Decommissioning equipment is a major part during any plant relocation or shutdown process. A lot of the time, you have machinery moving getting the spotlight. However, dismantling and decommissioning the equipment is just as important. You need to be 100% sure that you are handling any safety hazards, equipment damage, tackle compliance issues and avoid any costly delays which can become a problem more often than not.
What decommissioning means in an industrial environment?
At its core, decommissioning has a very important meaning. It focuses on safely shutting down, dismantling, disconnecting and also preparing any industrial equipment for relocation or removal. It’s not just about shutting down a machine and moving it. Instead, it also involves hazard mitigation, planning and coordination done across multiple disciplines.
In fact, in the industrial setting, decommissioning for a Plant Relocation can be very complex and it involves multiple tasks, such as:
- Disconnecting utilities
- Removing process materials and any residual substances
- Dismantling mechanical as well as structural connections
- Preparing the equipment for lifting as well as transport
- Restoring or preparing the site for any future use
Why equipment must be properly disconnected before removal?
Simply put, disconnecting and decommissioning is crucial because it isolates any problem-makers before you begin any type of physical work. In order to do that, you are using various lockout/tagout procedures, ensuring the energy sources stay isolated. Adequate disconnection also ensures that your equipment will retain its integrity, which can prove to be a very challenging thing more often than not.
Utility shutdown steps such as power, air, water, and gas isolation
When you are doing any Machinery Moving, it’s very important to isolate all the utility connections. Shutting them down is crucial, as it will help make the entire decommissioning process a lot safer. Different utilities will have their own approach when it comes to shutdown, as you will notice below.
Electrical power isolation
- Shut down the equipment by using standard operating procedures
- Then, disconnect from the main power supply
- You can also apply the lockout/tagout devices
- Verify that there is a zero state energy with the adequate testing equipment in place
- Label all the wiring for any future reinstallation, and ensure that everything is working right as expected.
Compressed air systems
- In this case, you want to shut off the air supply at the main valve first
- Then, you depressurize the entire system
- Go on by disconnecting the hoses and fittings
- Cap or even seal the open lines in order to prevent any type of contamination.
Water and cooling systems
- For these, you want to shut off the water supply lines
- Then, you can drain cooling systems and piping
- Disconnect the valves and hoses
- And of course, ensure that you are preventing any type of spills or leaks during the disconnection
Gas lines
- In this case, you need to shut off the gas supply at the source
- Purge lines if you need to, even if that’s not exactly necessary
- Disconnect and also cap all the gas connections
- Ensure that you have proper compliance with the local safety regulations
Utility systems need to be decommissioned properly, otherwise you can encounter major safety concerns. So, Understanding Utility Requirements Before Moving Industrial Machines (Power, Air, Water, Ventilation & Drainage) is a very good idea. It’s important to read such a guide, as it will help provide a lot more guidance and information.
Draining oils, fluids, and process systems where required
Most industrial equipment will have a variety of fluids, ranging from lubricating oils to hydraulic fluid, coolants, process chemicals or waste byproducts. You always want to drain these fluids, because it will allow you to prevent any contamination or spills. It will also help reduce weight for safer lifting. And of course, you can also avoid any internal damage during transportation, something that will end up helping a lot more than expected. Plus, you get to comply with the environmental laws, too.
Some best practices in this case would be to use designated containers for each fluid type and label as well as store everything safely. Clean the internal systems where you can, and also document any quantities, as well as disposal methods. Being organized during the decommissioning process does matter, and it will help in more ways than expected.
Removing anchor bolts and preparing equipment for lifting
After you disconnect utilities, you will need to remove anchoring bolds and prepare the machine for lifting and moving. First, identify the anchoring bolts and then use the right tools to remove them. The tricky thing in this case is that you want to avoid damage to the base frame. Unfortunately, that can happen very often, and it’s extremely important to address it properly. Ensuring stability during removal is also crucial here.
Aside from the anchoring bolts, you also want to remove the support frames, conveyor systems, adjacent machinery, overhead structures and anything of that nature. You can also prepare for lifting by determining the center of gravity, identifying the proper lifting points and inspecting attachment points or the lifting lugs. You also want to be 100% sure that the equipment is stable and balanced. It also helps if you are using the right rigging equipment, which a company like SolidHook will be able to provide without a problem.
Site preparation after removal, including slab repair, cleaning, and readiness for replacement equipment
After you remove the equipment, you do want to make sure that the site is safe and not full of problems. For example, you want to do some slab repair by filling holes, grinding or leveling surfaces, and also ensuring load-bearing integrity. It’s a crucial step when you decide whether the equipment will be installed in the same location or not.
Aside from that, you also want to be certain that the site is free of debris and fully clean. Since industrial environments are known for accumulating residues, debris and dust overtime, you want to clean the surfaces properly. Remove any waste and leftover materials, and dispose of debris according to the latest regulation. Plus, you need to be 100% sure that the area is free of any hazards.
Importance of documentation and inspection before equipment leaves the site
Is it necessary to do adequate documentation and inspections before the equipment leaves your site? Of course, because documentation will offer a reference for the reinstallation process. It also ensures compliance with safety and environmental regulations. You can also track the equipment conditions and see if any changes were made. Plus, it can support project coordination, too. What documentation should you maintain? The utility disconnection records, along with any logs, fluid disposal records, labeling and component identification, photos of configurations and connections, equipment condition reports, etc.
Also, before the equipment is leaving your site, you need to do a final inspection. Ensure that all the disconnections are made, there are no existing hazards, and the equipment is ready for transportation. Every component should also be accounted for, too.
Conclusion
Industrial equipment decommissioning is a difficult, yet essential process. You want to handle everything from isolating the utility to fully draining it, detaching structures, preparing the site and inspecting everything. Plus, having the right documentation is going to help save a huge amount of effort and time. You always want to approach decommissioning with a proper plan, and great attention to detail. Not only will that minimize downtime, but it will also ensure a seamless transition/moving process for your industrial equipment.
