UNIT 3

Documents used for

Operation of Process Plants
OBJECTIVES
1. Describe the various documents used in
operating a process plant.
2. Explain the purpose of Work Permit
System.
3. List the 3 types of work permit commonly
used in the process industry.
4. Describe the function of the 3 types of
work permit.
INTRODUCTION

• Process Plants have a collection of

documents related to the technology
and operations.
• Also include data and records of day-to-
day plant operation.
Examples of Important
Document
• Process Diagrams
• Daily Operating Instructions (DOI)
• Operator Log Books
• Product Specification Sheets
• Standard Operating Conditions (SOCs)
• Operating Procedures Manual
• Unit Technical Manual
• Safety Manual
• Material Safety Data Sheets (MSDS)
Examples of Important
Document
• Daily Operation Records
• Work Requests
• Standard Operating Procedures
• Work Permits
PROCESS DIAGRAMS

• System Diagrams
• Equipment Location Diagrams.
 SYSTEM DIAGRAM

• Drawings and diagrams that represent

parts of a system and the flows
between the parts.
• 3 common types are namely:
A. block diagrams,
B. piping system diagrams, and
C. electrical diagrams.
 BLOCK DIAGRAM

• Represents some of the basic parts that

all systems have.
 BLOCK DIAGRAM

• Another type of Block diagram is:

A. process flow chart
 PIPING DIAGRAMS

• Provide more details than Block

Diagram.
• 2 common types of piping diagrams are
namely:
A. flow diagrams and
B. piping and instrumentation diagrams (P &
lD's).
 FLOW DIAGRAM

• Used lines to represent process flows, and

symbols to represent process equipment
in the system, including tanks, pumps, and
valves.
• Does not show the devices used to
monitor the process or all of the devices
used to control the process.
FLOW DIAGRAM
PIPING AND
INSTRUMENTATION
DIAGRAM (P&IDS)
• To show how a process is monitored
and controlled.
• Show material flows, equipment in the
system, and the devices used to monitor
and control the system.
PIPING AND
INSTRUMENTATION
DIAGRAM (P&IDS)
 DAILY OPERATING
INSTRUCTIONS
(DOI)
• Include information such as product
scheduling, daily operating objectives or
targets, special operating instructions,
maintenance schedules.
• Also known as daily order book (DOB).
 LOGBOOK

• Also known as Log or LogBook.

• A written document to record significant
events, operating condition, safety hazards,
equipment problems and operational
problems to pass on to other operators on
future shifts and to the supervisors of the
plant.
• Should be kept accurately and completely.
PRODUCT
SPECIFICATION
SHEETS
• Provides information about the products
produced by the unit.
• Different grades of material, or completely
different products, each grade or product
will have its specification sheet.
• List the properties used to judge product
quality and the acceptable values for on-
specification product.
PRODUCT
SPECIFICATION
SHEETS
• Referred to when filling out a certificate of
analysis for a unit product.
• This is a way to prevent off-specification
product from being shipped.
STANDARD
OPERATING
CONDITIONS (SOCs)
• Known as the goals and acceptable
ranges for the controllable variables
(temperature, pressure, flow. level,
composition) of the processing unit.
• Operating within these ranges is
necessary to produce on-specification
product.
 OPERATING
PROCEDURES
MANUAL
• Contains detailed instructions for
properly operating the unit.
• Include startup, shutdown, and
emergency procedures, plus normal
operating procedures.
• Also include safety information.
UNIT TECHNICAL
MANUAL
• Contains detailed information about the
unit process and equipment.
• Include process description, process
chemistry, unit limitations, information
about major equipment (construction
material, stress rating, dimensions, etc.),
and a summary of the unit's instrument
control strategy.
 SAFETY MANUAL

• Contains information like unit safety

procedures, site safety policies, and
safety standard operating procedures
(SOPS).
 MATERIAL SAFETY
DATA SHEETS
(MSDS)
• provided by the Chemical Suppliers/ Vendors.
• Contain information on the hazards of the
chemicals present in the unit.
• Provide data on toxic, flammable, and
reactive characteristics of the chemical
materials.
• Provide information on safety equipment that
should be used and special precautions that
should be followed when handling these
materials.
DAILY OPERATION
RECORDS
• Are historical records
• Prove useful when troubleshooting and
updating procedures.
WORK REQUESTS

• Used to request service and repair of

process equipment.
• Also provides a record of the completed
maintenance work on each unit.
STANDARD
OPERATING
PROCEDURES (SOPS)
• Are procedures that may or may not
relate to the running of the unit to make
product.
• Are plant or unit policies that should be
followed without deviation.
LABORATORY
ANALYSIS REPORTS
• the bench mark for unit operations,
• and operating conditions are often
based on results included in the
reports.
 SAMPLE
INFORMATION
• Used while operating a process plant.
• The production pattern in many cases
may depend on this information.
 TEST RESULTS

• In some plants, operators would test

samples themselves,
• and the results of the tests become part of
the unit’s permanent written record.
• The tests must be done correctly, and the
results must be recorded accurately in
sample analysis reports.
 Permit To Work
System (Work
Permit)
• A special document (permit) before
certain types of work can be done.
• To force personnel involved in a
hazardous task to take the time to review
all the steps, personal protective
equipment (PPE), hazards, and additional
equipment required to perform the task
safely.
 Permit To Work
System (Work
Permit)
• A formal written system used to control
certain types of work which are identified
as potential hazardous.
• A means of communication between
site/installation, maintenance and
contractors to ensure all necessary safety
precautions are taken before commencing
the work.
 COMMON PERMITS
• Confined space
• Lockout/ Tagout (LOTO)
• Hot work
• Cold work
• Opening/ blindimg
• Radiation
• Critical lifts
• Electrical
 HOT WORK PERMIT
• any maintenance procedure that produces a spark,
excessive heat, or requires welding or burning.
• Must indicate the following:
– That fire prevention and protection measures will be in
place before the hot work is initiated.
– The date(s) the permit is approved for.
– The location and equipment in use where the hot work is
performed.
– That a fire watch will be posted and in place during
the procedure and 30 minutes after the work is
complete.
REASON FOR FIRE
WATCH
• To prevent any unseen spark from the hot
work igniting any material in the hot work
area.
 LOCKOUT/ TAGOUT
PERMIT (LOTO)
• To control hazardous energy.
• In a lockout system, a padlock is placed to
prevent energy from being turned on.
• A tagout system is just like a lockout
system except a tag is included with the
lock.
VESSEL ENTRY
PERMIT/ CONFINED
SPACE ENTRY
PERMIT
• A permit to enter the vessel/ confined
space.
• Confined space may contain a toxic
atmosphere, chemicals, an oxygen
deficient atmosphere, flammable
materials, power-driven equipment, or
other hazardous conditions.
EXAMPLES OF
CONFINED SPACE/
VESSEL
• Storage tanks
• Large pipes
• Distillation Towers
EXAMPLES OF
CONFINED SPACE/
VESSEL
QUESTIONS?

• TUTORIAL 3
• TO BE COMPLETED BY 29
JAN 09 11.30AM.