6 MONTHLY FILTER AND LAMP INSPECTION ON CCR CONTROL DISPLAY UNIT (DCS-OVERVIEW)

6 MONTHLY FILTER AND LAMP INSPECTION ON CCR CONTROL

DISPLAY UNIT (DCS-OVERVIEW)

Control Room Overview Screen Lamp Change out.

TASKS TO BE PERFORMED:

WARNING: THE LAMP MODULE MUST BE SWITHED OFF FIRST, THEN ALLOWED TO COOL DOWN FOR 5 MINUTES BEFORE THE POWER IS SWITCHED OFF.

1. Remove back panels of the CCR overview screen.

2. Switch off all the lamps by pressing STOP on each module.

3. WAIT 5 MINTUES.

4. Switch off power on each module by pressing OFF.

5. Remove filter pad from each module.

6. Remove to workshop and clean filter pad using airline, if the filter is excessively blocked, replace with new filter.

7. Install filter pads in the correct direction as indicated on the side of the filter.

8. Switch on power by pressing ON, at each module.

9. Switch on lamp by pressing START at each module.

10. Sign-off Work Permit and return to operations.

11. Report all findings to supervision and document in CMMS.

CHECK WITH CONTROL ROOM AND CAUSE AND EFFECTS AND PLACE OVERRIDE ON AUGUST SAFETY SYSTEM.

ANY REQUIRED OVERRIDE MUST BE IN PLACE PRIOR TO COMMENCING WORK.

ENSURE OVERRIDE IS PLACED IN THE OUT OF SERVICE POSITION.

1 MONTHLY PREVENTIVE MAINTENANCE ON ALL INSTRUMENTATION ON WEST HP FLARE IGNITION SYSTEM

TASK TO BE PERFORMED:

INSPECTION AND FUNCTION TESTING OF FLARE SYSTEMS CONTROL PANEL AND ALL INSTRUMENTS.

CHECK PANEL MOUNTED INSTRUMENT AIR, PILOT GAS AND IGNTION GAS PRESSURE GAUGES RANGE 0-30 PSIG.

1. Annual Inspection and Calibration of Pressure Gauges.

2. Inspect Pressure Gauge for any physical damage.

3. Check Pressure Gauge is securely mounted.

4. Check Pressure Gauge for vibration.

5. Ensure gauge glass is secured correctly and is not cracked or broken.

6. Check Pressure gauge pointer for any pulsation and is not bent

7. Isolate and vent pressure gauge.

CHECK PANEL MOUNTED INSTRUMENT AIR, PILOT GAS AND IGNITION GAS PRESSURE REGULATORS

8. Inspection and testing of Pressure Regulator.

9. Inspect Pressure Regulator for any physical damage.

10. Ensure Pressure Regulator is securely mounted.

11. Check all connections and fittings are secure and check there are no leaks.

12. Check Valve body flange bolts are tight and there are no leaks.

13. Check Valve stem packing for leaks and carefully tighten if required. Do not over-tighten.

14. Check Valve Actuator Bonnet bolts are tight and there are no leaks.

15. Check supply line fittings are tight and no leaks exist. Do not over-tighten.

16. Increase and decrease the regulator setting and ensure the output pressure responds correctly.

17. Adjust the pressure set-point of the Air and Ignition Gas to 1.04 BARG.

18. Adjust the pressure set-point of the Pilot Gas to 0.69 BARG

19. with the enclosure Power OFF, and purge system air supply on:

20. Test operation of the enclosure vent and seal the enclosure.

21. Adjust the enclosure flow meter until the value reads 60 SCFH.

22. Purge the enclosure for a Minimum of 3 minutes at the above flow rate.

23. Upon completion of the purge time, adjust the flow control to a rate that maintains a minimum of 4mm H2O pressure on the Magnehelic pressure gauge.

24. Ensure this pressure is 4mmH2O and only then energize the power to the ignition panel.

25. Upon successful testing of the ignition circuit of the flare pilot, de-energize the power to the panel before removing the positive pressure to the enclosure.

26. If several tests of the ignition circuit are made are made, ensure the positive pressure is always maintained to the enclosure.

IF AT ANY TIME POSITIVE PRESSURE IS LOST TO THE ENCLOSURE, DE-ENERGISE POWER IMMEDIATELY AND START THE PROCEDURE FROM STEP NO. I. (REPEAT THE PURGE SEQUENCE AGAIN AND RE-ESTABLISH A POSITIVE PRESSURE AGAIN BEFORE RE ENERGIZING THE PANEL ENCLOSURE.

27. Turn power on to the Ignition Panel. The three "pilot failure" lights will illuminate if the flare is not lit. If the flare is lit the three "pilot failure" lights will not illuminate.

28. Depress the Ignition button while checking for a spark in the sight glass. Release the Ignition button when a spark is confirmed. Close all three G4 valves.

29. Open the Pilot gas valves G1 and G5 to establish pilot gas flow to the flare tip.

30. Ensure Pilot gas pressure should is set at 0.7 - 1.04 BARG refer to panel gauge.

31. Open air valve A2, ignition gas valves G2 and G3, and only one G4 valve and establish ignition gas flow to the pilot tip.

32. Ignition air and gas pressure should be set at 1.04 BARG. Purge the ignition line to the pilot tip for approximately 20 seconds.

33. Press and release the Ignition button while checking for a steady flame in the sight glass and ignition at the pilot tip.

34. When a flame is confirmed in the sight glass, close the ignition gas valves G3 and G4. When the temperature elements at the pilot tip are lit, the "pilot failure" light will go out. IF THE FLARE IS LIT THE PILOT FAILURE LIGHTS WILL NOT BE ILLUMINATED.

35. Open Panel and inspect unit for any damage or loose connections, tighten connections as required.

36. Clean interior of panel carefully and remove all dust and sand.

TEMPERATURE SWITCH UNITS

37. Inspect temperature switch units for any physical damage.

38. Ensure units are securely mounted.

39. Ensure all alarms are now reset.

40. ENSURE OVERRIDE IS REMOVED AND THE SYSTEM IS RETURNED TO NORMAL MODE

41. Turn power off to the Ignition Panel.

42. Sign-off Work Permit and return to operations.

43. Report all findings to supervision and document in CMMS.