DO NOT let that Single Spark to start a Huge Blaze - … NOT let... · DO NOT let that Single Spark...

DO NOT let that Single Spark to start a Huge Blaze

Er. Lucas NG HK

General Manager of Plant

NFEC Fire Safety Seminar 2017

29 June 2017, Marina Bay Sands Convention Centre

Petrochemical Corporation of Singapore (Private) Limited


2

1. Introduction

2. Fire Triangle and Fire Tetrahedron

3. Ignition Source and Flammable Material

4. Facility Integrity, Detection and Monitoring

5. Emergency Response Plan and CERT

6. Conclusion and Takeaway

Source: website


3

1. Introduction






Source: website

4Source: PCS

Upstream company of Singapore Petrochemical Complex on Jurong Island

1977 – incorporation

1984 – first ethylene plant (cracker) in Southeast Asia on stream

1997 – second cracker unit on stream

Present shareholders

Japan-Singapore Petrochemicals Co., Ltd (50%)

(JSPC led by Sumitomo Chemical)

QPI and Shell Petrochemicals (Singapore) Pte

Ltd (50%) [*QPI: Qatar Petroleum International]

supply high quality ethylene, propylene,

acetylene, butadiene, 1-butene, MTBE and

benzene to companies within Island

1. Introduction

Jurong IslandSingapore

5Source: websites

Jurong Island

Petrochemical Corporation of Singapore

(Private) Limited, PCS

1. Introduction

6

Major transformation to

Total WSH

Believe solutions to problems

Believe Zeroincident target

achievable

Achieved: >12 years + >35

million worked hours LTI Free

PCS had painful falling from height

incident in 2004 Management made

major transformation

NO major fire incident

2011 bizSAFE

Mentor

1. Introduction

Source: PCS


7

1. Introduction






Source: website

8


Fire TriangleFire

Tetrahedron Fire

Ignition Source

+ Chain Reaction

9


Fire Tetrahedron or Fire Pyramid

Substance OxidiserEnergy -

Combustion

Chemical Chain Reaction

Free Radicals

Initiate + Propagate

Combustion


10

1. Introduction






Source: website

11


Ignition Source

Static Electricity

Lightning

Hot Surfaces

SparksOpen Flame

Friction (Dust)

Smoulder

Arcs, Sparks

Charges

Furnace

Idling Engine

Flame Welding

Ignited CigarettesGrinding

Impact

Screw-feeding

Chemical Reaction

Pyrophoric

Electrical

contact, SG

12


Source: http://webapps2.ucalgary.ca/~ursenbac/hazards/ignition_sources.php

Types of Ignition Sources Identified in Website Case Studies

- In Oil and Gas Industry

Ignition Source

http://webapps2.ucalgary.ca/~ursenbac/hazards/ignition_sources.php

13

Be

st C

on

tro

l E

ffe

ctive

ne

ss


In Oil, Gas and Chemical industry –

wide range of flammable material

Solid Liquid Gas / Vapour

Storage Transport Processing

Storage Distribution

Source: website

14

Hierarchy of Hazards

Controls

Be

st C

on

tro

l E

ffe

ctive

ne

ss

Ignition Source

Elimination

Substitution

Engineering Control

Administrative Controls

Fixed Fire Protection / Monitoring Facilities

Substitute or minimise use

of flammable materials

Segregation by design / e.g.

Fire Box – close monitoring

Strict ignition sources

control, housekeeping etc.

Fixed installations: fire

proofing, drencher etc.

“Fire Safety Guidelines for Open Plant Structures in Oil, Chemical and Process Industries”


15


Beware of Hidden Ignition Sources and Flammable

Material Release in Oil, Gas and Chemical Industry,

including Waste Management

Hidden Ignition

Sources

• Static Electricity

• Hot Surfaces

• Pyrophoric Iron Sulphide

Hidden Flammable

Material Release

• Stress Corrosion Cracking, SCC

• Corrosion Under Insulation, CUI

Facility Integrity and Reliability


16

1. Introduction






Source: website

17

Beware of Hidden Ignition Sources and

Flammable Material Release

4. Facility Integrity, Detection & Monitoring

Sulphur compounds and chlorides presence in petroleum – crude, natural gas

Both Sulphur compounds and Chlorides required by processes

Examples: anti-coking and catalyst

“Love them and Hate them”

Both of them can cause stress corrosion cracking of alloy steels and stainless steel

18


Tensile Stress

Corrosive Environment

Susceptible Material

Stress

Corrosion

Cracking

Sulphur compounds, Chlorides, (Hydrogen)

SCC Cracked Lines Flammable

Material Leaks Fire (Ignition Source)

Source: website; PCS

19


Source: website; PCS

Stress Corrosion Cracking, SCC

Small flame associated with small SCC at

affected location – warning sign

20

Beware of Hidden Ignition Sources and

Flammable Material Release


• Feedstock purchase specification

• Source of supply – avoid potential sources of high contaminants

Eliminate at Source

• Adequate process removal

• Retard stress corrosion cracking condition – keep dry

Control Operating Conditions

• Leak detection devices

• Periodical inspection

• Wear and tear replacement

Monitor Facility Conditions

21


Gas Detectors

Infra-red Gas Detector

Catalytic Gas Detector

Portable Gas Detector

22


Typical Schematic Drawing of Poly-Flo Tubes for Fire Detection

in Floating Roof Storage Tank

Local Control Panel

Control

Room

Pneumatic (Poly-Flo)

Tubes for Fire Detection

Fire Brigade(Main Fire Alarm

Panel and Mimic

Panel Indication)

Detection /

Alarm Signal

Copper

Tubes

Pneumatic Line Heat Detector

Source: PCS

“A Single Spark can start a Huge Blaze”

23


Source: PCS

“A Single Spark can start a Huge Blaze”

Pneumatic Line Heat Detector

Poly-Flo Tubing at Furnace Effluent Line

Poly-Flo Tubing at Compressor

Poly-Flo Tubing at

Spherical Tank Bottom

Source: PCS

24

Back to Basic Principles

Facility Integrity & Reliability


Facility I&R Engineering

Design

Process Operating Conditions

Changes in OC & Maintenance

Exceeded Operating Boundary

Management of Change, MOC

Debottlenecked,

Regulations /

Standards

Source: PCS

25

Back to Basic Principles

Facility Integrity & Reliability


Inspection & maintenance

strategies

Manage Risks

Senior mgtsupport

Safe plant operations &

lifetime extension

Detection Devices

• Wide range of gas detectors

• Wide range of fire detectors

• Pneumatic line heat detector – effective in wide application, especially furnace

Process Conditions Monitoring

• Process inventory, flow, pressure, temperature

• Equipment vibration, temperature, thermodynamic efficiency


26

1. Introduction






Source: website

27

Petrochemical Corporation of Singapore (PCS) - Company ERP

Situation: Area of Operations, Layout, Storage Area; Quantities of Hazardous Substances

Execution: Concept of Operations, Containment of Emergency (shutdown, fire fighting); Coordination / Instruction

Service Support: Provision of Fire Protection (detection facilities, extinguishing / drencher systems; first aid

Command and Signal: Incident Organisation, Appointment Holders (SMC, SIC, CERT); Communication


Singapore Petrochemical Complex Rules and Regulations

- Prevent Fire, Explosion, gas leak and Oil & HNS Spill

28


Complex Emergency Organization

SCDF

PCS Technical Team

Asst SMCPCS Gen

Affair Team

PCS Mgt Team Complex

Controller

SMC

Company CERT

PCS Fire & Security

SIC

Unaffected Co Mgt Rep

Inc

ide

nt

HQ

Inc

ide

nt

Sit

e

(Engrg, HSE,

Maint, Opns)

(Medical, Log,

HRA,Planning,

Mkt, Legal)

Complex Controller

- PCS GM of Plant

Table Top Exercise

Fire Fighting Training

Individual Emergency

Drills

Complex-wide Major Exercise

29

Use of Actual Size

Facilities

Planned Regular

Drills

Review for Gaps /

Improvements


Competency Development

30


Fire Fighting Training - 1

Source: PCS

31


Fire Fighting Training - 2

Source: PCS

32


PCS F&S and Individual Company Emergency Drill

Individual Emergency Drills

Source: PCS

33


Combined Exercise with Government Agencies including SCDF

Complex-wide Major Exercise

Source: PCS

34


Fire Fighting Equipment and CERT PPE

PPE

• Fire fighting helmets + face shields

• Fire retardant gloves

• Fire fighting safety boots

PPE (cont’d)

• Fire fighting suits

• Hazmat suits

• Self-contained breathing apparatus

Mitigation

• Fire hoses

• Water / foam nozzles

• Water foam monitors

• Hazmat adsorbent

• Spill kits

First Aid

• Type A first aid kit

• Double-fold pole stretcher

• Fire blanket

• AED

Communication: Loud hailer, Walkie-talkie


35

1. Introduction






Source: website

• Knowledge of Fire Tetrahedron

• “A Single Spark can start a Huge Blaze”

• Never Neglect Hidden Ignition Sources

• Good Integrity/Reliable Facility – NO Release

• Eveready Company Emergency Response

Plan and CERT

“Always be Prepared, Eliminate Ignition

Source and Stop Release, in Alleviating all

Potential Emergency Situations.”

36


THANK YOU

37Source: website


NFEC Fire Safety Seminar 2017

29 June 2017, Marina Bay Sands Convention Centre

DO NOT let that Single Spark to start a Huge Blaze - … NOT let... · DO NOT let that Single Spark...

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