Process Safety knowledge for live plants

1. Process Safety (ADNOC)
What is process Safety Engineer?
 Process safety focuses on preventing fires, explosions and accidental chemical releases in
chemical process facilities or other facilities dealing with hazardous materials such as
refineries, and oi; and gas(onshore and offshore) production installations
Commissioning
 Process commissioning is a key activity for any new plant and it is important that any issues are
identified and dealt with while Project resources are available rather than after hand over to a hard
pressed Operations team.
 Project commissioning is the process of assuring that all systems and components of a building or
industrial plant are designed, installed, tested, operated, and maintained according to the operational
requirements of the owner or final client.
 Commissioning / pre-commissioning means: functional testing of equipment before startup like air
blowing, load test, capacity testing
Question. what is pre-commissioning on natural gas pipeline?
Answer: Pipeline pre-commissioning is the process of proving the ability of a pipeline and piping
systems to contain product without leaking. This product may be liquid, gaseous or multiphase
hydrocarbons, water, steam, CO2, N2, petrol, etc.
Pre-commissioning is the series of processes carried out on the pipeline before the final product is
introduced.
The process during which the pipeline is made "live" i.e. the product is put in the pipeline, is called
pipeline commissioning or start-up.
Question: If you are near a pipeline right-of-way and you see or hear any of the following,
it could indicate a leak: An unusual whistling, hissing or roaring sound could indicate product leaking from
a pipeline. A smell of petroleum could indicate an oil leak, and the smell of rotten eggs could indicate a
natural gas leak Damaged or discolored vegetation build-up of frost on the ground or pools of liquid.
Bubbles rising in free-standing water Isolated vapor or mist clouds?
Answer Protecting yourself in an emergency If you notice any of the signs listed above, here’s what you
should do: 1. Leave the area immediately
2.if possible, walk into the wind for at least 750 meters.
3. Warn any others nearby to evacuate, particularly if there are children or others requiring assistance.
4. Extinguish any fires, smoking materials and potential ignition or spark sources – including any
unnecessary electronic equipment Call Emergency no.
5. Call the pipeline company look for pipeline right of way and warning signs for emergency call numbers
What is flow line?
The well flow line, or simply flow line, is the first “pipeline” system connected to the wellhead. The flow line
carries total produced fluids (e.g., oil, gas, and production water) from the well to the first piece of production
equipment—typically a production separator
What is pressure?
It is the force exerted on a fluid particle from all directions, and is typically measured with gauges and
transmitters attached to the side of a pipe or tank wall. Since static pressure is what most pressure gauges
measure, static pressure is usually what is implied when the term "pressure" is used in discussions

2. Question. what is pyrophoric material and hazards?
ANSWER
 Pyrophoric materials are substances that ignite instantly upon exposure to oxygen.
 They can also be water-reactive, where heat and hydrogen (a flammable gas) are produced.
 Other common hazards include corrosively, teratogenicity, and organic peroxide formation, along with
damage to the liver, kidneys, and central nervous system.
 Examples of such materials include metal hydrides, finely divided metal powders, nonmetal hydride and
alky compounds, white phosphorus, alloy of reactive materials and organometallic compounds,
including alkyllithiums. Failure to follow proper handling techniques could result in serious injury or
death.
 If possible, use alternative safe chemical. BEFORE working with pyrophoric reagents, read the relevant
MSDS sheets and associated technical bulletins.
 The MSDS must be reviewed before using an unfamiliar chemical and periodically as a reminder.
 If a person is exposed, or on fire, the use of the stop, drop, and roll method, safety shower, a fire blanket,
or fire extinguisher are the most effective means of controlling clothing on fire.
 If a safety shower is available, keep the person under the shower for at least 15-20 minutes to ensure all
chemicals are washed.
 USE D TYPE FIRE EXTINGUISHER
 PC1. means oil filling moved to fin fan area
 PC2. means gas filling area
 Closed drain there is not any opening all drains in pipes, finally moved to drum pit area then coming for
recycling, possible available hydrocarbon
Working in under commissioning area precautions are below:
 Commissioning area blue and white warning tape precautions:
 Check list there five people will sign including TCM site safety
 PTW
 TRA
 Signed by Commissioning manager
 Competent personal with access card
 No mobile, lighter or any ignition items
 Mandatory PPE’s personal gas monitor, H2S card, fire retardant cover all
Precaution of hot work in live lines:
 Covering all live lines by approved fire blanket
 Fire watcher
 Fire extinguisher
 Close supervision
Hazards in live lines
 Sudden release of pressure
 Fire and explosion
 Suffocation due to gas present
 Gases
Main Hazards in live facilities:
1. Energized equipments
2. Pressurized lines/ system
3. Hot surfaces
4. Steam release
5. Gas / chemical release

3. 6. Nitrogen purging
7. Rotating equipments / parts
8. Noise
Commissioning knowledge:
Conflicting activities:
1. Inadequate work permit for the particular activity
2. Lack of coordination between different disciplines e.g. piping modification vs commissioning activity
3. Lack of commissioning activity awareness
How to prevent:
1. Shall attend TCM access control training
2. Valid PTW and all attachments are available
3. Shall apply PTW precautions
4. In case of testing / energization communicate your activity to all other discipline and authorities through
proper channel
5. Conduct TBT
6. Coordinate with operation and HSE
7. Cordon off and barrication, signage’s
8. Follow work sequence as mentioned in approved M.S.
9. Close out work permit and remove all barricading & signage’s once you finish your activity
Air blowing and water flushing hazards and precautions:
1. Slip, trip, fall
2. Mechanical failure
3. Struck by
4. Unauthorized entry to flushing area
5. Dust
6. Over pressure
7. Noise
8. Oil fuel leakage during operation
9. Line of fire
10. Pinch points
Precautions:
 EPTW, MS, TRA
 Approved test pack shall be available
 Flushing water shall be disposed at designated area
 Visual inspection of all lines, blanks and fittings to be carried out prior to start the activity
 Positive isolation shall be ensured
 Keep blinding of temporary valve used on flushing when system header change
 Whip check applied
 Stay away from the pressurized hoses and valve
Knowledge point:
 Holding nitrogen in pipe lines to avoid rust / moisture in pipe lines
 Excavation near live line tell first scanning
 Hot bolting: re tightening, removing, replacing or freeing in live piping and equipment
 Reinstatement: checking all items that meet as per drawing e.g. valve, spool, elbows etc
What steps are taken before starting jobs in gas line? S/D Question
The requirement for the safe operation while working on gas line are the following:
Written clearance from the department which ensures that:
 Water sealed has been done ,

4.  Route valve is closed,
 Gasoline is blanked,
 Isolated portion of gas line is depressurized,
 Purging with nitrogen has been done,
 Carbon monoxide measured and found zero
 Gas safety equipment must be available at the spot
 SOP/SWP & gas safety training
 Cordoning off the work area & display a board with ,, man at work,,
 Rescue consideration
PSSR: pre-start-up safety review
The PSSR is a safety review conducted prior to start-up (commissioning) of a new or modifying
processing/manufacturing plant or facility to ensure that installations meet the original design or operating
intent to catch and re-assess any potential hazard due to changes during the detailed engineering and
construction.
PSM: Product safety management
PSM process means any activity involving a highly hazardous chemical including using , storing,
manufacturing handling, or moving such chemicals at the site, or any combination of these activities.
What is pigging?
 Pigging in the context of pipelines refers to the practice of using devices known as "pigs" to
perform various maintenance operations.
 This is done without stopping the flow of the product in the pipeline.
 These operations include but are not limited to cleaning and inspecting the pipeline
A Relief Valve, or Pop-Off Valve, is a secondary pressure regulating device used to back up the primary
regulating device. If the primary regulating device fails to by-pass at a set system pressure, the relief valve
will open and allow liquid to flow freely.
DIFFERENCE BETWEENPRV and SRV?
 Both are relief valves but serves different conditions. PRV is used when dealing with liquids and
opens gradually with gradual increase in pressure whereas PSV is used when dealing with
incompressible fluids especially gas phase where the opening must be spontaneous with the
sudden increase in pressure.
 An example of safety valve is a pressure relief valve (PRV), which automatically releases a
substance from a boiler, pressure vessel, or other system, when the pressure or temperature
exceeds preset limits. Pilot-operated relief valves are a specialized type of pressure safety valve.
Question. What four precautions must be taken before allowing repairs to proceed on an unidentified pipeline in a
chemical plant?
Answer.
1. Identify the line and its contents.
2. Isolate and depressurize the line.
3. Drain and flush the line
4. Gas free the line if necessary.
5. Issue a permit to work to cover the specific repair.
Question. Pump Start but Motor gets overloaded or Trip on overload. (multiple answer)
A. Alignment is wrong
B. Gland packing too tight
C. Worn out / Damaged ball bearing
D. Cavitation exists
ANSWER ABC
QUESTION: During flooding of a dry dock the following items must be verified (fb majority)
A. All sea valves are operational
B. All overboard discharge valves are operational

5. C. Stern tube seal are operational
D. All of the above
ANSWER D
QUESTION: Which type of valve is Bidirectional.
A. Globe valve
B. Gate valve
C. Ball valve
D. Butterfly valve
Answer A. GLOBE VALVE.
QUESTION: Which of the following V/V cannot be overhauled in place without removing piping?
A) Ball Valve
(B) Diaphragm valve
C) Globe valve
(D) Butterfly valve----not same but related
Answer D Note. ALL ABOVE ARE MEP RELATED QUESTION
Question. what is a midstream in oil and gas?
Answer Midstream activities include the processing, storing, transporting and marketing of oil, natural gas and
natural gas liquids
Question Are refineries midstream or downstream?
Answer. Midstream. As expected, the midstream sector is the second of the three petroleum market stages. The category refers to
the transportation of crude or refined petroleum products, usually via pipeline, oil tanker, barge, truck or rail. Thefinal destination
is refineries which will then commencethe downstream
Question What are plant products in oil and gas?
Answer. Plant products in oil and gas are included such are crude oil, lease condensate, unfinished oils, refined
products obtained from the processing of crude oil, and natural gas plant liquids