refinery hazards pres rev5 2006

UOP Field Safety Training UOP/Honeywell Confidential 1Refinery & Plant Hazards

UOP Field Safety Training

Refinery & Petrochemical Plant Hazards


Refinery & Petrochemical Plant Hazards

• Flammables (liquid/gas)

• Caustics

• Hydrogen

• Chlorine

• Nitrogen

• Benzene

• Hydrogen Sulfide

• Steam

• Rotating Equipment

• Asbestos (esp. overseas)

• Refractory Ceramic Fibers

• Ammonia

• Blocked PRVs

• Electrical

• Housekeeping

• Overhead Work

• Fired Heaters

• Hot vessels/pipes

• Polynuclear Aromatics

• Low Pressure/Vacuum


Review the Hazards & Potential Consequences

• Benzene- Carcinogen (leukemia)- Not to exceed 1 ppm for 8 hr workday- Respirators needed

• Caustic- Takes many forms- Corrosive- Irritant- PPE required

• H2S- quickly deadens the olfactory- replaces oxygen- Can kill at 1000 ppm- Protection: Sample atmosphere and wear HxS

monitor (as close to nose/mouth as possible).- See data sheets in back of section


Review the Hazards and Potential Consequences

• Electrical- Don’t handle equip. in wet environments- Unplug electrical equip. before working- Rely on qualified personnel- More on following slides

• Fired Heaters- Inadequate purging of box- Fire/explosive upon lighting

• Nitrogen- The “Silent Asphyxiant”- Can not be detected- More on next slides

Reference UOP Electrical Safety PR&G Manual (EWP-1, “Basic Electrical Safety”) in UOP Intranet


Incidences of Electrocution

• Department of Energy’s DOE’s summary states 36% of standard non-compliances were electrical violations

• Deaths normally result with direct contact with high voltage

• Risk from electrical shock is greatest for electricians and technicians

• Other workers at higher risk include mechanics, welders, laborers, and those using portable electrical tools.


Causes of ElectrocutionUnsafe Acts

• Accidentally slipping with wrenches, screwdrivers while working on or near electrical equipment with “live” parts

• Switching off the wrong circuit and then failing to verify that the circuit is de-energized

• Failing to implement LOTO

• Using non-insulated tools

• Wearing metal jewelry

• Using instruments/meters/tools not designed for the system voltage


Causes of ElectrocutionUnsafe Conditions

• Improper grounding, loose connections, defective parts, ground faults, unguarded live parts or faulty insulation in equipment

• Inadequate maintenance

• Hazardous environments, e.g., corrosive or flammable atmospheres, wet or damp locations

• Inadequate working clearance


Electrocution Prevention Overview

• Preventing low-voltage electrocutions relies on lockout/tagout or disconnecting or otherwise isolating the power

• Ground fault circuit interrupters should also be used to prevent electrical shock from damaged or defective tools

• To prevent high-voltage electrocutions use appropriate personal protective equipment and de-energize grounded lines prior to working near them.


Electrical Hazards


Nitrogen Health Information

• Nitrogen as a gas is:

• 79% of air & inert & non-toxic

• Classified as a “simple asphyxiant” (no exposure limits given)

• Nitrogen in liquid form is:

• Colorless, odorless, extremely cold

• A potential cause of severe frostbite if you contact the liquid (or vapors)


Nitrogen Asphyxiation

• Typically occurs in confined spaces.• Mechanical bubbles caused by high Nitrogen content (above 80%)

block ability of Oxygen to get to blood and tissue...... called Ischemia.

• Increased respiratory rate not caused by high Nitrogen or lack of Oxygen, but high level (>1%) of Carbon Dioxide.

• Person tires and without much warning (in minutes) faints• One deep breath of 100% nitrogen will be FATAL !


Oxygen Content (Volume %) Effects and Symptoms

21% Normal breathing.17% A candle is extinguished. Vision may be

impaired.12 - 16% Labored breathing, increased heart rate.

Lack of attention and coordination.11 - 14% Unable to think. No longer percieves danger.

Ability to self rescue is impaired. Fatigue, injury to heart, fainting.

8 - 11% Fainting without warning. Nausea, vomiting, unable to stand, walk or crawl. Person is dying but does not care. It's all quite painless.

6 - 8% Faint almost immediately, heart may continue beating for a few minutes, resuscitation possible if immediate.

0 - 6% Fainting, almost immediate coma, convulsions, respiratory arrest, death. Brain damage even if resuscitated.

Oxygen Deficiency


3,140 Pounds of Force

20 in. Man-way

10 psi pressure on a 20” manway (314 square inch surface area) is

3,140 pounds of force! (314 X 10= 3,140; manway = 275 lbs)

Force = pressure multiplied by area so:

LOW PRESSURE HAZARDS EXAMPLE

10 psig

…….if suddenly released, it goes flying!


VACUUM SAFETY

• The same concepts apply to vacuum, except pressure is pushing inward, not outward.

• The pressure comes from the atmosphere -- we don’t feel it, but a tank does !

• Atmospheric Pressure at sea level is about 14.7 psi, therefore “full vacuum” is 14.7 psi.

• Note the spills that result from this event

Vacuum

Atmospheric Pressure


Vacuum System Hazards

Tank Collapse

API Tank Photo


Reason for Tank Collapse

The vent valve cover was left on during the tank’s product draw-out.


Other Hazards

Watch Where You Park !


Methods for Identifying Hazards

• Visual

- steam

- asbestos

- ceramic fibers

- electrical

- rotary equipment

• Feel

- caustics

- hot lines

- hydrogen fires

• Smell– ammonia– hydrogen sulfide

(initially)– chlorine– benzene

• Hear– PRV– HC or chemical leaks


Refinery & Petrochemical Hazards

• Watch for signs• In Europe pictorial signs are used:

- Blue circular signs require or inform

- Yellow triangles warn of danger

- Circular signs with a red border prohibit


Accident Awareness

• Be Aware of accidents that have occurred at your site and on process units you will be working on and submit your near misses and safety suggestions

(UOP@Work homepage-Near Miss Form Icon or PT&E HSE Website homepage)

• UOP Near Miss Report (UOP@Work homepage or PT&E HSE Website-Near Miss Summary Icon)

- Report a Near Miss or Safety Suggestion: Access “Near Miss Form” icon via UOP@Work homepage or PT&E

HSE Website Homepage Can report US or International Refinery incidents (home or off-the-job

also) View existing reports (for awareness) at same location as the form. Can sort by incident location or date (submitted)


Disaster Area Safety

• Why would UOP go there?- Incident investigation of fire, explosion

- Earthquake area evaluation for revamps

• How to prepare to visit/work in these areas:- Ask site for briefing of hazards before entering

- Be very aware of potential hazards because no one else may have come across it yet !


Thai Oil Tank Farm - Fire

December 2, 1999 @ 11:30 pm - GasolineTank Overflow


Foam

a

Aqueous Film Forming Foam

Alcohol Resistant AFFF

How Foam Works

Aqueous FilmFoam

Foam

Smothers

Cools

Separates

UOP Field Safety Training UOP/Honeywell Confidential 24Refinery & Plant Hazards8 Fatalities - 13 Hospitalized


Tank shell has melted!


5 tanks destroyed - 100,000 liters of oil burned


Administration Building, maintenance shop,store, medical center, engineering office,

fire station and 3 fire trucks severely damagedfrom the blast!


No Process Units Damaged.

Fire water monitors -critical to fire fighting


Appears that fire started when a gasoline tank overflowedand a truck passing by created a spark.


AnyQuestions

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refinery hazards pres rev5 2006

Documents

hse website

uopwork homepage

miss form

petrochemical

plant hazards

refinery amp

uophoneywell

ptamp