Startup modifications

Startup is a time when many modifications may have to be made. It is always a time of intense pressure. It is therefore not surprising that some modifications introduced during startup have had serious unforeseen consequences. 

The line diagrams had been kept up-to-date despite the pressures on the plant staff during startup. This made it easier to repeat the relief and blowdown review. The plant staff members were so impressed by the results that they decided to have another look at the relief and blowdown after another year. 

Section 5.5.2 (c) describes a late change in design that had unforeseen results. 

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Telephones Allowance for modifications and extra construction work during startup... 

Demolition and alteration to existing structure Surplus equipment, supplies and materials, royalty payments Design modifications, construction modifications, and extra work during startup... 

Once the PSSR team is satisfied with their review, a form such as Example 4-1, Pre-startup Safety Review Completion Form can be used to capture their approval for startup. For simple changes, this one-page form may be all that is required. In the case of extensive modifications, a detailed checklist of items examined by the team may accompany this form. It could include unsatisfactory findings as well as respective recommendations. If recommendations were made, these must be prioritized. Some may need to be resolved before startup others may be appropriately addressed after processing has begun. Some items reviewed by one company for extensive modifications and logged in addition to the one-page form are ... 

The tolling team has analyzed the hazards, addressed the risks and modifications using a management of change system, revised and written procedures, trained the workers, performed a PSSR, and completed any required test runs. The pre-startup phase is complete at this point. 

Preliminary simulation results shall be available six weeks after Seller receives all the agreed to information from the Purchaser. The intent is to have results in time for necessary modifications or design changes to be incorporated into the process design without affecting the train startup. 

Startup following a process modification or after an emergency shutdown... 

At one plant, a repeat relief and blowdown review was carried out one year after startup. The startup team had been well aware of the need to look for the consequences of modifications and had tried to do so as modifications were made. Nevertheless, the repeat relief and blowdown review brought to light 12 instances in which the assumptions of the original review were no longer true and additional or larger relief valves, or changes in the position of a relief valve, were necessary. Figure 2-1 shows some examples. 

Any problems in the setup, startup, and operation of the CBMS also were recorded in the course of the field tests. These observations are important to improving the system before it goes into production. The field tests revealed three problems. The protective screens over electronics cooling air inlets and outlets on the CBMS II housing were damaged by operator activities in the vehicles and required reinforcement. The ground probe head, which protrudes outside the vehicle hull, required more power to maintain the correct temperature under colder or wetter weather conditions. Finally the automated mass and frequency calibration procedure was not reliable in the field and required modification. These problems have been corrected and are being incorporated in the LRIP units. 

A pre-startup safety review is a special safety review that is conducted after a modification to the process or operating conditions has been made and before the startup. In this review a team of reviewers ensures that (1) the system is constructed in accordance with the design specifications, (2) the safety, maintenance, operating, and emergency procedures are in place, (3) the appropriate training is completed, and (4) the recommendations from the PHA are implemented or resolved. 

The cost to treat 44,000 tons of contaminated soil and sediment at the Re-Solve Superfund site in North Dartmouth, Massachusetts, was approximately 6,800,000. This represents a unit cost of 155 per ton of soil treated. These costs include site preparation, mobilization, and demobilization of the unit, capital equipment, startup, labor, consumable materials, utilities, handling of residues and waste associated with the unit, transportation, disposal, maintenance, and modification (D19666B, p. 142). 

The program, however, will be modified quite often. It is thus convenient to include the command to load the program in the data file. For startup we then have just to load the data file, which will automatically load the program file. If modifications are made to the program file, we need only to reconsult the program file. Normally, the entries in a file to be consulted are not executed immediately, they are just put into the PROLOG data base. If we want a command to be executed, we have to include the respective prompt into the file. Thus, at the end of the data file TLCDATA.PRO we add the line... 

Just before a plant startup lots of details must be reviewed, and there are pressures to start up on the target date. Therefore it is not surprising that some modifications introduced by clever, concerned individuals during this time result in serious unforeseen consequences. This is especially the case where no disciplined method of dealing with changes of process technology is in place. 

Pre-Startup Safety Review. Employers must perform a pre-startup safety review for new facilities and for modified facilities when the modification is significant enough to require a change in the process safety information. The safety review shall confirm that prior to the introduction of highly hazardous chemicals to a process ... 

After the plant is constmcted, the operations phase of the project begins, which includes plant startup. Rarely does this operation proceed smoothly. Troubleshooting, process modifications, and repairs are generally required. 

Operational Procedures operator commands, override control, process monitoring, parameter modification, load scheduling, startup and shutdown, fault-finding instructions, user manuals and documentation... 

Shift Maintenance - Responsible to provide minor repairs or modifications to keep the startup going. Instrument/electrical, millwright, and pipefitter capabilities must be available around the clock. If the existing plant doesn t have the staffing to provide this, contractor support may be used effectively. 

Special emphasis must be placed on the particular hazardous conditions associated with startups confusion, modifications, and fatigue. 

Six months later when startup has been achieved, why is the product not coming out the way it did in the laboratory Is it an equipment malhxnction or a change in conditions somewhere between the laboratory and industrial process How can we find out What can be done to correct the problem Is it necessary to shut down the operation for modifications ... 

If you are performing the installation via CD, you must also make certain that the startup disk is capable of accessing the CD-ROM drive on your machine. In Windows 98, the startup disk automatically loads standard CD-ROM drivers and presents you with an option to load CD-ROM support on startup. Some Windows 95 startup disks also have this, but if not, you can modify the AUTOEXEC. BAT and CONFIG. SYS to load a CD-ROM driver. The exact modifications you will need to make depend on the type and manufacturer of your CD-ROM drive, but a sample CONFIG. SYS and AUTOEXEC. BAT follow ... 

Plant modifications were therefore implemented prior to startup. Based on these modifications and information gained from the models simulating the original method of startup the new anticipated method of startup was devised and multiple quasi steady state conditions developed as follows ... 

The net effect of these differing area investments for the two processes is that the total direct investment for the spray dryer MgO process is about 6 lower ( 72.OM vs. 76.2M) than that for the conventional MgO process. This cost advantage for the spray dryer MgO process is further increased as a result of the premise-derived indirect investments (construction expense, contingency, etc.,) and other capital investments (allowance for startup and modification and interest during construction) even though the cost factors (i.e., percentages) for both processes are identical. 

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