Sample checklist equipment

Continual monitoring of equipment and plant is standard practice in chemical process plants. Equipment deteriorates and operating conditions may change. Repairs sometimes are made with improvements whose ultimate effects on the operation may not be taken into account. During start-up and shut-down, stream compositions and operating conditions are much different from those under normal operation, and their possible effect on safety must be taken into account. Sample checklists of safety questions for these periods are in Table 1.7. 

In reviewing the checklist as described above, if there is a safety issue identified, an agreement must be reached between the employee and the supervisor as to the nature and type of the hazard and the potential risk before the equipment can be put into operation. Refer to Appendix P, Sample Machine/Equipment-Specific Checklist . 

Make a checklist of field sampling equipment and supplies. 

Example of a Lield Sampling Supplies and Equipment Checklist... 

During normal operations, checklists and samples are collected as advanced instrumentation monitors the process. The types of problems a fired heater or furnace system typically encounter include flame impingement on tubes, coke buildup inside the tubes, hot spots inside the furnace, fuel composition changes, burner flameout, control valve failure, and feed-pump failure. Other problems may include incorrect temperature indicator readings, failure of oxygen analyzers, oxygen leaks on the furnace, and the unexpected shutdown of downstream equipment. A fired heater system is designed to run almost continuously, 24 hours a day, 7 days a week. The operational team is in place to ensure that the equipment and systems operate safely, effectively, and produce a quality product that meets or exceeds customer expectations. 

The next component of ABSS is a machine/equipment-specific checklist. This is a checklist that is used to focus on specific identified safety issues for each piece of machinery and/or equipment in the organization. This checklist is developed and updated by the employees and supervisor who works with and around the specific equipment with the input from the safety staff. The key to this list is not to make it overly detailed. We suggest that no more than 15 of the most important items are listed on this checklist, which may cover specific inherent hazards of a machine or equipment. Refer to Appendix P, Operator General Observations and Machine/ Equipment-Specific Daily Inspection Checklist . For an overview, refer to Figure 11.2, Sample General Observations and Machine/Iiquipment-Specific Daily Inspection Checklist . 

Sample General Observations and Machine/Equipment-Specific Daily Inspection Checklist. 

Team size and frequency will depend on the size of the property. At the beginning of every shift, employees should inspect their work areas and equipment before starting work to ensure that all defects are noted and corrected. Figure 11.2 is a sample daily audit form. The safety reminder checklist is not a complete list of safety topics and should be structured for your work area or fadhty. Note that the items listed in Figure 11.2arenot only positive work practices, but also government requirements. 

When coordinating the ATC/FPT-TAB initiative, the auditors should use an equipment startup checklist to complete a static condition assessment of the new DOAS unit and to document system readiness. The TAB engineer should use her own system readiness checklist which is identified as a pre-TAB checklist. See The Facflity Files column for sample pre-TAB checklist for an energy recovery coil within ERU. Any installation deficiencies identified via the checklist need to be added to the corrective action log and corrections made before the balancing and commissioning of the new DOAS can proceed. 

Figure 11.9 Sample General Observations and Machine/Equipment-Specific Dally Inspection Checklist Development. Based on Roughton Crutchfield, 2013.

---