PMAOPS201 Operate Fluid Flow Equipment

OPERATE FLUID FLOW EQUIPMENT
PMAOPS201B
ABOUT THIS LEARNING RESOURCE
Being competent in the workplace

means:
 being able to do the job
 knowing why the job is being

done
 understanding the underlying

principles of that job.
Operating process plants requires

technical knowledge coupled with
workplace skills.
Once you are competent you will be

able to:
 perform at the standard required

for required tasks
 organise your tasks
 respond and react appropriately to

the unexpected
 be able to transfer existing skills and knowledge to new situations.
Operators and Technicians who are competent will operate a chemical, hydrocarbons or
oil refining facility safely and efficiently to:
 consistently achieve an “onspec” quality product
 meet production schedules.
What are the sections of the learning resource?
This learning resource contains
 learning resources
 self help activities
i
How to use this learning resource
The Learning resource is used to give you the knowledge and background you need to
achieve competency in this unit. You will also need to demonstrate on-the-job skills in
order to be assessed as competent. For you to gain a nationally recognised statement of
attainment or qualification, the required competencies must be assessed by a workplace
assessor for a registered training organisation (RTO).
The Self help activities are used for you to determine if you are ready to be assessed by
a workplace assessor. You may also check yourself against the competency standards
(Unit of Competency).
Start
Check own competency

using the self help and/or
the competency standard
Ready for Not ready for

assessment assessment
Assessor to Study relevant

conducts formal learning resource
assessment to meet Assessed as material and obtain
Training package not yet practical experience
requirements competent
Assessed as
Competent
Statement of
attainment
ii
USING THE LEARNING RESOURCES
Each of the learning resources supports the national Chemical, Hydrocarbons and Oil
Refining Training Package. The Training Package was developed with the help of
major companies and unions in the industry and is nationally endorsed.
The learning resources are general to cater to the needs of as many chemical,
hydrocarbons and oil refining companies as possible. Links to the learner’s own
specific workplace have been made by way of practical on-the-job assignments.
Successful completion of the learning resources, supported by practical experience,

will provide the workplace learner with basic knowledge and skills needed to perform
his/her duties as an operator or technician in the chemical, hydrocarbons and oil refining
industries.
Assistance to complete an on-the-job practical assignment can be provided by the

workplace trainer.
Who Should Use These Learning Resources?
These learning resources are designed to be used by:
 workplace trainers
 workplace assessors
 workplace learners
 applicants for recognition of prior learning.
iii
Icons Used Within the Learning Resources
Indicates a knowledge based outcome where an assessment of learning

may include written and/or oral question.
Indicates a practical, skills based outcome where an assessment of

learning will most likely be a practical exercise(s). Knowledge and skills
should often be assessed together.
Indicates a worked example.
Indicates important information.
Indicates additional learning resource material related to the unit being

studied.
Indicates the start of the self help activities.
iv
CONTENTS
Learning Resource:
ABOUT THIS LEARNING RESOURCE.....................................................i

USING THE LEARNING RESOURCES...................................................................iii
1.0 OPERATE PUMPS.............................................................................1

RECOGNISE PUMPS..................................................................................................1
PUMP STARTUP.........................................................................................................9
STARTUP AFTER MAINTENANCE OR CHANGEOVER....................................14
Starting Up a Pump After Maintenance......................................................................15
SELF HELP ACTIVITIES........................................................................................15
ROUTINE OPERATIONAL CHECKS......................................................................16
SELF HELP ACTIVITIES.........................................................................................17
2.0 OPERATE PUMP DRIVERS...........................................................18

PUMP DRIVER VARIABLES...................................................................................18
Electric Motor Drivers................................................................................................18
3.0 OPERATE VALVES.........................................................................21

VALVE TYPES...........................................................................................................21
Globe Valve.................................................................................................................22
Needle Valve...............................................................................................................22
Gate Valve...................................................................................................................23
Butterfly Valve............................................................................................................23
Plug Valve...................................................................................................................24
Ball Valve....................................................................................................................24
Diaphragm Valve........................................................................................................25
Non-Return Valve.......................................................................................................25
Pressure Relief Valve..................................................................................................27
Actuation of Valves.....................................................................................................28
VALVE ADJUSTMENT.............................................................................................32
4.0 RESPOND TO FLUID FLOW PROBLEMS...................................34

Plant Monitoring.........................................................................................................34
CORRECTING OPERATIONAL PROBLEMS........................................................37
5.0 CARRY OUT MAINTENANCE PROCEDURES...........................39

ISOLATION OF FLUID FLOW EQUIPMENT........................................................39
v
Tagging.......................................................................................................................40
Tagging.......................................................................................................................41
MINOR MAINTENANCE.........................................................................................42
Tightening Mounting Bolts.........................................................................................42
Nipping Up Glands.....................................................................................................43
Greasing Bearings or Topping Up Oil Levels.............................................................43
Tightening Leaking Flanges.......................................................................................43
PREPARING FLUID FLOW EQUIPMENT FOR OPERATION.............................45
Inspection After Maintenance.....................................................................................45
Equipment De-isolation..............................................................................................45
Removal of Blinds......................................................................................................46
Resetting of Controls Electrical Equipment...............................................................46
Tag Removal...............................................................................................................46
Purging Air And Pressurising.....................................................................................47
Precautions for Pressure or Thermal Shock................................................................48
6.0 CONTROL HAZARDS....................................................................51

PREPARING FLUID FLOW EQUIPMENT FOR OPERATION.............................51
What is a Major Hazard Facility.................................................................................51
MHF Regulations........................................................................................................51
What is a Safety Case?...............................................................................................52
The role of workers in hazard reduction.....................................................................52
Identifying hazards.....................................................................................................53
Assessing risks arising from a hazard.........................................................................54
Taking action to control risks......................................................................................55
Following procedures.................................................................................................55
Glossary.......................................................................................................57
vi
OPS 201
PROCESS 201
1.0 OPERATE PUMPS
RECOGNISE PUMPS
1.1 At the completion of this topic, you must be able to recognise the type
of pump.
Pumps used in the chemical, hydrocarbons and oil refining industry can be classified as:
 Centrifugal pumps
 Positive displacement pump.
Centrifugal Pumps
A centrifugal pump is a rotary machine where energy is continuously imparted to a

liquid by a rotating impeller, propeller or rotor.
The centrifugal pump is the most common pump used for moving large volumes of
liquids, slurries or high viscosity liquids. The centrifugal pump is simple in construction
as it has no valves or tight clearances.
A centrifugal pump consists of:

 One or more impellers mounted on a shaft
© Australian National Training Authority, 2002 1

Operate Fluid Flow Equipment
 Casing consisting of a suction, volute and discharge.
Centrifugal Pump
Volute Discharge
Shaft
Suction
Impeller
2 © Australian National Training Authority, 1999

OPS 201
When the centrifugal pump is operating, energy from the pump driver is transferred to
the liquid when:
 The rotating impeller increases the velocity energy of the liquid
 The liquid is slowed down at the pump discharge where the velocity energy of the
liquid is converted to pressure energy.
When a high discharge pressure is required, multistage pumps are used. Each stage of
the pump increases liquid pressure to the required discharge pressure.
Pump Stages
Suction
Coupling Discharge
Pump Driver
Impellers
Multistage centrifugal pump
A centrifugal pump differs from a positive displacement pump in that the impeller in a
centrifugal pump does not seal against the pump casing, so some leakage of liquid can
occur between the impeller and casing.
This leakage allows a centrifugal pump to run against a closed discharge valve for short
periods of time, but means the efficiency of a centrifugal pump drops off quickly at
flowrates above or below the designed range.
Pump Efficiency Curve

Positive Displacement Pumps
A positive displacement pump is a rotary or reciprocating machine where force is applied

to a liquid contained inside a moving boundary, causing its pressure to increase.
The moving boundary can be:

 Piston or plunger
 Screw
 Gear
 Lobe
 Diaphragm.
A positive displacement pump differs from a centrifugal pump in that:

 The moving boundary seals against the casing preventing any leakage of liquid
past the boundary
 A fixed volume of liquid is discharged on each revolution of the pump shaft.
Positive displacement pumps are commonly used for:

 Pumping liquids into high pressure lines or vessels
 Metering specified quantities of liquid into a process line or vessel.
The common types of reciprocating positive displacement pumps are:

 Reciprocating piston pump
 Reciprocating diaphragm pump.
Reciprocating positive displacement pumps contain a reciprocating piston, plunger or

diaphragm and are equipped with suction and discharge valves.
Reciprocating Piston Pump
Reciprocating piston pumps are high efficiency pumps used for pumping non-abrasive
liquids.
The reciprocating piston pump contains a piston which is driven forwards and backwards
by a crankshaft, connecting rod and crosshead.
The piston rings seal against the cylinder to prevent liquid leaking past the piston.
The reciprocating movement of the piston:

 Draws liquid into the cylinder through the suction valve on the suction stroke
 Forces liquid out through the discharge valve at high pressure during the
discharge stroke.

OPS 201
Discharge Reciprocating Piston Pump

Connecting
Piston Rod
Crosshead
Discharge Crankshaft
Valve
Suction
Valve
Suction
Reciprocating Diaphragm Pump
The diaphragm pump is a lightweight portable positive displacement pump commonly

used to pump liquids, slurries or sludges.
The reciprocating diaphragm pump contains diaphragms which are driven forward and
backwards by a compressed air supply.
The reciprocating movement of the diaphragm:

 Draws liquid into the pump through the suction valve on the suction stroke

 Forces liquid out through the discharge valve at high pressure during the
discharge stroke.
Diaphragm Pump
Discharge
Valve
Air Supply
Pressure
Diaphragm
Liquid Liquid
Side Side
Air Valve
Connecting
Rod
Air Side Suction

Valve
Suction
Rotary Positive Displacement Pumps
Rotary positive displacement pumps contain rotating gears, lobes or vanes which are
capable of pumping air, gas or liquid. These pumps are simple in construction as they do
not require suction or discharge valves.
The most common types of rotary positive displacement pumps are:

 Gear pump
 Lube pump
 Vane pump.
Gear Pump
The gear pump is a cheaply manufactured and efficient positive displacement pump
commonly used as lube oil pumps.
The gear pump contains two rotating intermeshing gears where:

 The drive gear is driven by the prime mover through a drive shaft
 The idler gear is driven by the drive gear.
The rotary motion of the meshing gears:

OPS 201
 Draws liquid into the suction port due to the low pressure produced when the
gears disengage
Gear Pump
Casing
Drive Gear
Suction
Suction Discharge
Idler Gear
 Carries liquid around the casing to the discharge due to the seal between the gears
and casing
 Discharges liquid through the discharge port due to the high pressure produced
when the gears engage.
Lobe Pump
The lobe pump is a high pressure positive displacement pump which is used commonly
as a lube oil pump.
The lobe pump contains two rotating, intermeshing lobes which are interconnected by
gears and driven by a prime mover.
The rotating motion of the gears:

 Draws liquid into the suction port due to the low pressure produced when the
lobes disengage
 Carries liquid around the casing to the discharge due to the seal between the lobes
and casing

 Discharges liquid through the discharge pot due to the high pressure produced
when the lobes engage.
Lobe
Suction Discharge
Lobe
Lobe Pump
Vane Pump
The vane pump is a positive displacement pump which is commonly used as a vacuum
pump.
The vane pump contains an eccentrically mounted rotor containing vanes which can slide
in or out of slots cut into the rotor.
As the rotor turns, the volume between the vanes and casing expands at the pump
suction, creating a low pressure, which draws liquid into the pump.
The liquid is carried around to the discharge, where the volume in the casing between the
vanes reduces, creating a high pressure which forces liquid out of the discharge at high
pressure.

OPS 201
Casing Casing
Suction Discharge
Rotor Shaft
Vane Pump
SELF HELP ACTIVITIES
List the main components of a centrifugal pump.

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Explain what a centrifugal pump is.

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Explain how a centrifugal pump increases fluid pressure.

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What is the purpose of a multistage centrifugal pump?

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Explain how a centrifugal pump differs from a positive displacement pump.
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List some common types of reciprocating positive displacement pumps.

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List some common types of rotary positive displacement pumps.

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Give one application for each of the following types of pump.
Pump Use
Centrifugal
Reciprocating piston
Diaphragm
Gear
Lobe
Vane

OPS 201
1.0 OPERATE PUMPS
PUMP STARTUP
At the completion of this topic, you must be able to:

1.2 Startup and shutdown a pump in a manner appropriate to the pump
type and duty.
1.3 Adjust flow and head pressure in a manner appropriate to the pump
type.
The method of starting and stopping a pump will depend on:

 Whether the pump is a centrifugal or positive displacement type
 The type of valves installed on the pump discharge line.
Centrifugal Pump Startup
When starting a centrifugal pump without a discharge check valve:

 Check that the lube oil levels are adequate
 Check the gland lubrication supply is turned on
 Prime the pump if it is not self priming
 Open the suction valve
 Close the discharge valve
 Start the pump
 Open the discharge valve.
The centrifugal pump is started against a closed discharge valve

as load on the motor is reduced
If the centrifugal pump is installed with a discharge check valve, the pump can be started
with the discharge valve open, provided the discharge line is pressurised.

Centrifugal pump with a discharge check valve

Discharge Discharge
Check Valve Valve
Discharge
Suction
Valve
Suction
In some processes where pairs of pumps are installed with discharge check valves,
process upsets can be caused due to flow surges when starting the standby pump or
stopping the duty pump if the discharge valves are left open.
To prevent flow surges:

 The standby pump should be started with the discharge valve closed, then the
discharge valve should be opened gradually
 The duty pump should be stopped after gradually closing the discharge valve.
 Closing the discharge valve before stopping the duty pump will also prevent
sudden backflow damaging the discharge check valve.
Check Valve Discharge
Discharge
Valves
Suction Suction
Valves
Check Valve
When starting or stopping pumps, discharge valves are closed to prevent flow surges
Flow and Head Pressure Adjustment
When started, pump discharge pressure will build up to the discharge line pressure before
the check valve will open.
The flowrate and discharge pressure can be adjusted and controlled by adjusting the
opening of discharge valve.

OPS 201
Centrifugal Pump Shutdown
A centrifugal pump is shutdown by:

 Closing the discharge valve
 Stopping the pump
 Closing the suction valve.
If a discharge check valve is installed on the discharge line, the discharge valve can be
left open when stopping the pump. The discharge valve is only closed to isolate pump
for maintenance.
Positive Displacement Pump Startup
A positive displacement pump must not be started with the discharge valve closed, as the
pump could be damaged or the discharge line ruptured.
To start a positive displacement pump:

 Check lube oil levels
 Open the suction valve
 If the pump is started with the suction valve closed, large suction pressures
could:
 Damage the suction valve housing
 Draw air into the pump past the shaft seal
 Vaporise the liquid in the pump causing cavitation.
 Open the bleed valve to bleed gas from the pump
 The bleed valve is closed when liquid flows from the bleed line
 Open the discharge valve
 If a positive displacement pump is started with the discharge valve closed,
extremely high discharge pressures will develop which could burst
discharge lines or cause severe mechanical damage to the pump
 Start the pump.
Discharge
Valve
Discharge
Check Valve
Bypass
Valve
Suction
Suction Valve
Positive Displacement Pump

Flow and Head Pressure Adjustment
When the pump is running, do not try to throttle the flow by closing the suction or
discharge valves.
If the suction valve is closed to throttle flow, a low suction pressure is created which
could cause the liquid to boil, resulting in cavitation.
If the discharge valve is closed to throttle flow, the pump could be severely damaged due
to very high discharge pressures developing.
The flowrate and discharge pressure can be controlled by:

 Adjusting the pump speed
 Opening the bypass valve to recirculate some liquid from the discharge back to
the suction.
List the main steps in starting a centrifugal pump that has no discharge check valve.
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At your workplace explain how pumps are started and shutdown in a manner
appropriate to the pump type and duty.
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OPS 201
List the main steps in stopping a centrifugal pump.

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At your workplace explain how the flow rate and pressure are adjusted for a variety of
pump types.
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List the main steps in starting a positive displacement pump.

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Explain how flow is throttled in both centrifugal pumps and positive displacement
pumps.
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1.0 OPERATE PUMPS
STARTUP AFTER MAINTENANCE OR CHANGEOVER

A the completion of this topic, you must be able to:
1.4 Startup from standby and after maintenance

1.6 Change over pumps as required.
Process pumps are usually connected in parallel where one pump is the duty pump while
the other pump is on standby. This arrangement allows the changeover of pumps without
stopping the flow to the process.
Discharge
Discharge
Suction Valves
Suction Valves
Parallel connection of pumps
To change over a pump:
The standby pump is started and put on-line by:

 Opening the suction valve
 Priming the pump, if required
 Starting the pump
 Opening the discharge valve
The duty pump is stopped and isolated by:

 Closing the discharge valve
 Stopping the pump
 Closing the suction valve
This method ensures at least one pump is operating at all times.

OPS 201
STARTING UP A PUMP AFTER MAINTENANCE
When starting a pump after maintenance, prestart checks must be made to ensure:
 All isolations are removed from the pump
 Spades and blinds are removed from suction and discharge lines
 All flowlines are connected
 Suction and discharge lines are lined up correctly
 Pump is in operational condition
 Oil level is correct
 Gland lubrication lines are connected
 Coupling is connected and the guard installed properly.
When prestart checks are completed, the pump can be started by following the startup
procedure.
List the steps in changing over a pump from standby to duty.

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List the checks made before starting a pump after maintenance.

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1.0 OPERATE PUMPS
ROUTINE OPERATIONAL CHECKS

1.5 A the completion of this topic, you must be able to complete routine checks,
logs and paperwork.
Routine inspections are used to detect early warning signs of pump problems so that
prompt action can be taken to prevent a costly pump breakdown.
Routine checks are performed on operating pumps to:

 Check levels in lubricators and add oil if required
 Check flowrate through the pump
 Check that suction and discharge pressures are within their normal operating
range
 Check for mechanical seal or packing leaks and nip up glands if necessary to stop
leaks
 Check for a change in noise or vibration of the unit which is an indication of:
 Valve breakages
 Coupling wear or misalignment
 Bearing wear
 Other mechanical problems that could result in pump failure.
 Check for cavitation noise which can produce a loud gravel like noise.
The performance of a centrifugal pump can be checked by:

 Observing the discharge pressure and suction pressure to determine the head
pressure across the pump
 Determining the flowrate through the pump
 Comparing the head pressure and flow rate against the pump performances curve
to check that the pump is performing efficiently.
Any problem identified during a routine check must be reported by

filling out the relevant logs and maintenance request forms.
Routine checks prevent costly breakdowns

OPS 201
Explain why pumps are routinely inspected during operation.
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List some of the routine operational checks performed on pumps.
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Explain how the performance of a centrifugal pump is checked.
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At your workplace explain how routine pump checks are done, including the type of log
sheets and associated paperwork.
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OPS 201
2.0 OPERATE PUMP DRIVERS
PUMP DRIVER VARIABLES

2.1 Monitor critical variables such as amps, temperature, vibration, etc.
2.2 Keep critical variables in range.
2.3 Recognise trends/patterns which indicate a potential or actual problem
with the pump driver
2.4 Take action to ensure driver is returned to full performance in a timely
manner.
Changes in operating characteristics of a pump driver can be an early warning sign of

future breakdowns.
Operating characteristics monitored and documented over a time period will provide a
trend or a behaviour pattern.
Operators must be able to identify changes in operating characteristics, diagnose the

problem, then take action to prevent or minimise damage to the driver.
ELECTRIC MOTOR DRIVERS
The most common type of prime mover used in the chemical, hydrocarbon and oil
refining industries are electric motor drivers. Electric motor drivers require little
maintenance, but any problem with the pump or coupling can be indicated by an:
 Increase in amperage drawn by the electric motor
 Increased motor temperature
 Increased vibration.
Pump drivers must be monitored to identify equipment problems

TREND CAUSE ACTION

Higher than normal current (in  Bearing wear or failure  Replace bearings
amperes) drawn due to
 Lack of lubrication  Lubricate bearings
increased load on motor
 Excessive pump load  Reduce load on pump
 Coupling failure or wear  Replace coupling
 Bent pump shaft  replace pump shaft
 Binding or rubbing of pump  Overhaul and check
components. clearances between
moving parts
Higher than normal  Excessive pump load  Reduce load on pump
temperature due to increased
 Lack of lubrication  Lubricate bearings
load on motor
 Binding or rubbing of pump  Overhaul and reassemble
components pump
 Binding shaft seals  Open valves in coolant line
to seals
Excessive vibration  Coupling misalignment  Realign coupling
 Coupling wear or failure  Replace coupling
 Unbalanced or damaged  Balance or replace rotor or
rotor or impeller impeller
 Worn bearings  Replace bearing
Problems with an electric motor drive are indicated by:
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List some causes of high current draw in an electric motor driver.
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OPS 201
List some causes of excessive vibration in an electric motor driver or coupling.
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At your workplace, with pump drivers, how are critical valves such as amps,
temperature, vibration, etc. monitored?
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At your workplace, with pump drivers, how are trends/patterns used to indicate a
potential or actual problem?
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3.0 OPERATE VALVES
VALVE TYPES
3.1 Recognise the type of valve

3.2 Operate the valve in a manner appropriate to the valve type.
Each type of valve used in the chemical, hydrocarbon or oil refining industry is selected
to perform specific functions.
Valves are selected for their:

 Ability to throttle flow
 Lack of turbulence or resistance to flow when fully open
 Quick opening and closing mechanism
 Tight shut off
 Ability to allow flow in one direction only
 Opening at a preset pressure for pressure control
 Ability to handle abrasive substance without rapid wear.
The most common types of valves used in the chemical, hydrocarbon or oil refining
industries are:
 Globe
 Needle
 Gate
 Butterfly
 Plug
 Ball
 Non-return
 Diaphragm
 Pressure relief.

OPS 201
Stem
Globe Plug
Flow Out
Seat
Globe Valve
GLOBE VALVE
The valve stem moves a globe plug relative to the valve seat. The globe plug can be at
any position between fully opened and fully closed to control flow through the valve.
The globe and seat construction gives the valve good flow regulation characteristics.

NEEDLE VALVE
Stem
Packing
Flow In Needle
Seat
Needle Valve
The valve stem moves the needle relative to the valve seat. The needle valve is similar in
construction to a globe valve as the needle can be operated at any position between fully
open and fully closed to control flow through the valve.
This construction gives the needle valve good flow regulation characteristics.

OPS 201
Stem
Gate
Flow Flow
In Out
Seat
Gate Valve
GATE VALVE
Gate valves are the most common type of on/off valve used in the chemical, hydrocarbon
and oil refining industries as they give a tight shutoff and have a low resistance to flow
when fully open.
The valve stem moves the gate in or out of the valve seat.
Gate valves must only be used in the fully open or fully closed position as rapid wear
occurs to the gate due to vibration and erosion if the valve is used to throttle flow. When
fully open, the valve creates very little turbulence or resistance to flow.
BUTTERFLY VALVE
The valve stem rotates a spindle and butterfly disc.
The butterfly valve is used to throttle flow where a tight shut off is not required. When
fully open, the butterfly creates little turbulence or resistance to flow.

Butterfly
Disc
Flow Flow
In Out
Seat
Butterfly Valve
PLUG VALVE
Plug valves are quick opening valves which give a tight shutoff and can be used to
throttle flow. The valve stem rotates a plug which contains an opening. The plug
opening can be moved between the fully open and fully closed position to throttle flow.
The taper on the plug ensures a tight seal between the plug and housing.
Rotation
Seal
Inlet Outlet
Port Port
Flow Flow
In Out
Plug Seal
Plug
Opening
Plug valve in closed position
BALL VALVE

OPS 201
Ball valves are a quick opening valve

that give a tight shutoff. When fully
Rotation
open, the valve creates little
turbulence or resistance to flow. Packing
Inlet Seal
Port
Outlet
Port
Flow Flow
In Out
Ball Ball
Seal
Opening
Ball valve in closed position
The valve stem rotates a ball which contains an opening.
The ball opening can be positioned in the fully open or fully closed position but must not
be used to throttle flow as any abrasive wear to the ball will cause leakage when the
valve is closed.
DIAPHRAGM VALVE
Diaphragm valves are used to control the flow of abrasive fluids, as the diaphragm
protects the valve mechanism from wear.
The valve stem pushes the rubber diaphragm towards or away from the weir to throttle
flow. When fully closed, the weir type diaphragm valve gives a tight shutoff.
The straight through diaphragm valve is used when low turbulence and resistance to flow
is required when fully open.

Stem Stem
Diaphragm
Diaphragm
Flow Flow Flow

Out In Out
Weir
Weir type diaphragm valve Straight through diaphragm valve
NON-RETURN VALVE
Flow
Non-return valves are installed in a flowline to:
In
 Allow flow in one direction only
 Prevent backflow in the line.
The most common types of non-return valves are:

 Swing Check Valve
 Lift Check Valve.
The Swing Check Valve contains a swinging disc or clapper which is held open by the
flow pressure in one direction. As flow increases, the disc opens further due to the
increased flow pressure.
In the fully open position, there is very little resistance to flow. If flow stops or reverses,
gravity and reverse flow pressure closes the disc against the seat.

OPS 201
The Swing Check Valve cannot be used in situations where flow starts and stops
continually such as in reciprocating pump discharge lines as the constant pounding of the
disc against the seat quickly destroys the valve.
Disc
Flow Flow
In Out
Seat
Swing Check Valve
In stop/start flow situations, Lift Check Valves are used as the slower action of the disc in
opening and closing reduces the hammering effect and prolongs the valve life.
Disc
Seat
Flow Flow
In Out
Lift Check Valve
PRESSURE RELIEF VALVE

Pressure relief valves are installed on gas and steam lines to prevent overpressurisation of
lines or equipment. At normal pressure, the spring pressure holds the valve disc against
the seat to close the valve. If gas pressure increases to a preset pressure, the force of the
pressure pushing against the valve
disc overcomes the spring force to
open the valve, allowing flow
through valve.
If pressure continues to rise, the valve disc opens further to allow a greater flow through
the valve.
VALVE TYPE CHARACTERISTICS

Globe valve  Suitable for regulating flow
 Tight shut-off
 Pressure drop when open
 Used for high pressure clean fluids
Needle valve  Suitable for regulating flow
 Fine control in small diameter piping
 Tight shut-off
 Used for clean fluids that have low flows
 High pressure drop when open
Ball valve  Not suitable for regulating flow except in some specialised ball valves
 Not suitable for tight shut-off
 Low pressure drop when open
 Used for gas, liquids or slurries
Butterfly valve  Suitable for regulating flow
 Tight shut-off
 Used for low line pressure and large pipe line diameters
 Wide range of service; gas, liquids and slurries
Gate valve  Not suitable for flow regulation, only suitable for on or off
 Tight shut-off

OPS 201

Diaphragm  Suitable for on/off or narrow range throttling control
valve  Tight shut-off
 Used for corrosive fluids and slurries

ACTUATION OF VALVES
All types of valves can be operated:

 Manually when valve stems are connected to handwheels or levers
 Automatically when valve stems are connected to pneumatic actuators or
solenoids.
Gate valves and ball valves that operate fully open or fully closed are usually operated by
handwheels or levers.
Valves such as globe valves or butterfly valves that are used to control flowrate are often
connected to pneumatic actuators for automatic control.
Handwheel
Stem
Flow
Out
Manual operated diaphragm valve
Solenoid
Stem
Solenoid operated plug valve

OPS 201
List some of the reasons for which valves are selected.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Identify the following valves and give the characteristics of each valve.
Valve type__________________________________
Throttling YES / NO
Tight shutoff YES / NO
Low flow resistance when fully open YES / NO

Valve type_________________________________
Throttling YES / NO
Valve type___________________________________
Throttling YES / NO

OPS 201
Valve type_________________________________
Throttling YES / NO
Valve type___________________________________
Throttling YES / NO
Low flow resistance when fully open YES/NO

Valve type_________________________________
Throttling YES / NO

OPS 201
Valve type_______
Throttling YES / NO
Valve type
_________________________________________
Throttling YES / NO

3.0 OPERATE VALVES
VALVE ADJUSTMENT
3.3 At the completion of this topic, you must be able to complete routine checks, logs,
paperwork, taking action on unexpected readings and trends.
Any adjustment to the opening or closing of a valve can affect variables in a process such
as: Valve used to
control pressure in
 Flowrate the vessel
 Liquid level
Fluid
Inlet
Valve used to
control liquid
level in the
vessel
Valve are used to control process

parameters
 Pressure
 Temperature
 Production throughput
 Product quality.
Regular inspection and monitoring of instruments in control rooms and in the field is
required to identify any abnormal readings or trends in a process.
Senses such as smell, sight, sound and touch can also be used to detect abnormal
operating conditions in the field.
If any abnormal readings or trends are identified:

 The readings or trends must be recorded in the appropriate logs
 Action must be taken to prevent process upsets, shutdowns or the production of
offspec. material by keeping process variables within the upper and lower control
limits.

OPS 201
To correct any abnormal readings or trends, it may be necessary to:

 Manually operate valves to maintain process parameters within normal operating
ranges
 Adjust the setpoints of controllers on automatic control systems
 Arrange for servicing or repair of a valve, actuator or control system.

Explain why regular monitoring and routine checks of process parameters is required.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Explain the action required if abnormal readings or trends are identified.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
At your workplace explain how routine checks, logs, paperwork, taking action or
unexpected readings or trends are achieved.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

OPS 201
4.0 RESPOND TO FLUID FLOW PROBLEMS
4.1 Frequently and critically monitor all plant throughout shift using
measured/indicated data and smell, sight, sound and feel as appropriate to monitor
plant
4.2 Recognise operational problems.
PLANT MONITORING
Fluid flowrates and pressure must be monitored in a process or plant to ensure

parameters are maintained within the upper and lower control limits so that a quality
product is produced.
To maintain the required flowrates and pressures:

 Pumps must deliver the required pressure and flowrate
 Valves must operate without sticking, plugging or leaking
 The direction of flow through a valve must be correct
 Manual valves must be adjusted to give the required flowrate
 Control valves must be properly calibrated.
Gauges, instruments and charts must be closely monitored to ensure pressures and flows
in the process are correct.
It is also essential to make regular field inspections using smell, sight, sound and feel to
monitor any problems where:
 Smell can be used to detect
 Overheated equipment
 Leaks
 Burning rubber or oil vapour
 Sight can be used to detect:
 Sticking valves or actuators
 Faulty gauges
 Damage to pumps, couplings or valves
 Leaking seals on pumps or valves
 Spills
 Sound can be used to detect:
 Liquid hammer in valves and other fluid flow equipment
 Cavitation in pumps
 Faulty bearings

 Faulty operation of equipment

 Steam leaks
 Feel can be used to detect:
 Excessive vibration
 Overheated equipment.
Warning: Senses such as sight, sound, smell and feel are useful in detecting
operational problems but cannot be relied on where safety and
health issues are involved
Results of routine inspections and monitoring must be compared against normal

operating parameters to identify any operational problems.
Experience and a thorough knowledge of the process and equipment is often required to
detect operational problems that are not monitored by instruments.
Smell, sight, sound and feel are tools for identifying equipment problems

OPS 201
List points that may affect flowrates and pressures.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
List some process equipment problems that can be identified using smell, sight, sound
and feel.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
At your workplace how often is equipment monitored?
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Describe how sight, sound, smell and feel is used to monitor plant.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

_______________________________________________________________________
_______________________________________________________________________

OPS 201
4.0 SOLVE FLUID FLOW PROBLEMS
CORRECTING OPERATIONAL PROBLEMS

4.3 Analyse cause of operational problem

4.4 Take action to solve operational problems.
Typical fluid flow problems are:

 Pump vapour lock
 Seal leakage from pump shafts or valve stems
 Low flow or high pressure drop across valves
 Low discharge pressure from pumps
 Bearing or coupling wear.
PROBLEM CAUSE ACTION

Vapour lock in pump Low liquid level in supply vessel Raise liquid level
Low flow rate through pump Raise flow rate by recycling some
discharge liquid back to pump
suction
Valve in suction line is partially Check that all valves in suction
closed piping are fully opened
Pump suction line obstructed Clean strainer on suction line
Disassemble suction piping and
remove obstruction
Low flow rate through Excessive head pressure due to:
pump  High discharge pressure  Check discharge piping for
partially closed valves
 Low suction pressure  Check for low level in vessel
pump is taking suction from
 Impeller or casing has worn  Replace worn parts
 Pump is vapour locking  Raise level in vessel pump is
taking suction from
 Recycle some discharge liquid
back to suction.
Vibration or noise due to Loss of lubrication or end of service Replace bearings or coupling
bearing or coupling wear life
Low pump discharge  Worn or damaged pump  Replace pump
pressure components
 Vapour lock  Action as for vapour lock
Excessive seal leakage  Loose or worn gland  Replace seal
from pump shaft or valve (or)
stem
 Nip up gland nut
High pressure drop or low Valve stuck closed or obstructed Try to unfreeze valve then fully open
flow through valve valve. If frozen, overhaul valve.

List possible causes of vapour lock in a pump.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
What action can be taken to remedy vapour lock in a pump.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
List possible causes of low flowrate through a pump.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
What action can be taken to remedy low flowrate through a pump.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
List the possible causes of low pump discharge pressure.
_______________________________________________________________________

OPS 201
_______________________________________________________________________

5.0 CARRY OUT MAINTENANCE PROCEDURES
ISOLATION OF FLUID FLOW EQUIPMENT
5.1 Isolate fluid flow equipment and prepare for maintenance as required
Before any maintenance is started on fluid flow equipment, it is essential to:

 Obtain the necessary work permits
 Isolate the equipment from:
 Electrical supply
 Mechanical movement
 Process flowlines, gland coolant lines, steam tracing lines or any other
connections to the pump
 Place danger tags on isolation valves, equipment and circuit breakers
 Depressurise the equipment
 Drain the equipment
 Flush out and purge any hazardous chemicals from the equipment using suitable
cleaning agents
 Steam clean the equipment to remove hazardous chemicals.
Steam should not be used to clean some equipment as the heat from steam cleaning may
damage some components such as rubber or teflon coated pipes or vessels and rubber
diaphragms on diaphragm pumps.

OPS 201
The equipment item must be left in a clean and

safe condition for maintenance so that Isolate
Discharge
maintenance personnel are not affected by:
Valve
Isolate
Suction
Isolate Valve
Electrical Power
Before starting any maintenance work, all

isolations and tags need to be in place
 Spills
 Fires or explosions
 Injury due to:
 Chemical splashes
 Unexpected startup of equipment
 Electrocution
 Sudden depressurisation of equipment.
All maintenance work must be carried out according to Standard Operating Procedures.
Personal protective equipment must be worn if specified in work permits or procedures.

Physical Isolation
If work is required to be performed on equipment such as inspections, maintenance or
repair, it must first be made safe by isolation so that injury to personnel and damage to
equipment or the environment is avoided.
Before equipment can be isolated an inspection of the equipment and work site is
required to check the isolation method, location and any other special precautions that
need to be taken. An isolation list is then completed indicating the relevant details of
each isolation.
The equipment must be completely isolated from the process and other services or
utilities to prevent the entry of flammable hydrocarbons or other harmful media such as
steam, nitrogen, plant air, heat, cold, pressure relief or blowdown systems, liquids or
gases.
Isolation is usually achieved by the installation of blinds or removal of valves, spools or
expansion joints as close to the equipment as possible.
Where these methods are impracticable, isolation by double block and bleed may be used
if approved. If the removal of valves or spools is to be carried out it may be necessary to
first isolate and depressure these systems.
The equipment will need to be depressured, drained, gas-freed and cleaned prior to the
fitting of blinds otherwise product spillage may result.
Other mechanical, electrical, pneumatic, hydraulic and instrument systems may also need
to be isolated to prevent injury to personnel.
DESCRIPTION RATING OPERATIONAL

TAG SIZE RATING
NO mm CONFIRM DATE CONFIRM DATE
(initial) (initial)
1
2 GAS INLET (Scaffold required) 400 600
3 GAS OUTLET 400 600
DRAIN 100 600

OPS 201
TAGGING
To ensure that equipment, controls, etc. are not accidentally or otherwise operated by
personnel, all isolated equipment must be tagged using Do Not Operate tags or lock out
tags as outlined in the permit to work procedure.
Do Not Operate tags should be recorded in a Do Not Operate tag log hook so that they
can be accounted for and inspected if required.
Describe how fluid flow equipment is isolated and prepared for maintenance at your
workplace.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

MINOR MAINTENANCE
5.2 At the completion of this topic, you must be able to complete minor maintenance
according to procedures.
Minor maintenance is required at regular time intervals to prevent premature equipment

failure.
Minor maintenance to fluid flow equipment could include:

 Tightening up mounting bolts on pumps or pump drivers
 Nipping up glands or replacing gland packings
 Greasing bearings or topping up oil levels
 Tightening leaking flanges.
Lubricant must
be topped up or
replaced at
Glands must be
regular intervals
tightened to give the
required leakage rate
Mounting bolts
must be tight
Minor maintenance can prevent costly equipment breakdowns

TIGHTENING MOUNTING BOLTS
Loose mounting bolts can cause severe vibration and fracture of machine mounting
brackets on rotating equipment.
Loose mounting bolts can also cause a pump to shift out of alignment with the driver,
causing rapid wear to couplings and bearings resulting in premature failure of these
components.

OPS 201
NIPPING UP GLANDS
Excessive leakage from a pump gland will require the gland to be nipped up or the
packing replace.
A leaking gland should be tightened evenly until the recommended leakage rate (2 to 3
drops per minute) is obtained for gland lubrication.
If the gland requires excessive tightening, the gland is worn and will score the shaft
unless it is replaced.
GREASING BEARINGS OR TOPPING UP OIL LEVELS
Small pumps are often lubricated by:

 Constant level oilers
OR
 Automatic grease lubricators.
Constant level oilers must be topped up at regular intervals to ensure adequate lubrication
supply to the bearing.
Automatic grease lubricators must be changed over at regular intervals to ensure

adequate lubrication to the bearings.
TIGHTENING LEAKING FLANGES
It is preferable if possible to replace the gasket as the cost of the gasket relative to the
leak is minor. If a gasket needs to be replaced, the flowline will need to be depressured,
isolated and drained before work commences.
If it is not possible to replace the gasket, the flange can be tightened by:
1. Checking the alignment of the flange to see that the two flange faces are parallel.
2. Reducing the tension on the flange bolts so when the flanges are tightened the two
flange faces can be pulled into proper alignment.
3. Tightening up the flanges by starting with the bolts furthest away from the leak,
working from the opposite end towards the leak.
All minor maintenance procedures must be carried out according

to Standard Operating Procedures ensuring the required Personal
Protective Equipment is worn

Explain why minor maintenance is carried out at regular time intervals.
_______________________________________________________________________
_______________________________________________________________________
Explain the consequences of loose mounting bolts on rotating equipment.
_______________________________________________________________________
_______________________________________________________________________
Explain why a small leakage rate is required through a gland.
_______________________________________________________________________
_______________________________________________________________________
Explain why a gland should not be excessively tightened.
_______________________________________________________________________
_______________________________________________________________________
List the methods used to lubricate pumps at your workplace and state how lubricant
levels are checked for each method.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Explain the method used to tighten a leaking flange if it is not possible to replace the
flange gasket.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

OPS 201
PREPARING FLUID FLOW EQUIPMENT FOR OPERATION

5.3 Receive plant back from maintenance
5.4 Prepare plant for the introduction of chemicals and operation
5.5 Return plant to operation
INSPECTION AFTER MAINTENANCE
When receiving plant back from maintenance, a site inspection is required to ensure all
maintenance work is completed and equipment is in a safe operating condition.
It is essential that equipment and the workplace is inspected to ensure the task has been
completed in terms of operations, housekeeping and safety.
All equipment should be correctly installed, securely bolted and not damaged. Loose
bolts are a common hazard encountered when returning equipment to service. Foreign
material or equipment such as welding rods, blocks of wood, tools, etc. can be left inside
a vessel and if present must be removed. Surplus equipment, rubbish, rags, scaffolding,
etc must be removed from the site before return to service, especially flammable
materials such as wood, paper or solvents.
Damage to equipment such as piping and instrumentation may have occurred and this
must be checked.
All covers, inspection hatches and accessways must be replaced and securely bolted.
Ensure gaskets have been installed in all flanges.
EQUIPMENT DE-ISOLATION
After checks have been completed to ensure the equipment is safe and free of hazards,
and approval has been given, the equipment may be de-isolated.
This will involve the removal of blinds, tags etc., resetting or activating controls, alarms,
interlocks and actuators, re-energising electrical and instrument equipment and closure of
all vents and drains.
Inspect the isolation log or register and check off each item as it is returned to normal
duty as required. Check Do Not Operate tag register and remove tags as required.

REMOVAL OF BLINDS
Blinds may be removed when approval has been given to return the equipment back into
service. Check the blind list for the locations of each blind.
Check and depressurise if necessary before loosening flanges. All blinds should be
returned to their original location. When rebolting equipment after blinds have been
removed always use new gaskets.
Depressurise before cracking flanges

RESETTING OF CONTROLS ELECTRICAL EQUIPMENT
Electrical motors will require re-energising and other instrumentation and electrical
equipment will need to be returned into service. Do not open flame proof enclosures if
flammable vapours are present.
Check instrumentation systems, alarm and interlocking systems which will operate when
put back into service. Equipment that has been racked-out in the sub-station must be
returned to normal by an authorised person.
TAG REMOVAL
All Do Not Operate tags and Lock Out tags should be removed as equipment is de-
isolated. Refer to the Do Not Operate tag register for the location of each tag used for
the equipment isolation.
TAG 5 VESSEL INLET
TAG 6 VESSEL OUTLET
TAG 7 PUMP SUCTION
TAG 8 PUMP DISCHAGE

OPS 201
PURGING AIR AND PRESSURISING
After all checks have been completed, and equipment has been de-isolated it may be
necessary to purge air from the equipment.
This can be achieved by using:

 Steam
 Nitrogen
 Fuel gas
 Product.
These systems should initially be checked open to check for leaks. To achieve flow
through the vessel a vent or blowdown line must be opened.
Purging using steam or nitrogen is usually vented to atmosphere. Flammable materials

should be directed toward the blowdown system if possible to prevent ignition, fires or
explosions.
Caution should be taken when purging with steam to avoid over-heating vessels or
equipment not designed for temperature.
After the equipment gas been purged of air (in some critical processes this can be
checked by performing a gas test of the vent to monitor the oxygen content), the vessel or
equipment can be pressurised.
Pressurising the vessel to normal operating pressure should be done by gradually opening
the inlet valve.
Care should be taken to check for leaks as necessary, and once pressurised and declared
leak free, process fluids may be admitted to the vessel or equipment.
Steam
Purging air

PRECAUTIONS FOR PRESSURE OR THERMAL SHOCK
When returning vessels into service care must be taken to bring them gradually up to
operating pressure and temperature to prevent shock.
High pressure vessels, equipment and piping may exhibit pressure shock or hammer
which can fracture materials if not pressurised correctly. Pressurising should be
completed in stages with rest periods in between if required. Vessels, equipment and
piping will expand when pressure is applied and time must be allowed so that connecting
piping can settle and adjust to these changes.
High temperature vessels, equipment and piping also must be brought up to operating
temperature to avoid thermal shock.
Heated product systems such as towers or columns may require circulation to gradually
increase temperature. Steam equipment such as heating coils should be commissioned
progressively.
Heated equipment will also expand and time should be taken so that connecting
equipment and piping can settle and adjust to these changes.
Crack, Crack
Steam
Condensate
Thermal shock on heating coils will occur if steam is admitted too rapidly

OPS 201
Explain what checks need to be made after receiving plant back from maintenance.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Explain what is involved in de-isolating equipment after maintenance.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Explain what must be checked before loosening a flange to remove a blind.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

_______________________________________________________________________

OPS 201
Explain when isolation tags can be removed.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
At your workplace describe the steps in receiving plant back from maintenance.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
At your workplace describe the steps in preparing plant from the introduction of process
fluids.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

6.0 CONTROL HAZARDS
PREPARING FLUID FLOW EQUIPMENT FOR OPERATION

6.1 Identify hazards in fluid flow work area and equipment
6.2 Assess risks arising from those hazards
6.3 Take appropriate action to control risks to procedures and duty of care
All work areas are hazardous to some extent. A chemical, oil or hydrocarbons plant
contains special hazards, due to:
 the nature of the product (inflammable, explosive, toxic etc)
 the type of equipment and machinery used to process the product (high pressures,
high or very low temperatures, the use of steam, compressed air etc).
Hazard identification has become particularly important in the Chemical, Oil and
Hydrocarbons industries since the Longford Incident. In this incident, which occurred on
September 25, 1998 at Esso’s Longford (Victoria) gas processing plant, two workers
were killed, and eight others injured. As a result of this incident, and the subsequent
findings, Victoria has revised its OH&S legislation with additional regulations pertaining
to Major Hazard Facilities. Other states are likely to follow with similar changes.
In Victoria, the OH&S (Major Hazard Facilities) Regulations came into effect on 1 July
2000. The Regulations focus on the safety of people at major hazard facilities (workers,
contractors and visitors), the safety of those who may be affected by an incident at a
major hazard site (neighbours, local community) and the safety of property.
WHAT IS A MAJOR HAZARD FACILITY
A site is considered a major hazard facility (MHF) primarily if it stores, handles or

processes quantities of dangerous chemicals or products above a threshold, as defined in
Schedule 1 of the Regulations. Typically, such facilities include refineries, chemical and
gas processing plants, LPG storage and distribution sites and even certain types of large
warehouses and transport yards. While major incidents at these sites are rare, the 1998
Longford incident highlighted the potentially catastrophic nature of such incidents in
terms of loss of life and damage to property.
MHF REGULATIONS
The Victorian Occupational Health and Safety (Major Hazard Facilities) Regulations set
out specific obligations for companies operating major hazard facilities. Under the new
laws the operating companies must:
 establish and implement a safety management system

OPS 201
 identify all major incidents that could occur, and the hazards that could cause
those major incidents
 assess the risk of these hazards and potential major incidents
 adopt control measures to eliminate or reduce, so far as is practicable, risk to
health and safety
 prepare emergency plans in conjunction with local emergency services and
municipal councils
 consult with health and safety representatives in all relevant matters
 provide safety information to the local community and consult with municipal
councils in relation to matters that could affect the local community
 prepare a safety case and apply for a licence
 revise the safety case at time frames and following specific requirements.
WHAT IS A SAFETY CASE?
A Safety Case is a written document in which the operator of a major hazard site
describes what measures are in place to prevent a major incident and also to deal with the
situation should such an incident occur. The Safety Case must demonstrate that the
measures are appropriate and adequate and that risks have been reduced as far as
practicable. A Safety Case can only be written following a full examination of:
 the facility’s activities
 the potential for major incidents
 risk control measures.
Preparing a safety case is the employer’s responsibility, but a significant aspect of a

safety case is the role of employees.
THE ROLE OF WORKERS IN HAZARD REDUCTION
The New South Wales Occupational Health and Safety Act 2000, though not applicable
outside NSW, states that:
“Employees must take reasonable care of the health and safety of themselves and others.
Employees must co-operate with employers in their efforts to comply with occupational
health and safety requirements.”
Other states have similar legislation, often referred to as “duty of care”. That is,
employees in all parts of Australia have obligations regarding Occupational Health and
Safety regulations.

The following diagram illustrates the general principle of hazard reduction.
Controls to Controls to
Event causing reduce likelihood Incident reduce severity
a hazard of an incident of incident
Concept of control measures
An example is shown below:
Initiating event Control measures Effect of loss Mitigation measures

Occurrences Eg: of control The systems to
with the ? mechanical Eg, loss of minimise the
potential to safety devices containment of consequences of loss
cause a toxic or of control
? safety
dangerous flammable
procedures
situation substances
? operator
presence
Incorrect Site wide

Operator High Hydrants
quantity in a Loss of emergenc
presence pressure and
pentane pentane y response
trip monitors
weigh tank plan
Example of effects arising from a hazardous situation
In the above example, because of an incorrect quantity of pentane in the pentane weigh
tank, there is potential for a loss of containment of pentane, leading to a fire and other
possible consequences, including injury and loss of life.
The control measures include the presence of an operator who has the skills to recognise
that there is potential for an incident to occur as a result of the incorrect quantity of
pentane in the weigh tank. The operator would then follow procedures to prevent the
incident. The important aspect is that the operator identifies the situation in the first
place.
IDENTIFYING HAZARDS
A hazard is any situation with the potential to cause harm, injury, or damage to plant and
equipment. All workplaces have possible hazards that can lead to a minor or major
incident. Identifying and dealing with a hazard is often common sense, such as seeing a
leaking gland in a pipe and notifying the appropriate personnel. Other examples include
hearing unusual noises in an item of plant, noticing a leaking containment vessel,
observing incorrect or unusual instrument readings (eg pressure, temperature, flow rate
etc).

OPS 201
In some cases, a certain level of skill is needed to identify a workplace hazard. That is,
the operator needs to know if a noise is indeed unusual, that the instrument readings are
incorrect, or that a containment vessel should not be leaking. Employers operating a
major hazard facility are obliged under the Victorian legislation to provide training for
employees. Plants that are not categorised as major hazard facilities also have obligations
under the relevant OH&S acts, which include providing a safe workplace. In other
words, there are obligations on employers to provide appropriate training in hazard
control, and obligations on employees to recognise and assess a potential hazard.
Hazards can also arise from the normal operation of items of equipment. For example,
you might notice that the barriers or warning signs around a certain item of equipment
are missing. The hazard is therefore not the item of equipment, but the missing signs or
barriers.
ASSESSING RISKS ARISING FROM A HAZARD
The risks arising from a hazard will depend on many factors, including:
 the type of workplace (eg, oil refinery, chemical plant, hydrocarbons plant)
 the nature of the hazard (eg, small or large leakage, fire, loss of containment)
 the situation at the time (eg, circumstances where a loss of containment of a
flammable substance would be greater if welding was being conducted nearby).
The risks that could arise also vary considerably and could include:
 environmental risks (pollution, chemical fallout over adjacent properties, fire)
 risks to other workers (injury or death)
 risks leading to plant damage and failure (eg, bearing failure causing a shaft to
seize, which in turn could cause other equipment items to fail, due to a loss of
output from the equipment suffering bearing failure)
 risks leading to loss of product (eg, gases or liquid products escaping, which in
turn could mean the plant loses profitability, leading to potential closure).
You would normally assess the likely risks from a hazard you have identified before
taking action. If the potential risks are high, you need to take action immediately. If there
are minimal risks (eg, a very small leak from a gland), you would still report the leak, but
perhaps after you return to base. However, if in doubt about the potential risks, report the
hazard immediately.

TAKING ACTION TO CONTROL RISKS
In some cases you will be able to deal with the hazard yourself. For example, if you
notice a leaking gland that simply requires tightening, you would tighten the gland,
providing it’s within your scope of skill level. Or you might hear a noise that indicates a
bearing problem that you can solve by topping up the bearing oil containers. The
important thing to remember is that you should only make repairs you are qualified to
undertake.
In many instances, you would need to report a potential hazard to appropriate personnel.
However there could be things you can do while an emergency response team is on its
way. For instance, if a gas bottle is leaking, you could isolate that gas bottle and warn
others of the hazard. If a pressure gauge indicates an abnormally high vessel pressure,
you would first report the problem, then take action to warn other workers, including
placing barriers to prevent others from getting too close to the vessel.
FOLLOWING PROCEDURES
Most workplaces have procedures in place to deal with hazardous situations. The aim of
these procedures is to ensure the correct action is taken and by the appropriate personnel.
If you identify a hazardous situation, you would take appropriate action in accordance
with the correct procedures. Otherwise you might make the situation worse, or cause
yourself injury. If there are no procedures, you would take action in accordance with
your skill level.
The essential aspect is to take appropriate action. If there are no procedures and the
problem is outside your skill level, report the problem immediately, even if it appears
minor. The Longford incident could have been prevented if the observation of ice around
a pipe had been acted on appropriately.

OPS 201
List the hazards associated with the fluid flow equipment you will be operating.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Assess the likely risks arising from each of the above hazards.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
State the type of action you should take to control each of the above hazards.
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

GLOSSARY
Glossary
assessment Evaluation of a person’s competence against the

hydrocarbons, chemical and oil refining standard
assessor Person carrying out the workplace assessment.
bleed valve A valve used for removing gas or air from a pump casing
blind Cover plate used to seal off the end of a pipe
centrifugal pump A pump that uses centrifugal force to increase the energy of
a fluid
check valve A valve which allows fluid flow in one direction only,
sometimes referred to as a 'non return valve'
commissioning Starting up new plant or equipment
competency Ability to demonstrate a skill according to specified

standards
condensate Liquid resulting from the condensation of steam or

hydrocarbon vapour
flange Joint in a pipe held together usually by bolts
gland Adjustable shaft seal
hazard Object, material or disturbance that has the potential to

cause harm to people
housekeeping A program for maintaining the workplace in a clean, orderly

and safe state
interlocks Electronic sequencing of operations in a process to prevent

malfunctions, accidents or other emergencies
isolation Removal of electrical and physical hazards from an

equipment item
OH&S Occupational Health and Safety
OH&S Act Legislation designed to prevent accidents and injuries in the

workplace

OPS 201
parameter A measurable process variable (eg. pressure, temperature,

rotational speed etc.)
performance criteria The required level of performance expected in the

workplace.
plant Chemical, hydrocarbons or oil refining facility
positive displacement A pump where there is no leakage of fluid between the

pump pumping element and pump casing
PPE Personal Protective Equipment
purging Removing flammable or toxic substances from vessels or

pipework
range statement Conditions under which performance to the identified

standard is expected if an individual is to be deemed
competent.
recognition of prior Assessment process that formally acknowledges the skills

learning and knowledge acquired through formal training (conducted
by industry), work experience and life experience. The
focus is on the possession of appropriate skills and
knowledge, not where they were achieved.
record of competency Each workplace learner has an individual skills record.

assessment This is used to record the competencies attained, regardless
of whether competencies are achieved through
measurement using the Assessment Instrument or RPL.
risk The potential for a hazard to cause harm to people
risk assessment Exercise used to determine the degree of risk to workers

from a hazard
risk control Measures taken to reduce the risk to workers from a hazard
routine task A task performed at regular time intervals according to a

schedule
safe work practices Procedures and methods for work that are designed to
minimise health and safety risks to workers and the
environment
schedule A timetable for performing tasks
spade Solid metal disc inserted between flanges to prevent flow or

leakage of fluid
spool piece Removable pipe section
Standard Operating Instructions for performing workplace tasks safely and

efficiently
Procedures
steam trap Device for separating and removing condensate from a

steam line
Units of Competency A general area of competency, for example, “Operate Fluid

Flow Equipment”.
viscosity A measure of a liquids resistance to flow
workplace/worksite Area in the plant where a person normally works.

OPS 201

PMAOPS201 Operate Fluid Flow Equipment

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OPERATE FLUID FLOW EQUIPMENT

Being competent in the workplace

 being able to do the job

 knowing why the job is being

 understanding the underlying

Operating process plants requires

Once you are competent you will be

 perform at the standard required

 organise your tasks

 respond and react appropriately to

 be able to transfer existing skills and knowledge to new situations.

 consistently achieve an “onspec” quality product

 meet production schedules.

What are the sections of the learning resource?

This learning resource contains

 self help activities

Check own competency

Ready for Not ready for

Assessor to Study relevant

Successful completion of the learning resources, supported by practical experience,

Assistance to complete an on-the-job practical assignment can be provided by the

Who Should Use These Learning Resources?

These learning resources are designed to be used by:

 applicants for recognition of prior learning.

Indicates a knowledge based outcome where an assessment of learning

Indicates a practical, skills based outcome where an assessment of

Indicates a worked example.

Indicates important information.

Indicates additional learning resource material related to the unit being

Indicates the start of the self help activities.

OPERATE FLUID FLOW EQUIPMENT

ABOUT THIS LEARNING RESOURCE.....................................................i

1.0 OPERATE PUMPS.............................................................................1

2.0 OPERATE PUMP DRIVERS...........................................................18

3.0 OPERATE VALVES.........................................................................21

4.0 RESPOND TO FLUID FLOW PROBLEMS...................................34

5.0 CARRY OUT MAINTENANCE PROCEDURES...........................39

6.0 CONTROL HAZARDS....................................................................51

A centrifugal pump is a rotary machine where energy is continuously imparted to a

A centrifugal pump consists of:

© Australian National Training Authority, 2002 1

 Casing consisting of a suction, volute and discharge.

2 © Australian National Training Authority, 1999

Pump Efficiency Curve

Positive Displacement Pumps

A positive displacement pump is a rotary or reciprocating machine where force is applied

The moving boundary can be:

A positive displacement pump differs from a centrifugal pump in that:

Positive displacement pumps are commonly used for:

The common types of reciprocating positive displacement pumps are:

Reciprocating positive displacement pumps contain a reciprocating piston, plunger or

Reciprocating Piston Pump

The reciprocating movement of the piston:

4 © Australian National Training Authority, 1999

Discharge Reciprocating Piston Pump

Reciprocating Diaphragm Pump

The diaphragm pump is a lightweight portable positive displacement pump commonly

The reciprocating movement of the diaphragm:

© Australian National Training Authority, 2002 5

Air Side Suction

Rotary Positive Displacement Pumps

The most common types of rotary positive displacement pumps are:

The gear pump contains two rotating intermeshing gears where:

The rotary motion of the meshing gears: