RESEARCH REPORT 076 - HSE: Information about …

1 HSE Health & Safety Executive Machinery and rotating equipment integrity inspection guidance notes Prepared by ABB Ltd for the Health and Safety Executive 2003 RESEARCH REPORT 076 HSE Health & Safety Executive Machinery and rotating equipment integrity inspection guidance notes Jeremy Lewis and Brian Stark ABB Ltd Belasis Hall Technology Park PO Box 99 Billingham Cleveland TS23 4YS The Machinery and Rotating Equipment Integrity Inspection Guidance Notes provide guidance for Inspectors offshore. This document gives sufficient detailed guidance to enable informed and rational judgements to be made, during inspection visits to an offshore installation, on the state and general health of safety critical areas of machinery and rotating equipment.

2 This REPORT covers the development of inspection guidance notes on major safety issues for process machinery and rotating equipment used on offshore installations. This Inspection Guidance Note REPORT focuses on the equipment included within commonly applied machinery and rotating equipment packages for offshore installations. These notes also provide a Review Process to be used to assess a complete installation, in order to help an inspector understand the impact of operating culture, and context on the safe operation of machinery and rotating equipment installations.

3 This REPORT and the work it describes were funded by the Health and Safety Executive (HSE). Its contents, including any opinions and/or conclusions expressed, are those of the authors alone and do not necessarily reflect HSE policy. HSE BOOKS Crown copyright 2003 First published 2003 ISBN 0 7176 2174 X All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the prior written permission of the copyright owner. Applications for reproduction should be made in writing to: Licensing Division, Her Majesty's Stationery Office, St Clements House, 2-16 Colegate, Norwich NR3 1BQ or by e-mail to ii MACHINERY AND ROTATING EQUIPMENT INTEGRITY INSPECTION GUIDANCE NOTES SECTION 1 - INTRODUCTION This REPORT is made available by the Health and Safety Executive as part of a series of reports supported by funds provided by the Executive.

4 Neither the Executive, nor the contractors concerned assume any liability for the reports nor do they necessarily reflect the views or policy of the Executive. iii SYNOPSIS The Machinery and Rotating Equipment Integrity Inspection Guidance Notes provide guidance for Inspectors offshore. This document gives sufficient detailed guidance to enable informed and rational judgements to be made, during inspection visits to an offshore installation, on the state and general health of safety critical areas of machinery and rotating equipment. This REPORT covers the development of inspection guidance notes on major safety issues for process machinery and rotating equipment used on offshore installations.

5 This issue of the Inspection Guidance Notes REPORT focuses on the equipment included within commonly applied machinery and rotating equipment packages for offshore installations. These notes also provide a Review Process to be used to assess a complete installation, in order to help an inspector understand the impact of operating culture, and context on the safe operation of machinery and rotating equipment installations. iv FOREWORD This REPORT covers the development of inspection guidance notes on major safety issues for process machinery and rotating equipment used on offshore installations.

6 This Inspection Guidance Notes REPORT focuses on the equipment included within commonly applied machinery and rotating equipment packages for offshore installations. The packages are grouped by typical process duties: The REPORT covers aspects of design, operation and maintenance which might contribute to a major incident and the ways in which the hazards might be designed out, risk level reduced, or the potential consequences minimised. Section 1 introduces the Inspection Guidance Notes REPORT , providing a list of the contents of this REPORT , and provides a map to aid navigation through the notes structure.

7 Section 2 covers the Package concept, outlines the features of the common packages found on off shore installations and discussing the key design issues and hazards related to the complete package Section 3 covers Machines (Drivers). Key design issues and relevant hazards are discussed. Section 4 covers Rotating Equipment (Driven Equipment). Key design issues and relevant hazards are discussed. Section 5 covers Ancillary Equipment & Systems. This REPORT covers the significant support systems and equipment included within the package or as part of an equipment item. Section 6 provides Operational Support Guidance identifying operational activities which will have an effect on the safety and reliable operation of the equipment.

8 Section 7 provides a Review Process that may be used to assess a complete platform, in order that an inspector may understand the operating culture. This may be of particular value as a training aid. The inspector can thus consider the potential effect of the operating environment on the equipment hazards. The objective of the document is to aid understanding of the technology used and aspects of the equipment which might present seen or unforeseen major risks to operators of the equipment. In cases where concerns are identified which need to be amplified, then reference to a Topic Specialist Inspector should be considered to ensure all aspects of the concern are explored.

9 The last phase in the development process will translate the guidance into an interactive electronic version to improve accessibility of the Information and evaluation processes. v vi SUMMARY Inspection visits by safety inspection engineers to process plants operating major machinery have historically concentrated on dangers due to potential contact of operators or technicians with parts of the machine. These concerns are valid, and in some cases will pose a significant hazard to the operators and technicians. The contact dangers, however, are in general not the worst case event, loss of process fluid containment, loss of restraint of a high energy element within a machine, or dangers introduced from enclosures and service supplies can result in significant damage to the machine and anything or anybody near it.

10 The objective of the document is to aid understanding of the technology used and consider aspects of the equipment, which might present hidden major risks to operators of the equipment. The health of the equipment needs to be viewed both in terms of the context of the process integration of the equipment, and the operating and maintenance management. USE OF THE GUIDANCE NOTES These guidance notes provide background Information on the machines and rotating equipment by duty and typical combinations or package of equipment in use offshore. The guidance does provide for a general evaluation of the operating on the machines and rotating equipment in use.