Attachment 38 hpu whb boil out procedure

P-400-22 Steam Generation WMS: Waste Heat Boiler Boil Out Procedure

000-ZA-E-79443 Commissioning of Hydrogen Production Unit 400

Attachment_38

Work Method of Statement

P-400-22 Steam Generation Waste Heat Boiler Boil Out Procedure

System: “P-400-22” (Steam Generation)

Description: Waste Heat Boiler Boil Out Procedure

Unit: 400

SCMC: A1057

WMS Number: A1057_P-400-22_Attach_38

Reference Procedure: Commissioning Procedure – Hydrogen Production Unit 400 (000-ZA-E-79443)

Medium used:, BFW & Steam



Contents

1. SCOPE................................................................................................................................................. 3

2. HSE REFERENCE DOCUMENTATION ........................................................................................ 3

3. REFERENCE DOCUMENTATION .................................................................................................. 3

1. General documents ........................................................................................................................... 3

2. Marked-up Drawings......................................................................................................................... 3

4. PREREQUISITES .............................................................................................................................. 4

5. PREPARATION .................................................................................................................................. 7

6. PROCEDURE .......................................................................................................................................... 9

7. ACCEPTANCE CRITERIA.............................................................................................................. 13

8. FORMS ................................................................................................................................................. 13



1. SCOPE

The internal surfaces of the new WHB (C-4002) contain deposits of residual oil, grease do to manufacturing procedures. It is important that these deposits being removed from the heating surfaces because this contamination determine reduction of the heat transfer rate that will cause overheating of pressure vessel metal. These deposits can generally be removed by an alkaline boil-out using readily available chemicals. The boil out cleaning method will be applied at the same time the H-4001 refractory dry out process is in progress. The boil out generally include the following step:

Pre-flushing.

Chemical loading.

Heating up and cycling the pressure.

Emptying.

Water rinse.

Finally the steam drum inspection will take place

2. HSE REFERENCE DOCUMENTATION The following HSE documentation is required to perform this Work Method of Statement

Document Number Description

000-ZA-E-XXXXX Lock Out and Tag Out Procedure

000-ZA-E-85803 HSE Manual for Construction, Pre-commissioning and Commissioning

3. REFERENCE DOCUMENTATION

1. General documents Document Number Description

000-GB-A-62030 Overall Plot Plan

400-RA-E-75319 H-4001 Operating & Maintenance Manual

400-PV-E-98118 C-4002 (WHB Package) Operating & Maintenance Manual

2. Marked-up Drawings Drawing Number Description

400-GD.B-06102 Process Feed Preheat

400-GD.B-06108 Flue Gas WHS II

400-GD.B-06109 Tubular Reformer

400-GD.B-06110 Steam Generation

400-GD.B-06120 HP Steam System

400-GD.B-62903 sheets 1, 2 & 3

Utilities – Steam/Condensate Distribution Units 400-450-850

400-GD.B-62904 Utilities – LPGV Distribution Units 400-450-850



4. PREREQUISITES

The following activities must be achieved prior the beginning of the activities:

No Prerequisites Description Responsibility

Initials Time

Certificates check

1

All pre-commissioning activities have been completed and all required Quality Verifying documents detailed in the unit, system or sub-system Commissioning Manual have been completed and signed by all parties

2 A standard of cleanliness and tidiness acceptable to the CSU Team and Owner has been achieved within the required area.

3

The sub-system/system been punched by Commissioning Organization and all category A punch items are completed and category B punch items are reduced to the minimum to prevent interfere with commissioning activities.

4

The following general instructions shall be followed and adhered to.

Dedicated work permit must be obtained following dedicated procedure.

An emergency procedure has to be issued considering unwanted events coming from boil out activity.

All personnel working at site must be informed in advance when boil out will be carried out

Preliminary Activities – Operations

5 Check if all the relating piping and process equipment are fully installed, hydro tested and cleaned.

6 Check if the supports of the line to be flushed are properly installed

Preliminary Activities - Safety

7

Before starting any operation, the Commissioning personnel responsible of boil out has to give notification to all people present at site. Therefore a communication has to be sent to Construction Manager, Vendors, Sub-contractors and Client which work at site. Due to the risk of the activity, the responsible of the boil out give a notification at least 24 hours prior to start the operation. The notification can be sent early due to the high complexity of the activity or area in which the activity has to be done. The communication has to contain, at least, the following information:

Area involved in the activity. It is better to annex a plot plan with highlighting the area.

The extension of the area to be fended off.

Time and data of starting the activity.

The location of the discharge point.



8

Before start the boil out activity Commissioning personnel have to prepare dedicated “Circuit Flow Diagram” (marked up P&ID) in which the pipes to be cleaned have to be highlighted. The diagram has to also show all circuit modifications to be applied to carry out the activity. In particular the following information has to be shown:

Temporary blinds to be installed.

Valves to be maintain close during boil out activity.

Temporary spools to be put in place.

Chemicals loading point.

Discharge point. All additional supports and anchors to be installed

9

Commissioning supervisor will verify, before start activity, that the circuit has being prepared complying with all prescriptions written in the Circuit Flow Diagram. Commissioning personnel have also to prepare a map showing:

The location of the boil out.

The required barricaded area.

Any temporary road closure. Date and time of starting the activity

10

Commissioning responsible of the boil out has to guarantee, through sub-contractors, that at site the following actions are put in place.

Fence off at safe distance from the tested circuit.

Post signs around the barricaded area showing:

“DANGER: NO ENTRY TO UNAUTHORIZED PERSONNEL” “BOIL OUT IN OPERATION” “USE DEDICATED PERSONAL PROTECTIVE EQUIPMENT”

Install a visible pressure gauge on the system to be pressurized up, in order to continuously monitor the pressure build up in the circuits.

Isolate any electrical connections and ensure that can not be energized.

Load chemicals from manhole.

Install a drum of fresh water or, if available, hose connected with the plant water system if safety showers are not in operation.

Barricade 1 meter from both sides of the pipeline where lines are not fully insulated.

Install identification signs on all pipes involved in the activity,

Remove, at the end of the boil out, all



materials (e.g. temporary pipe, silencer, target plates…) from the area.

11

Commissioning response of the boil out has to carry out the following activities.

Obtain dedicated work permit.

Inspect the system verifying that all mitigation measures are put in place. Particular attention has to be given in verifying if the system is proper supported /anchored. The check-list shown in annex 1 must be used.

Make available Material Safety Data Sheets (MSDS) on work area.

Suspend all activities inside the barricaded area when the activity is carrying on.

Verify that all people involved in the activity wear appropriate Personal Protective Equipment (PPE).

Carry out a tool box meeting before start the activity.

Activate the emergency procedure in case an unwanted situation happen.

Inspect the system during boil out to verify if there are not leaking.

Ensure that a confined space entry permits is made available before carrying on the internal inspection.

An HSE Officer has to assist the Commissioning team to prevent non authorized personnel or vehicles from entering the barricaded area.

12 All work carried out during the commissioning phase will be covered by a work permit



5. PREPARATION

No Preparation Description Responsibility

Initials Time

13

Boil-out and passivation should not commence until all related piping and process equipment are fully installed, the system has been checked for conformance with the P&ID’s diagrams, Manufacturer drawings and Project specification, the piping systems have been hydro-tested and insulation material installed.

14 Calculate the volume of the equipment and piping connected.

15 Detailed boil-out and passivation procedure shall be made available and approved by Manufacturer, Contractor and Client.

16 MSDS shall be attached to the procedure for each chemicals that will be used.

17

Check that the construction’s material of the equipment is suitable for the type of chemicals that are going to be used. Note that an improper boiling out can produce: a. stress corrosion cracking of stainless steel induced by chlorides. b. stress corrosion cracking of carbon steel induced by hydrogen sulphide released during chemical cleaning c. caustic embrittlement of carbon steel d. risk of hydrogen induced cracking/blistering because sulphide-containing scale is present.

18

In case of a fired boiler, check that firing equipment and controls are installed, operational and documented as per Site Quality Control Plan. In particular: - Make sure that boiler purging procedure have been carried out - Make sure that pilot and burners have been tested - Make sure that interlock system has been tested

19 In case of a HRSG, check that gas turbine is installed, operational and documented as per Site Quality Control Plan.

20 Clean the internal surfaces of the steam drum from deposits, scales, grease and foreign materials that are residues of the erection.

21 Check that the area is provided with proper drainage for collecting the liquid that is drained out from the steam generator during washing and rinsing.

22

The following list includes the minimum equipment required for the boil-out procedure: - Steam drum gauge glass; - Steam drum pressure manometer; - Water sampling facilities.

23 Close all primary connections of instruments that are not required during boil-out.

24 Check that feed water line (demineralized water or boiler feed water) has been properly cleaned and commissioned up to the



heat generator steam drum.

25

Prepare a map showing:

The location of the Activity

The required barricaded area

Any temporary road closure, if any

Date and time of starting the activity

26 Fence off at safe distance from the purged circuit

27

Post sign around the barricaded area showing:

“DANGER: NO ENTRY TO UNAUTHORIZED PERSONNEL”

“COMMISSIONING IN PROGRESS”

“USE PROPER PERSONAL PROTECTIVE EQUIPMENT”

28

In addition to the PPE required for the normal activities (helmet, safety shoes, goggles, gloves) inside the plant, it is mandatory to use the following personal protection: During chemical filling operation and vessel emptying the following PPE must be used:

Coveralls Rubber gloves Dedicated gas mask Rubber apron

During check operation and preparation of circuit the following PPE must be used:

Coverall

During internal inspection All PPE required to enter in a confined space

(see the general specification SPC.PR.CMS.0118 - Confined spaces entry permit safety instructions)

29

Ensure that a confined space entry permits is made available before carrying on the internal inspection. Moreover ensure that confined spaces procedure is followed. NOTE: An HSE officer has to assist the Commissioning team to prevent non authorized personnel or vehicles from entering the barricaded area.

30

Commissioning supervisor has to fill out the check list shown in Annex 1. The activity can start only if all applicable answers are positives. When one or more answers are negatives Supervisor, involving if necessary his Superintendent or Commissioning Manager, must find proper mitigation measures. Any decision taken has to be written in the form. The activity can’t start until all answers are positives

31

The check list filled out has to be handed over to Commissioning Superintendent who maintains a store. During the activity the check list filled out has to be available at site and, when request, has to be shown to the HSE Officers.



6. PROCEDURE The boil out cleaning method will be applied at the same time the H-4001 refractory dry out process is in progress. It is of paramount importance to adhere to the maximum temperature increase and holding time stipulated in the WMS “H.4001 Refractory Dry Out Procedure”. The holding time at the different BWT levels can be extended if the Boil Out holding time is not achieved yet but never it should cut short. This concern is further detailed in the Refractory Dry Out WMS.

No Procedure Description Responsibility

Initials Time

32

33

34

35

36

37

CHEMICAL CHARGES



38

39

40

PRELIMINARY WASHING

1 Make sure that all connections are tightly closed.

2 Open the Steam Drum vent and connect it to a hose pipe.

3 Start-up the Feed-Water pump and maintain a large flow

through the by-pass of the Feed water control valve

4 Fill-up the system with clean de-mineralized Water until it

overflows through the vent nozzle.

5 Stop filling the Water and drain it through the valves at the

lowest point.

6 Repeat this operation once

41

HOT DEGREASING

1 This operation is done when starting-up the upstream equipment, by sending hot Gases in the Boiler. Its purpose is to remove grease and oil deposits from the internal surfaces of the unit

2

3



4

5

6

7

8

9

10

42

PRESSURIZED BOILING-OUT

The purpose of this last stage is to achieve degreasing, to remove scales and to pickle internal surfaces.

Ensure to interact with the WMS “Refractory Dry Out Procedure” with respect to temperature increase and holding time at different BWT levels (Appendix 3)

1

2

3

4

5

6

7

8



9

10

11

44

45

46

47

48

49

50

51

52



7. ACCEPTANCE CRITERIA The acceptance criteria for this WMS is when all the steps are completed to satisfaction.

8. FORMS



Appendix 1 CHECK LIST

BOIL OUT ACTIVITY

DESCRIPTION CHECK

YES NO N.A.

1 Dedicated work permit obtained.

2 System under boil out is marked up on P&ID.

3 System under boil out is inspected.

4 System under boil out is properly supported.

5 The system under cleaning is barricaded off.

6 Tool box meeting done.

7 MSDS is exposed on area.

8 Safety showers are in operation.

9 Drum of fresh water or, if available, hose connected with the plant water system.

10 "DANGER: NO ENTRY TO UNAUTHORIZED PERSONNEL”, “BOIL OUT IN

OPERATION” and “USE PROPER PERSONAL PROTECTION signs are posted.

11 All personnel not involved with the boil out are evacuated.

12 An HSE Officer is present on the area.

13 All involved personnel worn PPE.

14 Special PPE (_________________________________________) are worn.

15 Any electrical connections are de-energized.

16 All lines are fully insulated or adequately barricaded 1 meter from both sides of the

pipeline and, as “live line” signs are posted.

SUBCONTRACTOR CONSTRUCTION SUPERVISOR SIGNATURE

COMMISSIONING SUPERVISOR SIGNATURE



Appendix 2 QUALITATIVE JOB HAZARD ANALYSIS BOIL OUT ACTIVITY

Step

no

Description

of task

step

Hazard

Potential

incident

Who or

what might

be harmed

Control measures / recovery measures

1

Check the

circuit before

the activity

Fall from elevation Commissioning

Operator

Scaffold verification.

Correct use of safety harness (installation of the life

line).

Permit to work.

2 Preparation of

the circuit Fall of materials Worker Area barricaded and personnel removed

3

Motor

energization

(pump)

Electrical and

mechanical

Commissioning

Operator

Worker

Electrical tag and lockout verification

4 Chemical filling

Corrosion material

Environment

pollution

Commissioning

Operator

Worker

All adequate PPE must be used and verify the use

before start.

Follow the MSDS for control measure.

5 Boil-out activity

Chemical exposure

from:

- flange connection

- vent

- drain

All workers at

the vicinity

Restrict area. Remove all people from the vicinity.

Install all safety signs related.

Fire fighting system working.

Wear adequate gloves and goggles.

Safety showers in operation.

Tool box meeting.

Corrosive material

during chemical

analysis

Worker

All adequate PPE must be used and verify the use

before start.

Follow the MSDS for control measure.

High temperature Worker

Barricade the pieces of the lines without proper

insulation 1 meter from both sides.

All lines involved in boil out must be clearly identified

with safety signs.

Warn personnel by signs and wear adequate gloves.

Pipes insulation.



Appendix 2 QUALITATIVE JOB HAZARD ANALYSIS BOIL OUT ACTIVITY - CONTINUED

Step

no

Description

of task

step

Hazard

Potential

incident

Who or

what

might be

harmed

Control measures / recovery measures

6 Vessel

emptying

High temperature All workers

at the vicinity

Before change the filter assure that the temperature is

reduced as ambient temperature

Corrosive material

contact Worker Wear adequate PPE

Environment

pollution

Surrounding

area

Collect the solution in dedicated container and dispose it

following waste management procedure or send in the oily

sewer

7

Internal

inspection

(confined

space)

Asphyxiation

People in the

confined

space

Atmospheric monitoring of confined space.

Installation of lifeline.

Foreseen a safety watch.

Ensure a natural or forced ventilation.

Dedicated isolation of the system (electrical and

mechanical).

Adequate lighting.

Safe access/egress.

Emergency e rescue procedure in operation.

8 Reinstatement

of the circuit Fall of materials Worker

Area barricaded and personnel not involved on the work

have to removed



Appendix 3 H-4001 Refractory Dry Out Diagram



APPENDIX 4 Documentation

General Documents

Document Number Description

000-GB-A-62030 Overall Plot Plan

400-RA-E-75319 H-4001 Operating & Maintenance Manual

400-PV_E_98118 C-4002 (WHB Package) Operating & Maintenance Manual

Marked Up P&ID

Drawing Number Description

400-GD.B-06102 Process Feed Preheat

400-GD.B-06108 Flue Gas WHS II

400-GD.B-06109 Tubular Reformer

400-GD.B-06110 Steam Generation

400-GD.B-06120 HP Steam System

400-GD.B-62903 sheets 1, 2 & 3

Utilities – Steam/Condensate Distribution Units 400-450-850

400-GD.B-62904 Utilities – LPGV Distribution Units 400-450-850

Attachment 38 hpu whb boil out procedure

Technology

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