Process safety management and business impact analysis
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An explosion occurred at an atmospheric distillation tower during maintenance work on a manhole (MH). The maintenance team had difficulty opening the MH and improperly used a torch and sledgehammer in an attempt to force it open, causing a spark that ignited gases from residue in the MH. This led to injuries of two workers. An investigation found failures in process safety management elements like procedures, training, and mechanical integrity that allowed barriers to fail and the accident to happen. A business impact analysis determined costs of over $1 million and impacts to profits, sales, and fuel deliveries from the 40-day operational disruption.
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Business Continuity Analysis in oil and gas industries , applied with Process Safety Management (PSM)
Sistema de utilidades
O documento descreve o sistema de utilidades de uma refinaria, incluindo o fornecimento de vapor, água, gás combustível e oleo para as caldeiras, turbinas e outras unidades. Ele também discute os problemas comuns de corrosão e como tratar a água para evitar danos às tubulações e equipamentos. Por fim, apresenta esquemas dos fluxos de vapor, água, gás e oleo combustível na refinaria.
Fornos
O documento descreve as principais partes e operação de fornos em refinarias. Resume que os fornos são usados para aquecer e vaporizar parcialmente produtos e compreendem seções de radiação, convecção e chaminé. Detalha também os principais componentes de um forno como queimadores, refratários e variáveis operacionais como temperatura e fluxo.
Compressores
Os principais tipos de compressores usados em plantas de processo incluem compressores de deslocamento positivo (como de palhetas, parafusos e pistões), compressores dinâmicos (como centrífugos e axiais) e compressores alternativos. O surge é um fluxo reverso indesejável que pode ocorrer em compressores centrífugos quando a pressão de saída aumenta, levando a uma redução no fluxo. É importante evitar o surge para proteger o compressor.
Torres , vasos , tanques apostila
As torres na RPR incluem torres de destilação com diferentes tipos de internos como pratos furados, pratos com válvulas e recheios. Estas torres são usadas para separar misturas por diferenças nas taxas de evaporação dos componentes e estão distribuídas em várias unidades da refinaria.
Caldeiras apostila cg
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Caldeiras sistema de controle
O documento discute os sistemas de controle de caldeiras, incluindo controle de combustão, medição de ar de combustão, elementos de controle de vazão de ar, controle de nível e temperatura do vapor superaquecido. Também aborda os principais sistemas de intertravamento de segurança de uma caldeira.
Trocadores de Calor
Este documento descreve os principais tipos de trocadores de calor, incluindo trocadores de casco e tubos, trocadores de placas, trocadores de serpentina e trocadores duplo tubo. Detalha também aplicações comuns de trocadores de calor na indústria de petróleo e gás, além de dicas operacionais e a equação da conservação de calor para cálculos em trocadores.
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Process safety management and business impact analysis
- 1. Process Safety Management and Business Impact Analysis eteX- june 2021 ete X eteX 1
- 2. Case : Explosion in a Manhole (MH) in an Atmospheric Distillation Tower eteX 2 In 2004, maintenance was carried out on an atmospheric distillation unit of 100,000 barrels/day. The Atmospheric Distillation Unit (ADU) is part of the refining complex with this simplified configuration: ADU VDU FCC Crude oil AR HVGO Diesel Naphtha Atmospheric Residuum Fuel Oil LPG Gasoline AR: Atmospheric Residuum VDU: Vacuum Distillation Unit FCC: Fluid Catalytic Cracking HVGO: Heavy Vacuum Gasoil MH Manhole Distillation Tower MH Stripping ete X
- 3. Tower opening release steps eteX 3 Emptying the Distillation Tower Start of Steam out End of Steam out Cooling Gas measurements inside the tower through openings in the bottom drains, bottom level taps and top vent. With safety conditions, release of the tower for opening the manholes (4). Distillation Tower Steam out Steam out Gas test Gas test Gas test ete X
- 4. Opening the Manhole at the bottom of the tower eteX 4 Security Team releases the opening of the Tower for maintenance and inspection. Maintenance Team starts opening the Manhole (MH) at the bottom of the tower. – Does not use the proper torque tools due to damage to them. Start with common tools. Difficulty for opening is very high. Maintenance team, very experienced (~30 years of activity), starts heating the MH nuts with a torch in an attempt to make the opening easier by loosening the nuts with heat. First attempt didn't work. Continued heating, using more time. MH increased the temperature. Success in removing the nuts for opening. MH still locked even without the nuts. Torch ete X
- 5. The Explosion eteX 5 ete X An employee from the maintenance team hits the MH with a sledgehammer to try to open it. The MH opens, with a spark from the sledgehammer hitting it. Explosion in MH when it opens. The two maintenance team employees are injured, one with a 2nd degree burner and the other with head trauma from being thrown into a pipe in the explosion. The inside of the bottom of the tower is also damaged. Distillation Tower
- 6. Probable cause eteX 6 ete X The probable cause was the entry of oxygen at the time of forced opening of the MH, plus the spark caused by the hammer hitting the MH plus the gas that was generated when the MH was overheated. Gas origin: Heavy material residues (bottom of the column sticked to the inside of the MH that did not come out with the Steam Out operation.When the MH was overheated, there was an evaporation of the light part associated with the residue creating a gaseous atmosphere. Spark oxygen Gas
- 7. Failed PSM Elements - Barrier Failure eteX 7 ete X 1.Process Safety Information 2.Process Risk Analysis 3.Operational procedures 4.Employee Participation 5.Training - Initial / Reinforcement / Documentation 6..Contracted Outsourcers - Application / Responsibilities 7.Pre-Start Up Safety Review 8.Mechanical Integrity 9.Hot Work Permit 10.Change Management 11.Accident investigation 12.Emergency Response Plan 13.Compliance Audit OHSA -PSM Barriers Fail > Accidents Happen *Unfulfilled items marked in red Grêmio X Real Madrid – Final World Championship
- 8. Business Impact Analysis - BIA eteX 8 ete X Accidents have an impact on the physical structure and on people who are studied and investigated within the PSM , which also has barriers to prevent them from occurring , but we still have an analysis tool for the impacts on business that is part of a business continuity plan . Business, which is an important part in a company beyond the PSM implementation. -5% IN PROFITS -10% ON SALES DELAY IN DELIVERY OF FUEL TO CUSTOMERS MORE THAN U$ 1MM in costs
- 9. eteX 9 Business Impact Analysis - BIA ete X Accident 40 days Operational Return Service Level Return 20 days