolume,pressure,andtemperatureofthematerialthatcouldbereleasedfromalinebreakshouldbeconsideredpriortomakinganybreaks.Addedhazardsexistwhenvacuumsarecreatedduringcooling.Vacuumscanholdliquidsthatunexpectedlyreleasewhenthetemperatureequalizesandcausespressurization.ExamplesofliquidsthatcreatevacuumduringcoolingareDP:DPO(Dowtherm),steam,andsteamcondensate.Hazards,continued4. Hotliquidsthatcooltosolidcancreatespecialproblemsofgasesandhotliquidsbeingtrappedbetweensolidifiedplugsthatcanblowout.Examplesofhotliquidsthatcooltoasolidinclude:polymer,prepolymer,TPAresidue,DMTsludge,DMT,monomer,oligomer,ICLorTCL,andothers.Examplesofheatsourcesthatcreatehotmoltenproductsinclude:steamtracing,DP:DPO(Dowtherm)jacketing,steamjacketing,hotoiljacketing,electrictracing,andothers.5. Chemicalreactionscanoccurthatareuniqueforgivensituations.Theseconditionsmaycausethereleasetobeflammableortoxic,thusrequiringspecialplanning.6. Thespecificstepsforisolatingallprimaryandsecondary(e.g.,steamtracingandelectrictracing)energysourcesshallbeidentified.Thisisespeciallyimportantinpolymerandmeltsystemsthatare“frozen”(i.e.,solidified)toisolatethemandforacidsthatcanvaporizeifcooledandthenreheated.OtherDefinitionsWet/hottapInitialbreakControlledbleedDoubleisolationFlushingPurgingDepressurizationVentingDrainingIsolationProprietorWorkgroupSecondaryenergysourceStandbyRoutinetaskBlindflangeLineblankHazardousprocessorsystemQualifiedpersonnel

Wet/HotTapAmechanicalmethodofaddinganewtie-inordrainpointtoexistingserviceorequipmentwithoutinterruptingtheexistingservice.Note: Awet/hottapisconsideredalinebreak,butrequiresspecialprocedures.

AsareferenceseeFacilitiesConstructionSafetyManualB-20.1(/sheprocs/word/b-20-1.doc).InitialBreakThefirstopeningofdrainedandundrainedlinesorequipmentbydisconnectingflanges;breakingpipeortubingjoints;removingblinds,blanks,andplugs;orpenetratingalinebymechanicalmeans.OpenClosedInitialbreakControlledBleedAvalvedopening(bleed)locatedbetweentwoblockvalves.Thebleedconsistsofanopenblockvalveandterminateswithanopenendorpressuregauge.Thebleedservesasanindicatoroftheintegrityoftheupstreamblockvalve.Selectionandpositioningofthebleedterminationpointaredependentonthehazardsassociatedwiththeprocessmaterialandlocalconditionsatthetimeofthelinebreak.ControlledbleedClosedClosedVentDoubleIsolationDoubleblockvalveandcontrolledbleed(i.e.,blockvalve/controlledbleed/blockvalve)orblockvalveandblank/blindflange.FlowDoubleblockvalveandcontrolledbleedFlowBlockvalveandblank/blindflangeWorkareaWorkareaFlushingTheremovalofhazardouschemicals(vapororliquid)byflushingtheline/equipment.LiquidforflushingDrainvalveopenforflushingfluidFlowClosedOpenOpenPurgingTheremovalofhazardouschemicals(vapor)bypurgingtheline/equipmentwithagas.GasforpurgingDrainvalveopenforpurgingfluidClosedOpenFlowOpenDepressurizationTheloweringofpressureintheline/equipmentbyreleasingthepressuretootherline/equipmentandventsystemspriortoventingordraining.VentsystemPressuredroppingtozeroVentingThecontrolledreleaseofremainingpressurethroughavent.PressuredroppingtozeroOpenClosedDrainingThecontrolledremovalofliquidremaininginthelineorequipmentbyopeningadrain,bleed,orblowoutvalveatthelowestpossiblepointontheline.Thedrainpointmustbeverifiedtobeclear.LowpointdrainvalveOpen

IsolationTheclosingofvalvesandde-energizingofotherenergysourcestopreventprocessflowentryintotheline/equipment.Thehierarchyforisolatinghazardousprocessesstartingwiththemostprotectivelevelis: 1.Doubleblockvalveandcontrolledbleed 2.Blockvalveandblank/blindflange 3.Doubleblockvalve 4.Singleblockvalve 5.EngineeredprocessplugProprietorThepersonorgroupwhohasprimaryoperatingresponsibilityfortheequipmenttobeopened.WorkGroupPersonnelperformingtheactualline/equipmentbreak.SecondaryEnergySourceSourcesofenergythatcanposeahazardtothoseperformingaline/equipmentbreak(e.g.,steamtracing,electrictracing,springs,andgravity).StandbyAqualifiedpersonwhoseresponsibilitiesincludebeingphysicallycapableofperformingtherequireddutiesandassistinginthecontrolofreleasesorhazards.

RoutineTaskAtaskthatisperformedbyasingleworkgrouponaperiodicbasisthatisbasedonannuallyreviewedwrittenprocedures.TheproceduremustclearlyoutlinethestepsandcontrolsnecessaryandspecifyrequiredPPEforthetask,consistentwithsitesafetyprocedures.Trainingonthis“RoutineTask”shallbedocumentedandcurrent.BlindFlangeAsolidflangemanufacturedaccordingtoANSI/ASMEStandardB16.5.Blindflangesmayrequirematerialmatchingthepipingsystemorequivalentbasematerial.Insomecases,carbonsteelblindflangesmaybecladwiththepipeorequipmentbasematerial.LineBlank

(Alsocalledaskilletblankandfryingpan)Aslipblankinstalledbetweentwoflanges,fabricatedinaccordancewiththecurrentissueofDuPontEngineeringStandardP9E*.Whenselectingalllineblanks,thefollowingmustbeconsidered:thebasematerialofthepipeorequipment,theserviceorprocess,the

operatingpressureandtemperature,andthelengthoftimetheisolationblankwillberequiredinservice.Insomecases,carbonsteelblanksmaybecladwiththepipeorequipmentbasematerial;requirementsofthelineblankdirectthisdecision.*P9Eisdesignedforpressuretestingonly.ContacttheTechnicalAssistanceGroupfortemporaryblankingunderoperatingconditions.HazardousProcessorSystemAprocessorsystemthatcontainsanymaterialatanypressurethatcouldcauseariskofinjurytoanindividual(s),ariskoffireorexplosion,anenvironmentalrisk,oranoff-siterisk.Examplesofhazardousprocessesorsystemsinclude,butarenotlimitedto,compressedfluids,especiallygasesinpipesandvessels;corrosiveand/orflammablesubstances;andtoxicprocesslinesandanyotherlinesthatcouldcontainmaterialthatishazardousoncontactorinhalation,includingfluidwhosetemperatureishigherthan140F(60C)orlowerthan14F(-10C).Example:3to15psiairinanimpulselinemightnotbehazardous,but3to15psiairinalargetankcouldbeveryhazardous!QualifiedPersonnelThosewhobyextensiveknowledge,training,andexperiencehavesuccessfullydemonstratedtheirabilitytosolveorresolveproblemsrelatedtolinebreaksinaccordancewithDuPontSHEStandardS27G.LineBreakFAQsQ: Whyisitnecessaryforastand-bypersonfromOperationstobepresentwhenhotsuitsarerequiredwhenmakingalinebreak?A: TheOperationspersoncanrenderassistanceinanemergencyandisthemostknowledgeablepersontofindanotherisolationpointifneeded.

Q: Iamusingahotsuitwhilemakingalinebreak,thelineisopen,andnothingisdraining.CanIremovemyhotsuitbeforeinstallingaslipblankorablindflange?A: Youcanonlyremoveyourhotsuitbeforeinstallingaslipblankorblindflangeaftertheinitiallinebreakwhentheworkisbeingperformedbehindadoubleblockvalveandcontrolledbleedisolation.Ifyouareworkingbehindasingleblockvalve,potentialleaksposearealdangeruntilaslipblankorblindflangeisinstalled.

LineBreakFAQs,continuedQ: WhyshouldIsuitupbeforeremovingablankorblind?ThevalvewasnotleakingwhenIinstalledtheblind/blank.A: Noonecanpossiblyknowifthevalveleakedthroughornot.Theblind/blankmaybeholdingbackafluid/gasandmaycontainpressure.Q: Inahot-suitsituation,whyshouldastand-bymechanicbeinahotsuitwhilealinebreakisbeingperformed?A: Thestand-bymechanicistheretoaidtheworkingmechanic(s),ifneeded.Ifanemergencysituationarose,itwouldbeimpossibleforthestand-bymechanictogetintoahotsuitquicklyenoughtohelp.LineBreakFAQs,continuedQ: Howbigshouldabarricadebeforalinebreak?A: Ataminimum,thebarricadeshouldbeaslargeastheareathelinecouldpotentiallysprayortowhichitcouldrelease.Thisshouldincludethepotentialfortherele