Hazards in a refinery

Slide 1

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTHAZARDS IN A REFINERYM.ELAMARANPNM-CG1AGENDA

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT INTRODUCTION

BASICS

TYPES OF HAZARD

HAZARD CONTROL

VIDEOS AND ANIMATION

SPECIFIC TO COMMISSIONING2INTRODUCTION

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTPLEASE TELL US VARIOUSINCIDENTS YOU HAVE SEEN OR HEARED ABOUT?3INTRODUCTION

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT

4INTRODUCTION

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Q1 . Do you believe that these incidents could have been prevented?

Q2. How many people could have prevented it?5BASICS-Hazard

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT What is a Hazard?

A potential to cause harm or damage.

Damage to Life , Health , Environment and Property .

The potential to damage is realized with certain probability in the absence of its control. 6BASICS- Risk

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTWhat is Risk?

The likelihood that a specified undesired event will occur due to the realisation of a hazard by work activities, or during work activities or by the products and services created by work activities.

Risk = Hazard * Exposure

Risk = Severity * Likelihood7BASICS- Personal and process safety

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTPersonal safety incidents Relatively high frequency low consequence incidents.- controlled by PPE, Work permit systems

Process safety incidents Relatively low frequency high consequence incidents. Controlled by Process safety management, Work permit system8Basics- Spot the Hazards


9Basics- Spot the Hazards







A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT13Basics- Spot the Hazards




15Hazard control -Principles

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTAt its source. Along its path. (erect a barricade between the hazard and the worker.)At the worker. (remove the worker from the exposure, such as automated/remote controls, worker rotation, providing PPE when all options have been exhausted.)Monitoring activities (locate new hazards and assess the effectiveness of existing controls.) 16Hazard control - Hierarchy


17Hazard control Various stages

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT18CONCEPTUAL DESIGNSITE SELECTIONPROCESS DESIGNDETAIL ENGINEERINGSTART-UPOPERATIONCOARSE HAZOP, WHAT-IF, HAZARD RANKING, HAZIDPRELIMINARY RISK ASSESSMENT, CONSEQUENCE ANALYSISHAZOP, FMECA, SIL STUDY, SAFETY REVIEWDETAILED RISK ANALYSISSAFETY AUDIT, EMERGENCY PLAN, HIRASAFETY AUDIT, HAZOP, RA, RBM, HIRA18Hazards in Refinery - Physical

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Fall from height , impact from tools , slips and trips , Objects falling from height

From Heat Hot burn , cold burns

From Light Eye damage due to looking at welding arc

From Sound Ear damage

From Pressure whiplash of hoses , danger during hydro jetting

Electrical Hazards. Static Electricity.

Impact Hazard.

Fire and Explosions.

Radiation.19Hazards in Refinery - Chemical

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Uncontrolled runaway reaction

Asphyxiation

Gases H2S , Cl etc

Other catalyst and chemicals respiratory damages, carcinogens ,dusts

Uncontrolled release Air , water and land pollution.

20Hazards in Refinery -Process

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Uncontrolled release.

Fire.

Explosion.21Hazards Pre commissioning and Commissioning

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Layout Impact Hazards , Dangerous approaches and Hindrances, no escape routes- address in Format checking

Flushing - Mix up in flushing media , improper flushing .

Air blasting Rupture and blast , abrasion.

Box up improper box up , improper gasket leaks . Missed LPD, HPV , small bore piping box up.

Pressure test rupture dangerous with hydrogen

Inertisation improper. Vacuum pulling after steaming.

Fuel gas back up leaks , release through small piping's.

Utility charging Hammering , Nitrogen going to wrong place.22Hazards Pre commissioning and Commissioning

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Lining up wrong line up , wrong blinding and deblinding

Equipment line up Missed PSV line up. Wrong sequence, inadequate adherence to procedure.

Pump/ equipment trials wrong line up, missed pre requisites , missed coupling guard, earthing from motor missing, improper junction box sealing.

Instrument points mix up, wrong control valve action, missed square rooting in flow, non line up, non calibration, junction box improper sealing, wrong interlock implementation.

First heating Constraints to expansion leading to rupture, line falling of support, fouling , unreleased expansion bellows and spring supports

Hot Bolting- wrong spanner material , leaks, gasket rupture23Hazards Pre commissioning and Commissioning

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECT Start up improper adherence to procedure, wrong procedure, too quick heat up , bypassing safety interlocks, doing start up before the unit is ready.

Leaks small points like orifice flange spare tapings, bull plugs in NRVs, pump strainers, Valves, HPVs , LPDs , instrument tapping drain points etc

Operators Not familiar with the plant and operation, incomplete and inadequate training.

Major Hazards mix up in MOC, Design errors , wrong calculations etc.24

A Sunrise Project for a Sunshine FuturePARADEEP REFINERY PROJECTThank You25

Documents

Hazards in a refinery