Prepare and isolate Reactor 1 for the bottom flange gasket replacement

You are an outside operator acting as isolation authority for Reactor 1.

Simulated workplaceIntermediate missionCAQA Hydra Chemical and Refining

What is going on

Reactor 1 has a weeping bottom outlet flange recorded as PSE-26-061 and the batch in it was transferred to T-204 on Monday. Maintenance will replace the gasket on Wednesday under permit PW-26-0784. The reactor still contains a heel of ferric sulfate, the acid charge line, the caustic scrubber return and the transfer line all connect to the vessel, and the agitator and bottom outlet valve are electrically driven. The isolation schedule for R-101 lists the isolation points, but one of the block valves on the transfer line is known to pass. Kylie Bassett's crew will fit their personal locks to the lockbox. Yolanda Ferreira wants the isolation to the spade or double block and bleed standard with the blind list reconciled and zero energy proven.

Yolanda Ferreira, Maintenance and Integrity Manager
Subject: Prepare and isolate Reactor 1 for the gasket replacement

Reactor 1 has a weeping bottom outlet flange under PSE-26-061 and I need the reactor prepared, isolated and blinded so that Kylie's crew can replace the gasket on Wednesday. Plan the isolation to the double block and bleed or spade standard, arrange the drain, flush and purge, complete the isolation certificate and blind list, and be ready to prove zero energy with the permit issuer. When the joint is remade, plan the de-isolation and leak test before the reactor goes back into service.

Your brief

Plan and apply the process and electrical isolations for Reactor 1 to the required standard, drain, flush and purge the vessel and the flange, complete the isolation certificate and blind list, prove zero energy with the permit issuer, and plan the de-isolation and leak test for the return to service.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the permit to work and plant isolation procedure, the isolation schedule for R-101 and the dangerous goods policy section on compatibility, and review PSE-26-061 and PW-26-0784 in the registers.
List every process, electrical and stored energy source connected to the reactor and select the isolation standard for each, treating the passing block valve as unacceptable for a single isolation.
Plan the drain of the heel to the slop tank, the water flush and the purge of the vessel and the bottom outlet flange, considering where the flushings will go and the scrubber return.
Apply the isolations with a second operator, fit locks and tags, install the spades from the blind list and record every point with its tag number on the isolation certificate.
Prove zero energy at the flange by draining the bleed, checking pressure and temperature indications and testing the agitator and outlet valve for dead, and walk the job with the permit issuer.
Complete the permit to work and isolation certificate form and update PW-26-0784 in the permit and isolation register with the isolation standard applied and the blind list entries.
Prepare the de-isolation and return to service plan including blind reconciliation, joint tagging, leak test before ferric sulfate is reintroduced and the shift log entries required.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Isolation plan listing every energy source and the standard applied
Completed isolation certificate and blind list
Zero energy proof record
Permit register update
De-isolation and leak test plan

Printing this is a record of what you explored. It is not a certificate or a qualification.