LIST OF CONTENTS - MKO Process Safety...
Transcript of LIST OF CONTENTS - MKO Process Safety...
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LIST OF CONTENTSLIST OF CONTENTS
ⅠⅠ INTRODUCTIONINTRODUCTION
ⅡⅡ LOPA STUDYLOPA STUDY
ⅢⅢ CONCLUSIONSCONCLUSIONS
1. Consequence and Severity2. Developing Scenarios3. IPLs
and Frequency of Scenarios
4. Risk Calculation
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II INTRODUCTIONINTRODUCTIONDescription of System I
Jetty
PropaneCavern
ButaneCavern
ButaneTank area
PropaneTank area
FlareStack
Un-loading
Area
UtilityPlant
PumpCompressorEvaporator
ETC
Building&
Control room
Parking Lot
1ea1ea AddAdd
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II INTRODUCTIONINTRODUCTIONDescription of System II
Facility Equipment Capacity (Unit)
Storage Butane tankPropane tank
20,000 ton (3EA)20,000 ton (5EA)
Loading
Loading arm 1,000M3/hr(2EA)
Jetty Boosting Pump 600M3/hr(1EA)
Boosting Pump 1,000M3/hr(3EA) Heater -46℃ -> 2℃
Unloading Pump 480M3/hr(3EA) Loading arm 120M3/hr(6EA)
Safety Flare stack 8,000 SCFM Butane evaporator 100M3/hr(3EA) Refrigeration compressor 500M3/hr(1EA)
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Cavern Tank
Storage Tank Ordoring Tank Lorry
Unloading
140 ~ -6.0 mbarg50 ~ -6.6
Pressure Safety DeviceSafety Valve, Pressure Regulating Valve,
Cryogenic Compressor
Description of System III
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Description of System IV
Sensor
Cryogenic Compressor
Safety Valve
Boil-off Gas Condensing
Sensor
EvaporatorPressure
Regulating Valve
Low Pressure(Vacuum)
High Pressure
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LOPA I
Release RateCase A : 12.5 mm diameter equivalent(Flange or Gasket)
Case B : 25.0 mm diameter equivalent(25A Rupture)
Case A : 50.0 mm diameter equivalent(50A Rupture)
gcm PgACQ 20
Equivalent diameter of release (mm)
Release rate(kg/s)
Liquid phase Vapor phase
12.5 2.28 0.21
25 9.12 0.85
50 48.57 -*
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LOPA II Consequence and Severity 1Jet/Pool Fire, BLEVE, UVCE
Time (s)
Diameter of pool fire (Case A, m)
Diameter of pool fire (Case B, m)
Diameter of pool fire (Case C, m)
0 0 0 0
10 4.3 8.7 17.5
20 5.0 10.1 20.4
30 5.2 10.5 21.0
40 5.2 10.5 21.0
50 5.2 10.5 21.0
60 5.2 10.4 20.8
70 5.1 10.3 20.7
80 5.1 10.3 20.6
90 5.1 10.2 20.6
100 5.1 10.2 20.5
110 5.1 10.2 20.5
120 5.1 10.2 20.5
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LOPA III Consequence and Severity 2Heat Flux at 21m by Jet/Pool Fire, and BLEVE
Fire hazard
Equivalent diameter of
release (mm)
Releaserate
(kg/s)
Heat flux
(kW/m2)Corresponding damage Hazard
level
Jet fire
12.5 (Vapor line) 0.21 1.38 No discomfort for long
exposure Low
25 (Vapor line) 0.85 2.77 Time to pain threshold in 30~40 seconds Medium
Pool fire
12.5 (Liquid line) 2.28 15.1 Operators are not likely
to perform duty High
25 (Liquid line) 9.12 41.6 Sufficient to cause damage to equipment High
50 (Liquid line) 48.57 187.1 100% fatality about 10 seconds exposure Very high
BLEVE - - 421 100% fatality less than 3 seconds exposure
Extremely high
mQ xq
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LOPA IV Consequence and Severity 3Overpressure at 21m by UVCE
xQ TNTmez
)/( 3/1kgmoP
(kg/s)m(kg) (kg) (kPa)
Corresponding damage
Hazard level
0.21 12.6 6.67 11.16 14.18Minor damage of cooling tower or atmospheric tank
High
0.85 51.0 27.0 2.33 233.0 Catastrophic failure, floating roof tank
Very high
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LOPA V
Developing Scenario
Scenario 1 : High pressure causes leak or rupture storage
tank, which results from excess boil-off gas of
butane storage tank
Scenario 2 : Low pressure or over vacuum causes rupture
storage tank results from butane unloading
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Frequency Study
J
jij
Ii
Ci PFDff
1
ignitionJ
jij
jetIi
jeti PPFDff
1
,
ignitionJ
jij
poolIi
pooli PPFDff
1
,
heatingJ
jij
BLEVEIi
BLEVEi PPFDff
1
,
ignitiondelayedJ
jij
UVCEIi
UVCEi PPFDff
1
,
Jet Fire
Pool Fire
BLEVE
UVCE
LOPA VI
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LOPA VII
IPLs & PFD for Scenario 1
Safeguard IPL Fail rate of IPL
Pressure Gauge 2EA
Pressure High High Alarm 1EA
Pressure Safety Valve 5EA
Pressure Control Valve 1EA
Pressure High Alarm 2EA
Hand Switch 1EA
Human Intervention
Refrigeration compressor (A)Start byStart by pressure high alarm (A) 1 ×
10-1
Refrigeration compressor (B)Start byStart by pressure high alarm (B) 1 ×
10-1
Pressure control valve oopen 1 ×
10-1
Operator action 1 ×
10-1
Relief valve 1 ×
10-2
Total PFD For all IPLs 1 ×
10-6
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LOPA VIII
IPLs & PFD for Scenario 2
Safeguard IPL Fail rate of IPL
Pressure Gauge 2EA
Pressure Low Low Alarm 1EA
Vacuum Relief Valve 22EA
Pressure Controller 1EA
Pressure Low Alarm 2EA
Human Intervention
Evaporation 50% on byy pressure low alarm (A) 1 ×
10-1
Evaporation 50% on byy pressure low alarm (B) 1 ×
10-1
Refrigeration compressor (A,B)stop bystop by pressure low low alarm (A) 1 ×
10-1
Pressure control valve oopen 1 ×
10-1
Operator action 1 ×
10-1
Vacuum relief valve 1 ×
10-2
Total PFD For all IPLs 1 ×
10-7
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Category 1 Category 2 Category 3 Category 4 Category 5
Optional(evaluate
alternatives)
Optional(evaluate
alternatives)
Action at next
opportunity
Immediate action
Immediate action
Optional(evaluate
alternatives)
Optional(evaluate
alternatives)
Optional(evaluate
alternatives)
Action at next
opportunity
Immediate action
No further action
Optional(evaluate
alternatives)
Optional(evaluate
alternatives)
Action at next
opportunity
Action at next
opportunity
No further action
No further action
Optional(evaluate
alternatives)
Optional(evaluate
alternatives)
Action at next
opportunity
No further action
No further action
No further action
Optional(evaluate
alternatives)
Optional(evaluate
alternatives)
No further action
No further action
No further action
No further action
Optional(evaluate
alternatives)
No further action
No further action
No further action
No further action
No further action
< Table : Risk Matrix with Individual Action Zones >
Frequency
Consequence
10-0/y
10-1/y
10-2/y
10-3/y
10-4/y
10-5/y
10-6/y
10-7/y
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CONCLOSIONS
Constructing butane storage tank is
evaluated to have ‘optional action’ criteria
Although the present risk is acceptable,
adding pressure transmitter to butane
storage tank reduces risk by leak/fire
remarkably
Good sample to apply LOPA to design
step
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