Decontamination of Process Equipment

Decontamination of Process Equipment DP-11-031-30
This is a Controlled Document that complies with Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards. Please check that this is the latest available version before use. Title: Number: Version Number: Date Revised: Owner: Authoriser: Reasons for Creating or Amending Document Actual Change Details:
DECONTAMINATION OF PROCESS EQUIPMENT DP-11-031-30

12.0 06 December 2012 Nikola Maksimovic Melanie Jensen
New or Amended Process
Created Hyperlink and refernce to sodium cyanide deconatmination procedure GM-KC-000-07
TABLE OF CONTENTS
1. 2. 3. 4. 4.1 4.2 PURPOSE .................................................................................................................................. 3 OVERVIEW .............................................................................................................................. 3 PROCEDURE ........................................................................................................................... 5 REFERENCE MATERIAL ..................................................................................................... 5 GUIDELINES FOR EQUIPMENT DECONTAMINATION ............................................... 5 RECORD KEEPING TABLE ............................................................................................... 7
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Document last modified: 06 December 2012. PDF created: 23 April 2013.
Figure 1 Decontamination Tag System Flow Chart
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1.
PURPOSE
The purpose of this procedure is to describe the decontamination tag system used when any item of equipment, especially those of which have been in contact with hazardous materials, are taken out of service or off hire for transport and/or repair offsite.
2.
OVERVIEW
Many items of equipment such as pipes, valves and pumps, when in service, can be in contact with hazardous materials. When these items need to be taken out of service for transportation and/or repair off site or on site, they must be decontaminated so that persons involved in transportation and repair of the items can handle them safely. The decontamination process described in this procedure shall be applied equally to hire equipment that has been in contact with any hazardous material. Hire equipment must be free from contamination before being taken off hire. To ensure that contaminated items are decontaminated before transportation and repair, a decontamination tag system is used. The system also ensures that readily accessible records of decontamination are available. Hazardous materials include but are not limited to: Note: Sodium cyanide. Ammonium nitrate. Acids. Hydrogen peroxide. Chlorine. Sodium hypochlorite. Ammonia. Strong alkalis. Flammable liquids and gases, for example sulphur dioxide and sulphur trioxide. Some trace elements: molybdenum, copper, selenium and manganese. Concentrate scrubber liquors. Fungicide. For decontamination of plant and equipment within the Sodium Cyanide Manufacturing Facility refer to Sodium Cyanide Decontamination Procedure GM-KC-000-07
Prior to equipment being moved out of the plant area or off site for repair, it must be free from any hazardous materials. Equipment and hired machinery used in our processes come into contact with other materials which are not necessarily of a hazardous nature but could be construed as being hazardous. These materials are classified as being non hazardous. It is considered good practice to ensure equipment or hired machinery has been thoroughly cleaned before being sent off site for repair or taken off hire. Non hazardous materials include but are not limited to:
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Note:
Sulphur. Some trace elements: zinc. Fertilisers. Sulphate of ammonia. Oil. Grease. If in doubt, material classifications can be obtained from the Occupational Hygiene Coordinator, or Chem Alert
The decontamination tag is used to: Detail and record the method of decontamination. Authorise movement of the item from the plant area or off site. Communicate to the receiver of the item that it has been decontaminated and any special precautions to be used in working on the item. Decontamination Tag is Form PF 941. Be sure to use the latest version.
Note:
For equipment worked on in the plant, the plant service centre or on site, the decontamination requirements must be detailed on the normal job instruction and the decontamination tag is used when required. For the purpose of this procedure: Trained & Competent Person Historically all operations personnel will be conversant with decontamination methods for the particular hazardous substances in that particular area. Further to this a formalised training package will be introduced in the base operations modules for each area. Person decontaminating the equipment refers to any person who understands and can competently perform decontamination instructions, including testing as required.
WARNING
FOR A MATERIAL THAT IS CLASSIFIED AS HAZARDOUS, THE TRAINED AND COMPETENT PERSON AND PERSON DECONTAMINATING THE EQUIPMENT SHALL NOT BE THE SAME PERSON. FOR A MATERIAL THAT IS CLASSIFIED AS NON HAZARDOUS, THE TRAINED AND COMPETENT PERSON AND THE PERSON DECONTAMINATING THE EQUIPMENT CAN BE THE SAME PERSON.
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3.
a.
PROCEDURE
Trained & competent person: 1. 2. 3. Determines the method of decontamination. Fills out the identification and procedure sections of the tag and signs it. Gives and explains the tag to the person decontaminating the equipment.
b.
Person decontaminating the equipment: 1. Decontaminates the item according to the procedure on the tag (including sampling and arranges analysis of the wash water if required). Arranges assistance from other departments as required. Signs and dates the tag in completed section (each step in the procedure is initialled when done). Informs the Qualified Person that the item is ready for inspection.
2. 3. c.
Trained & competent person: 1. 2. 3. 4. 5. Spot checks and/or inspects to ensure that decontamination is effective. Writes any special precautions that are required on the tag. Signs and dates the tag ensuring the copy is filled in and retained either in the control room or with the area Planner Attaches the tag to the decontaminated item. Arranges transport, refers to Outward Goods - Supply and Maintenance (DP-10063-01) or Rotable Repair - Kwinana Works (DP-10-020-01) for correct procedure.
4.
4.1
REFERENCE MATERIAL
GUIDELINES FOR EQUIPMENT DECONTAMINATION
WARNING
FOLLOW CLEARANCE PROCEDURES, ISOLATION AND SAFE WORK PRACTICES. IDENTIFY APPROPRIATE DECONTAMINATION AREA BEFORE PROCEEDING.
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a. b.
Dismantle Many items such as pumps & blowers will require complete dismantling and washing if they are going to be overhauled elsewhere. Draining and washing will be required before dismantling. All control valves are to be stroked to the open position where practicable Steam Purge Can be used to remove residual hydrocarbons or chemical fluids.
c. d.
Water Wash Ensure that all surfaces and internal spaces are flushed. Flush from lowest point, through to the highest point. (Initially reverse flushing flow to remove solids). Drain from the lowest point when flushing is complete. Neutralise
For example: e. f. g. Use weak sodium hypochlorite (1% available Cl) to destroy cyanide after water flushing. Generally for acids and alkalis, neutralisation is not necessary. For chlorine drums use sodium carbonate (refer to Process Engineer). Water wash and drain after neutralising. Ensure that all surfaces and internal spaces are flushed. Flush from lowest point, through to the highest point. (Initially reverse flushing flow to remove solids). Drain from the lowest point when flushing is complete. Test the wash water. Sample and analyse the last water running out or the contents of wash bath after the last wash. Allowable concentrations in wash water for CN : 1 ppm. For acids and bases pH 6 to 8. Gas test. For toxic, explosive or flammable contaminants. Allowable gas concentration. - For flammable contaminants, the contaminant in the equipment must be below 5% of its lower explosive limit.
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- For toxic gases the contamination in the equipment must be zero. h. Cover manholes and nozzles. In some cases openings may have to be blanked to prevent ingress of water and dust which may be mistaken for contaminant. Generally, manholes and nozzles should be blanked to prevent: - ingress of water and dust which may be mistaken for contaminants later; - escape of residue water which may be mistaken for contaminants. i. Degreasing: All process equipment 'externals' shall be free from oil and grease. Oil galleries drains and breather ports shall be sealed to prevent loss of oil during transport.
4.2
RECORD KEEPING TABLE
RECORD IDENTIFICATION STORAGE Form No. Document Title CSBP Decontami nation Tag MEDIA STORAGE LOCATION INDEXING METHOD RETENTION PERIOD AUTHORISED DISPOSER DISPOSAL METHOD
F941-0793
Paper
Control room or Planner
12 Months
Business Unit Manager
Recycle
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Decontamination of Process Equipment DP-11-031-30