Off Load Bulk Chemicals

Transcription

1 Revision Date: 2017/07/25 Revision: 1 Review Cycle (years): 3 Off Load Bulk Chemicals Operating Procedure NORMAL Plant: Firebag Plants Area: All areas in operating plants Document Number: FBOP10123 Level: Facility: Oil Sands Firebag 2 In-Hand Use This is considered a controlled document and verified as latest revision in ECMS. It is valid for duration of work. Verifier: Print Sign Date: yyyy/mm/dd Purpose / Scope The purpose of this OP is to bring a bulk carrier onto site and safely offload into a bulk storage tank. The scope of this OP includes minimum bulk offloading guidelines for any tank at Firebag. Area specific and/ or chemical offloading procedures must meet or exceed this procedure. Precautions The following precautions apply to this procedure. Initial/date to indicate understanding of each Hazard, or performance of the action required by the Control. Hazard Controls (Admin/Engineering/Operator) Initial/Date Exposure to chemicals Hazardous atmospheres Prerequisites Ops Rep - Review MSDS for chemicals being offloaded and verify controls are satisfied before potential exposure to area chemicals including: Mono goggles Chemical resistant gloves Chemical approved outerwear, such as rubber coveralls Face shield Chemical resistant boots Respirator Ops Rep - Determine if this offload occurs in a Classified Area? Yes - Complete gas testing as per RGP0007A. No - Perform initial check to confirm conditions. Time H 2 S ppm CO ppm O 2 % LEL % Time H 2 S ppm CO ppm O 2 % LEL % Time H 2 S ppm CO ppm O 2 % LEL % The following prerequisites must be completed before starting this procedure. Initial/date to confirm completion of each Action. Category Step Action Initial/Date N/A N/A Document Approver: Richard Babb Manager, Operations, Plants 91/92/, Firebag Document Owner: Richard Babb Page 1 of 12

2 Compliance Failure to comply with an Operating Procedure, without an approved deviation, may result in a hazardous situation which could result in: Personnel injury or death Harm to the environment Equipment or property damage. IF YOU ARE IN DOUBT AT ANY TIME DURING THIS PROCEDURE, STOP AND ASK YOUR SUPERVISOR. Note: If a problem with the procedure is identified during performance of work, use the deviation process per RGP Complete the following table during the offload as information becomes available. Table Suncor Bulk Offloading Information Record Offloading Time Data Trucking ID Tank ID Date yyyy/mm/dd Ops. Rep. print signature Appt. Time hrs / min Driver Name print signature a Arrival Time staging area hrs / min Carrier Name print Tank Number print b Time back at staging area hrs / min Truck Unit # print Available Volume in Tank Total time (b minus a) hrs / min Carrier BOL# print Eligible Wait Time * hrs / min Product Name print Start Tank Level print Number of trailers 1 or 2 Volume on truck print Final Tank Level print *Carrier wait time eligibility Appendix 2 Deviation from BOL: Explain if product is being put in alternate tank or if load is being split. If load splitting: Shift Supervisors or designates in both affected areas must direct and approve load splitting. Blowdown fittings must be connected to load line before initial offload as per Appendix 1. Approved by Shift Supervisor or designate from Initial offload site signature Approved by Shift Supervisor or designate from second offload site signature Information Record for Second Offload Tank when Load Splitting Date yyyy/mm/dd Ops. Rep. print signature Appt. Time hrs / min Driver Name print signature a Arrival Time, staging area hrs / min Carrier Name print Tank Number print b Time back at staging hrs / min Truck Unit # print Available area Volume in Tank Total time (b minus a) hrs / min Carrier BOL# print Eligible Wait Time * hrs / min Product Name print Start Tank Level print Number of trailers 1 or 2 Volume on truck print Final Tank Level print print print Page 2 of 12

3 Procedure 1. Prepare for Offloading Responsibility Step Action Initial Ops Rep 1.1 Meet Carrier at staging area. Ops Rep & Carrier 1.2 Review Bill of Lading (BOL) to determine offload tank location and add this information to table 1.0. Ops Rep & Carrier 1.3 Determine wind direction and review exit direction in the event of vapor or gas release or required evacuation. Ops Rep 1.4 Escort driver to tank location. Ops Rep & Carrier 1.5 Ensure carrier has signed entry/exit log and supply the carrier with bumped monitor and radio. Ops Rep & Carrier 1.6 Ensure trailer wheels are chocked and trailer is grounded. Ops Rep & Carrier 1.7 Complete FLHA and mitigate all hazards in area. Ops Rep 1.8 Install barricade and warning sign to prevent unauthorized entry into tank filling area and to control traffic on adjacent roadway. Ops Rep & Carrier 1.9 Show carrier nearest eyewash and safety shower. CONTACT CRO BEFORE TESTING SHOWER OR EYEWASH: CRO MAY THINK AN ACUTAL EMERGENCY HAS OCCURRED. Ops Rep & Carrier 1.10 Inform CRO and test safety shower and eye wash. Ops Rep 1.11 Ensure PVC containment pans (drip trays) are empty, available, and in place below each connection point. Ops Rep & Carrier 1.12 Review high level alarms. Ops Rep & Carrier 1.13 Review emergency truck shut down process. Ops Rep & Carrier 1.14 Use the following table to determine next action. If offload product is then wet chemical go to major step 2. dry chemical go to major step 4. Carbon dioxide Refer to FBOP5127C - 191V A GT 191 CO2 Supression System Fill & Startup Page 3 of 12

4 2. Complete BOL Review for Wet Chemicals Responsibility Step Action Initial STOP WORK IMMEDIATELY AND CONTACT OPERATIONS SUPERVISOR IF THERE ARE ANY DOCUMENTATION DISCREPANCIES: TO PREVENT FILLING THE WRONG TANK OR SPILLS FROM OVERFILLING TANKS. Ops Rep & Carrier 2.1 Cross reference Bill of Lading (BOL), tank number, product placard and UN number to verify correct product, tank, and product line and add this information to table 1.0. ENSURE TANK HAS REQUIRED CAPACITY: OVERFILLING TANK MAY LEAD TO SPILLS OR DANGEROUS BACK PRESSURE IN TRAILER. DO NOT SPLIT LOADS WITHOUT AUTHORIZATION: SEE TABLE 1.0 FOR AUTHORIZATION INFORMATION. Ops Rep & CRO 2.2 Compare amount of product in trailer to available tank capacity and add this information to table 1.0. Ops Rep & CRO 2.3 Ensure current tank level supports amount being delivered. VERIFY TANK LEVEL: INCONSISTENT LEVEL INDICATIONS MAY LEAD TO TANK BEING OVERFILLED AND SPILLING. Ops Rep & CRO 2.4 Confirm level using tank gauge and remote gauge before offloading. Ops Rep 2.5 Record initial/start tank level in table Complete Wet Chemical Offloading Responsibility Step Action Initial Ops Rep 3.1 Unlock envirobox / hose connector caps and confirm envirobox is clean (if applicable). ENSURE HOSE AND FITTINGS DO NOT LEAK AND ARE SUITED FOR CHEMICAL BEING OFFLOADED: LEAKS COULD RESULT IN SPILLS AND EXPOSE PERSONNEL TO HAZARDOUS MATERIALS. Carrier 3.2 Check hose connector seal condition and replace seals as required. Carrier 3.3 Attach hose lines and blowdown connector with blowdown facing downward as per Appendix 1. DO NOT USE UTILITY AIR FROM PLANT. EACH TRUCK MUST USE ITS OWN AIR SYSTEM TO PRESSURIZE TANK ON TRUCK. Continued on next page Page 4 of 12

5 Continued Responsibility Step Action Initial/Date DUE TO GAS BLANKET ON 99-SRU AMINE TANK, TRUCK IS EQUIPPED WITH A PUMP AND AMINE IS PUMPED OFF. AIR IS NOT USED. Carrier 3.4 Test equipment for leaks as per carrier company offloading process. Ops Rep 3.5 Open tank valve. Carrier 3.6 Begin offload. Ops Rep & Carrier 3.7 Review steps with Carrier and initial here to confirm understanding of actions required in these steps. OFFLOADING ACID, CAUSTIC OR PEROXIDE REQUIRES AN OPERATIONS REPRESENTATIVE TO REMAIN WITH THE CARRIER THROUGHOUT THE ENTIRE OFFLOAD. Ops Rep 3.8 Maintain radio contact if leaving offload site. Note: Ops Rep to remain at offload site if acid, caustic or peroxide are being offloaded Ops Rep, Carrier & CRO 3.9 Monitor tank levels during offload. OFFLOADING MUST STOP IMMEDIATELY IF HIGH LEVEL ALARM SOUNDS: ALL SPILLS MUST BE REPORTED. CONTACT OPERATIONS SUPERVISOR. Carrier 3.10 Watch for leaks while ensuring appropriate venting. Carrier 3.11 Monitor that pressure in trailer remains within appropriate range as per carrier company offloading process. Carrier 3.12 Contact Ops Rep to return to offloading site when offload of each trailer is complete. Ops Rep & Carrier 3.13 Utilize pressurized air from tank truck to blow lines clear of chemical. Note: Do not use utility air from plant. Ops Rep & Carrier 3.14 Close offloading valves. Ops Rep & Carrier 3.15 Disconnect offload hose and reinstall connector caps. Ops Rep 3.16 Record final tank level in table 1.0. Ops Rep 3.17 Advise CRO that offload is complete. Ops Rep 3.18 Go to major step 6. Page 5 of 12

6 4. Complete Dry Chemical Offload BOL Review Responsibility Step Action Initial/Date STOP WORK IMMEDIATELY AND CONTACT OPERATIONS SUPERVISOR IF THERE ARE ANY DOCUMENTATION DISCREPANCIES: TO PREVENT FILLING THE WRONG TANK OR SPILLS FROM OVERFILLING TANKS. Ops Rep & Carrier 4.1 Cross reference BOL, tank number, product placard and UN number to verify correct product, tank, and product line and add this information to table 1.0. Ops Rep & CRO 4.2 Ensure silo vent filter cleaning impactor is ON for duration of offload plus a minimum of one hour. DO NOT OFFLOAD IF SILO DOES NOT HAVE THE AVAILABLE CAPACITY: OVERFILLING THE SILO CAN LEAD TO SPILLS OR CREATE A HAZARDOUS BACK PRESSURE IN THE TRAILER. DO NOT SPLIT LOADS WITHOUT AUTHORIZATION AS PER TABLE 1.0. Ops Rep & CRO 4.3 Compare amount of product in trailer to available silo capacity and add this information to table 1.0. Ops Rep & CRO 4.4 Ensure current silo level supports amount being delivered. TEST THE SILO HIGH LEVEL ALARM TO ENSURE PROPER OPERATION: IF THE DCS TRANSMITTER FAILS, THE SILO MAY BE OVERFILLED AND DRY CHEMICAL OVERFLOW FROM THE TOP OF THE SILO. Ops Rep & CRO 4.5 Confirm level using silo gauge and remote gauge before offloading. Note: Using current silo dip reading if applicable. Ops Rep 4.6 Record initial tank level in table Complete Dry Chemical Offloading Responsibility Step Action Initial/Date Ops Rep 5.1 Unlock hose connector cap if required. Ops Rep 5.2 Remove hose connector cap. Carrier 5.3 Check hose connector seal condition and replace seals as required. Carrier 5.4 Attach hose lines. Page 6 of 12

7 Responsibility Step Action Initial/Date EACH TRUCK MUST HAVE ITS OWN BLOWER FOR THE DRY CHEMICAL. DO NOT USE PLANT AIR. Carrier 5.5 Test equipment for leaks. Note: As per carrier company offloading process STOP OFFLOAD IF THE HIGH LEVEL ALARM SOUNDS AND CONTACT OPS REP AND OPERATIONS SUPERVISOR TO DETERMINE PATH FORWARD: TO PREVENT OVERFILLING TANK AND SPILLS. Carrier 5.6 Begin offload. Ops Rep & Carrier 5.7 Review steps with Carrier and initial here to confirm understanding of actions required in these steps. Ops Rep 5.8 Maintain radio contact if leaving offload site.. Carrier, Ops Rep, & CRO 5.9 Monitor tank levels during offload. Carrier 5.10 Watch for leaks while ensuring appropriate venting. Carrier 5.11 Monitor that pressure in trailer remains within appropriate range as per carrier company offloading process. Carrier 5.12 Contact Ops Rep to return to offloading site when offload of each trailer is complete. Ops Rep & Carrier 5.13 Use pressurized air from tank truck to blow lines clear of chemical. Note: Do not use utility air from plant. Carrier 5.14 Close truck valve and remove hose when offload is complete. Ops Rep 5.15 Reinstall hose connector cap when offload is complete and relock if applicable. Ops Rep & CRO 5.16 Ensure silo vent filter impactor remains on for a minimum of 1 hour after offload completion. Ops Rep 5.17 Record final tank level in table 1.0. Ops Rep 5.18 Advise CRO that offload is complete. Page 7 of 12

8 6. Complete Post-offload Activities Responsibility Step Action Initial/Date Ops Rep 6.1 Ensure all containment trays are cleaned out and stored appropriately. Ops Rep 6.2 Clean envirobox and relock envirobox / hose connector (if applicable). Ops Rep & Carrier 6.3 Disconnect grounding cable. Ops Rep & Carrier 6.4 Remove wheel chocks. Ops Rep & Carrier 6.5 Remove signs and barriers. Ops Rep 6.6 Sign BOL clearly including written name, badge number, and signature. Note: Arrival time to staging area and departure time MUST be confirmed accurate before signing. Add this information to table 1.0. Ops Rep & Carrier 6.7 Ensure that table 1.0 is completed before leaving offload site. Ops Rep & Carrier 6.8 Ensure Carrier has signed out of Entry/Exit log and returned monitor and radio to Ops Rep. Ops Rep 6.9 Escort truck back to staging area. Ops Rep 6.10 Deliver all BOLs to drop box inside northeast corner of Doc X at warehouse on that same day. Ops Rep 6.11 Ensure completed procedure along with FLHA is filed with permits every day. Ops Rep 6.12 Notify supervisor to assign an Action Management to SCM with any issues or concerns with this offload. End of Procedure Page 8 of 12

9 Operator Review (Filled out by last Operator to use document) Status of this procedure Yes Initial / Date Action 1 Procedure has been completed. A Procedure is correct as written. Give this entire document to your Supervisor. B Procedure is correct but needs to be enhanced. Write suggested changes on the document. Give the markup to your Supervisor. 2 Procedure cannot be completed. Procedure needs corrections. Stop work. Circle the step(s) that cannot be completed. Discuss with your Supervisor to try to resolve issues. If necessary, obtain a deviation per RGP11007 before completing work. Procedure Use Log Name (Print) Date Badge No. Signature Initial Completion The above steps have been performed as instructed. Initials and dates (if required) have been entered on the fields provided to indicate successful completion of the steps. This document is ready to be uploaded as required by Operating Area process. yyyy/mm/dd Action Shift Supervisor Print Name Shift Supervisor Signature Date Upload this entire document as required by Operating Area process. Page 9 of 12

10 References Document / Type P&ID TOE ILPs / MOCs MSDS Safety Systems / PTP / PSI Related Procedures Associated Checklists Associated Diagrams Vendor Documentation PHA Other Use the following documents for clarification or support: Reference Site drawings showing locations of tanks are available As required for chemicals being offloaded FBOP5127C - 191V-5090-A GT 191 CO2 Supression System Fill & Startup Table 1.0, Suncor Bulk Offloading Information Record Definitions Acronym / Term BOL Op Rep Carrier TDG CRO The following acronyms and terms are used in this procedure: Bill of Lading Definition Operations representative who has been specially trained to monitor bulk offloading. Qualified truck driver with required certification/training in TDG, bulk offloading and chemical handling. Transportation of Dangerous Goods training Control room operator Page 10 of 12

11 Roles and Responsibilities The following individuals and groups have the following defined responsibilities: Document Owner Ensures this document is reviewed according to the required revision cycle. Ensures the document is updated to accommodate engineering changes within the plant. Ensures the document is updated to mitigate risks found as the result of an incident. Document Approver Ensures this document is necessary and that it aligns with management and company direction. Provides resolution of any interpretation issues associated with this document. Shift Supervisor Ensures the proper use of this document. Verifies this document has been signed off correctly. Uploads document record to working folder as required. CRO Confirms tank levels before off-loading begins Monitors tank levels during off-loading Operations Representative Accompanies truck and driver to offloading site to assist & monitor offload as required Carrier/Truck driver Performs all actions related to operation of truck and trailer Summary of Changes Rev Date (yyyy/mm/dd) Section(s) Changed Revisions Made Notes: Page 11 of 12

12 Blowdown Valve (Supplied by Carrier) - Appendix 1 Blowdown valve assembly provided by Carrier is installed on the truck valve. The offload hose is attached to the blowdown valve and the other end of the hose is attached to the Suncor line/valve. Blowdown valve is positioned downward so that it can function as a drain if required. However the primary intent is that trucker can install the truck airline to the fitting/valve if needed. If an offload is stopped and the truck valve closed while there is still product in the hose, air can be introduced to blow the hose contents into the Suncor line/tank before closing the Suncor line/valve. The air supply line must be equipped with a check valve so that the product being offloaded cannot enter the truck air system. The air supply pressure must also be controlled so that it does not exceed the air pressure used to pressurize the truck tank. Carrier Wait Time Eligibility Appendix 2 Carrier is eligible to charge wait time if total offload time exceeds 3 hours for single trailer or 4 hours for B train and: Carrier arrives at scheduled appointment time and Suncor cannot proceed with offload Suncor requests a split load Suncor requests a stoppage of the offload Suncor equipment issues prevent the offload from proceeding Carrier is NOT eligible to charge wait time if: Carrier is late for appointment and waiting for new appointment time Delay is due to Carrier s inability to manoeuvre truck and trailer into offloading position Carrier equipment issues prevent offload from proceeding Page 12 of 12

13 The following individuals have approved and signed this document UserName: Richard Babb (rbabb) Title: Mgr Operations Plant 91/92 Date: Monday, 31 July 2017, 03:21 PM Mountain Daylight Time Meaning: I approve that this document is valid. ================================================