refinery hazards pres rev5 2006
DESCRIPTION
Refinery HazardsTRANSCRIPT
UOP Field Safety Training UOP/Honeywell Confidential 1Refinery & Plant Hazards
UOP Field Safety Training
Refinery & Petrochemical Plant Hazards
UOP Field Safety Training UOP/Honeywell Confidential 2Refinery & 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
UOP Field Safety Training UOP/Honeywell Confidential 3Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 4Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 5Refinery & Plant Hazards
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.
UOP Field Safety Training UOP/Honeywell Confidential 6Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 7Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 8Refinery & Plant Hazards
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.
UOP Field Safety Training UOP/Honeywell Confidential 9Refinery & Plant Hazards
Electrical Hazards
UOP Field Safety Training UOP/Honeywell Confidential 10Refinery & Plant 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)
UOP Field Safety Training UOP/Honeywell Confidential 11Refinery & Plant Hazards
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 !
UOP Field Safety Training UOP/Honeywell Confidential 12Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 13Refinery & Plant Hazards
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!
UOP Field Safety Training UOP/Honeywell Confidential 14Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 15Refinery & Plant Hazards
Vacuum System Hazards
Tank Collapse
API Tank Photo
UOP Field Safety Training UOP/Honeywell Confidential 16Refinery & Plant Hazards
Reason for Tank Collapse
The vent valve cover was left on during the tank’s product draw-out.
UOP Field Safety Training UOP/Honeywell Confidential 17Refinery & Plant Hazards
Other Hazards
Watch Where You Park !
UOP Field Safety Training UOP/Honeywell Confidential 18Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 19Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 20Refinery & Plant Hazards
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)
UOP Field Safety Training UOP/Honeywell Confidential 21Refinery & Plant Hazards
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 !
UOP Field Safety Training UOP/Honeywell Confidential 22Refinery & Plant Hazards
Thai Oil Tank Farm - Fire
December 2, 1999 @ 11:30 pm - GasolineTank Overflow
UOP Field Safety Training UOP/Honeywell Confidential 23Refinery & Plant Hazards
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
UOP Field Safety Training UOP/Honeywell Confidential 25Refinery & Plant Hazards
Tank shell has melted!
UOP Field Safety Training UOP/Honeywell Confidential 26Refinery & Plant Hazards
5 tanks destroyed - 100,000 liters of oil burned
UOP Field Safety Training UOP/Honeywell Confidential 27Refinery & Plant Hazards
Administration Building, maintenance shop,store, medical center, engineering office,
fire station and 3 fire trucks severely damagedfrom the blast!
UOP Field Safety Training UOP/Honeywell Confidential 28Refinery & Plant Hazards
No Process Units Damaged.
Fire water monitors -critical to fire fighting
UOP Field Safety Training UOP/Honeywell Confidential 29Refinery & Plant Hazards
Appears that fire started when a gasoline tank overflowedand a truck passing by created a spark.
UOP Field Safety Training UOP/Honeywell Confidential 30Refinery & Plant Hazards
AnyQuestions
?