System Inspections: What’s Wrong (and Right!) with this System

Why Perform System Inspections? • Verify existing and transitioned systems are safe and effective before continuing with O&M • Ensure compliance with company standards • Confirm regulatory and code compliance • Check for changes in system or construction quality • Familiarize project team with site and systems • Identify lurking hazards • Project transition is best time to propose improvements, make recommendations, improve on past performance

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What to Bring to a System Inspection • • • • • • • • •

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Safety gear and traffic control Checklists and inspection forms P&ID copy to mark-up with changes As-built layout plans to mark-up with changes O&M data form to mark-up with changes CE/CSD inspection and testing checklists Digital camera Tools (keys) to open panels and well vaults “Fresh eyes”

Inspection Completion Overview Five categories of inspection 1. 2. 3. 4. 5.

HSSE and general site conditions Enclosure (accessibility, protection, condition) Mechanical (thermal, integrity, support) Electrical (national electric code) Compressed air and pressure vessels

Each category is equally important and inspectors should have sufficient skill to evaluate all hazards

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Warning: REAL Examples! • All of these systems were operating “as is” before being observed • Prior to inspections, the hazards had not been recognized • Some hazards were found only after a Loss Incident

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1. 2. 3. 4. 5.

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HSSE and general site conditions Enclosure (accessibility, protection, condition) Mechanical (thermal, integrity, support) Electrical (national electric code) Compressed air and pressure vessels

HSSE and general site conditions Nitrile glove vacuum seal Vault skirt bend or compromised

Bent hose creates back pressure

1,2,3,4,5,6,7,8,9,10 worm-drive hose clamps! 7

HSSE and general site conditions

t the e g r ’t fo wells! n o D in g r o t i mon

Sinkholes, backfill eroding, pavement is being undermined

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HSSE and general site conditions Trim tree to maintain minimum 3-ft clearance in front of panels

Brand new control panel and load center

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HSSE and general site conditions Fire extinguisher mounted, tagged, and inspected!

A bi t o u

e Fir

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r? e ish u ng i t Ex

t of d at e

...

1. 2. 3. 4. 5.

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HSSE and general site conditions Enclosure (accessibility, protection, condition) Mechanical (thermal, integrity, support) Electrical (national electric code) Compressed air and pressure vessels

Enclosure (accessibility)

W

bl m e s ell-as

skid e g r r spa i a d e

... e g a pack

with e r osu &M ! l c n in e s for O d e l er tal w s o n l i b rly d Poo tors an o to m 12

ss e c c no a

Enclosure (accessibility, protection, condition)

ifold o public n a ing m ssible t p i p SVE and acce op en

Trailer exposed to vehicle damage without bollard (crash post)

Trailer poorly supported by blocks

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Enclosure (condition) d; e t r o supp n u ipe p t hes s c u n a a h r ex yb SVE rence b fe inter

No door latch to protect from swinging in wind

Product drum unvented, ungrounded, with no secondary containment 14

Enclosure (condition)

A SH O ith w fan ard t s au d gu h x E rove app

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-

ttle i l A

ty dus

th

h. g u o

.

Enclosure (condition)

..

Years of water on the floor… 16

ts i l u s . re

le. o h na

1. 2. 3. 4. 5.

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HSSE and general site conditions Enclosure (accessibility, protection, condition) Mechanical (thermal, integrity, support) Electrical (national electric code) Compressed air and pressure vessels

Mechanical (thermal) PVC pipe used on SVE blower exhaust without temperature switches or heat exchanger

Source: www.dwyer-inst.com

Source: www.xchanger.com

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Mechanical (thermal) PVC piping on “hot” SVE blower exhaust caused piping damage and potential leak of untreated vapors

At least it was identified as “HOT” 19

Mechanical (support) Unsupported hose places stress on pipe and fittings

Flow meter dial facing wall, hard to read

Hose instead of pipe elbow Cam-lock levers not pinned or secured

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Mechanical (support)

Replaced with Zip-Tie

String broke

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Ro

“S e p

ort p up

”

Mechanical (support)

iate r p ro p p n a ort a OT supp N k is pipe c o A r ns of a me

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Mechanical (integrity)

Leaky fittings repaired with clear tape

N

Unglued PVC fittings

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Cam-lock levers not secured

ps m a l se c o h o

Mechanical (integrity) SVE n o e st p u i a p h PVC wer ex b lo

Rust stains on moisture separator drum reveals . . . 24

. . . pinhole leaks from metal drum rust-through from age, moisture, and lack of inspection

Mechanical (integrity)

No pressure gauges or vent ports on filter housing

Worn-out O-rings allowing pressurized liquid to leak

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Mechanical (integrity)

o ed t ” s u gs n i e nd t t b i “ f d ow un b l o r e a e ng Pipi ition pip s tran

Piping elbow fitting NOT used. Stress on compressed air pipe; potential future leak.

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1. 2. 3. 4. 5.

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HSSE and general site conditions Enclosure (accessibility, protection, condition) Mechanical (thermal, integrity, support) Electrical (national electric code) Compressed air and pressure vessels

Electrical Area Classified Class I, Division 2: 1) Non-XP fan motor 2) Incorrect wiring art for single phase – 120 VAC (needs conduit & seal fittings) 3) Nail used as wire support 4) Electrical tape used to splice wires

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Electrical Electrician installed 230-volt wiring on brand-new motor, but did not set the “jumper bars” per tag on motor

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Electrical al Po c o L y lled b

ic Electr

ta s n I p al Dro

A power drop is no place for electrical tape

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wer

any p m o C

!!

Electrical

Missing XP plug/ seal fitting not poured

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Electrical

Good: seal fittings installed (and poured) on “power” conduits

Bad: seal fittings not installed on “sensor” conduits (need seal-off even if intrinsically safe!)

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1. 2. 3. 4. 5.

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HSSE and general site conditions Enclosure (accessibility, protection, condition) Mechanical (thermal, integrity, support) Electrical (national electric code) Compressed air and pressure vessels

Compressed air and pressure vessels Pressure is 160 psi – Are the hose and clamp rated for this?

Gasoline hose used for air line – is this acceptable?

Worm-drive hose clamp not allowed by client design standards

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Compressed air and pressure vessels end m m eco r s r c tur e a f u an ily! m a r d o k ress iver tan p m ir co air rece a t s Mo ng the i drain

No Access to Drain Plug

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Compressed air and pressure vessels Air compressor condensate auto-drain

tain n o c Oil-

in

mp o c r i ga

ress

nde o c r o

ns

u st m e at

b

n ag a m e

e

pe o r p d

Discharge to exterior of trailer without treatment

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r ly

Compressed air and pressure vessels Hoses not supported, subject to kinking, hose instead of pipe elbow

Insulated liquid GAC units insulated but not heat traced – subject to freezing

ch i l b Pu

No secondary containment or leak detection capability 37

ess c c as a

Summary – Why does this happen? • Field-built, pieced-together systems vs. integrated vendor-built • Used, not-rehabbed equipment installed to ‘save’ $$ • Designers not aware of best practices and/or codes • Installation does not follow design and/or codes • Failure to read the installation manual • Systems not designed for long term use • Lack of O&M, “ownership”, inspections • Fatigue, complacency, “always been this way” 38

What Should Be Expected?

• Lessons learned, hazard identification, and changes in technology have all contributed to better system design, installation, and operation • The following slides share “best practice” examples of remediation system design, installation, and operation

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Good System Design and Installation

exhaust fan outlet weatherproofed, soundproofed

All safety signs: No Smoking, Hearing Protection, Flammable Gas, Emergency Contacts

Warning tape for head knocker

Extra hearing protection sign on building Well-spaced bollards Sealed joint paving flush to grade

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Well box set flush/ slightly crowned, concrete good, all bolts present

Good System Design and Installation Intake filter above well roof line

Locked GFCI outlet

Containerized system Sound and weatherproofed inlet/exhaust

Industrial safety rails

Engineered retaining wall

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Good System Design and Installation

Good condition concrete well pad

Hot tar seal on trench seams

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Good System Design and Installation

Containerized system

Product tank vented, set back from container Primarily rigid piping Bollards

Insulated water piping

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Good System Design and Installation Pipe clamps and unistrut

Sch 80 PVC above grade

Piping sleeved through concrete

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Good System Design and Installation Posted P&ID and Trenching Diagram

Fire extinguisher inspected and tagged

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Good System Design and Installation Containerized System

Pipe supports

Shop-built manifold, mostly rigid piping

Hose runs limited to connection

Hose cam-locks pinned Containment lip and strip sump for leak detection and control 46

Good System Design and Installation

Flow arrows CE/CSD/PSD labeled and inspected

“Head knocker” identified

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Good System Design and Installation Cam locks zip-tied

CE/CSD/PSD is tagged Sample port labeled

Strip sump for leak detection

Wet floor sensors can be used 48

Good System Design and Installation Phase and voltage labeled

Locked control panels

Multiple sources of electricity warning

Arc flash hazard labeled

Seal-offs poured

GFCI outlet with in-use cover 49

What’s Common to “Right” Examples? • Vendor-built systems of recent vintage • Nearly all new equipment • Layouts, installs well planned • Designs have learned from past experience • Designs and installs meet latest client specs • Systems meet best GES engineering practices • Safety, reliability, operability embodied in designs

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For more information…

Contact [email protected]

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