Major Accidents in Oil and Gas, Petrochemicals Slide Presentations

8/13/2019 Major Accidents in Oil and Gas, Petrochemicals Slide Presentations

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Major Accidents in Oil and Gas, Petrochemicals, and

Pharmaceutical Plants - The causes, relief measures,

consequences and lesson learnt

GROUP MEMBERS:

1. Mohamad Afif bin Che Aziz (ME)

2. Muhammad Afieq Zakwan (ME)

3. Nurul Aimi Bt Saari (ME, 13656)

4. Angel anak Richard (ME)

5. Nurul Hannah (PGS)


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CONTENTS

Introduction

Phenomena associated with major accidents:

I. Loss of containment

II. Reactive incident

III. Ignition source: Dust explosion, Vapour cloud

explosion

Lesson learn

Conclusion


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INTRODUCTION

Accident is an undesired event that results in personal injury and property

damage. (National Safety Council )

Major accident is a significant event, which demands a response beyond the

routine, resulting from uncontrolled developments in the course of the

operation of any establishment or transient work activity. This event may

involve death, injuries and illness to the workers and community. Other than

that, it can cause serious disruption and damage to property inside or outside

the event place. (www.hse.gov.uk)

Objective:

1. To understand more on the causes of major accidents

2. The consequences

3. Relieve measures taken

4. Examine lessons to be learned

What to achieve?

To create awareness on health, safety and environment in plants.

To challenge some existing paradigms.

Identify opportunities for the future.


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Loss of containment exists of material contained in anenclose place to atmosphere through a hole, crack or opening

valve.

Major accidents always start with loss of containment.

Causes: Corrosion, mechanical impact or human error The effects depends on: condition of material, its properties,

meteorological conditions and measures taken to relieve the

leak.

Potential to cause major accidents in oil and gas production,

pharmaceutical industries and petrochemical industries.

PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT

Loss of containment


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ACCIDENTS CAUSES CONSEQUENCES RELIEF MEASURES

Montora oil spill Leakage of oil & gas

Failure of the operator

& regulator :failures by

PTT (Petroleum

Authority of Thailand)

personnel to verify and

test the well integrity

before BOP (blowoutpreventer) was removed

to the next well which

cause the reservoir

fluids entered the well

bore

Cause catastrophic

marine ecosystems

Pumping about 3400 barrels of mud into

well

Capping the blowout through the

wellbore cement

Sprayed 10 000 litres of chemical dispersant

onto parts of the slick by mobilising

Hercules aircraft

environmental monitoring program wasexecute by Australian Government

process safety indicators was created Swiss

Cheese Model

Linz Austria, 2003

(Pharmaceutical

plant)

Leakage in pipe released

methanol/peroxide

Rise in temperatureaccelerate

decomposition of grid

(peroxide) that

maintained insulation

material on column

20 workers suffer

burns, bone fractures

& bruises Office destroyed

Materials in 150m

radius perimeter

were damage

Loss estimated to be

20 million euros

Ozonolysis column was installed in separate

cold box in different building with video

control Leakage indicator system installed

Pressure & temperature measurements

added

Reactor resist explosion

Pressure relief valve installed

2004 replacing ozonolysis with reaction of

air and inert gases


Loss of containment


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Flixborough 1974

(Petrochemical

plant)

Leakage of nitrates

No calculation & concern was voiced out

over structural strength of the bellows &

bypass

No bellows manufacturers published

users guide

Failed in employed column/ other meansto prevent bypass movement

28 employee were

killed & 36 were

badly injured

53 injuries outside

facility & hundreds

more mild injuries

Risk fromcombustion fumes

of chemicals

substances

Property damage

Buildings, house &

retail business

were destroyed &

damaged Environment

pollution

Adopting Seveso

directive

Rebuilding plant with

strict attention.

Replacing the process

involving cyclohexane

oxidation with the use ofphenol hydrogenation.


Loss of containment


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Reactive Incident


Reactive incident

occurred in the

Catalyst System

Inc. Facility in

Gnadenhutten,

Ohio.

HAZARDOUS

Failure of the temperature probe

Contamination in the dryer from exposure to

metal surface

Hot spot in the dryer

Contamination in the dryer from exposure to

metal surface

BPO remaining in the dryer too long

Generation of heat energy from friction

Failure of the vacuum pump causing loss of

evaporative cooling

Generation of a spark due to static electricity

Violation of good practise in terms of

equipment handling and safety measures to be

taken

One employee

received small

puncture on his

shoulder from flying

debris

A small fire in the

southwest corner of

the building.Runoff water from the

building was also

tested in several

locations to see if they

were hazardous.

The dryer propelled

through the steel

dividing wall andlanded 35 feet from the

initial location

Extensive damaged

from the support at the

south side of the

building. The roof was

also badly damaged.

Instantly after the

explosion, the

automatic building

sprinkler activated and

the employees went to

the designated

evacuation area.

Gnadenhutten Policeand Fire Departments

helped in preventing a

bigger consequence of

the incident.

The fire brigade

extinguished the fire

and several other fire

departments werecalled to assist.


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Ignition source

Ignition: process or event capable of causing a fire or explosion.- happened whenever flammable or combustible materials or substance involved

19 possible ignition source by Health and Safety Executives :

- Flames; Direct fired space and process heating; Use of cigarettes/matches

etc;

- Cutting and welding flames; Spontaneous heating;- Hot surfaces; Heated process vessels such as dryers and furnaces; hot

process vessels; Space heating equipment;

- Mechanical machinery; Electrical equipment and lights; Impact sparks;

Friction heating or sparks; Sparks from electrical equipment;

- Stray currents from electrical equipment Electrostatic discharge sparks:

Lightning strikes;

- Electromagnetic radiation of different wavelengths Vehicles, unless specially

designed or modified are likely to contain a range of potential ignition

sources


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Ignition source: dust explosion

Dust explosion: combustible liquids, combustible or flammable powder could be

ignited whenever they are dispersed or finely divided into specific concentration andmake contact with an ignition source.

- Primary explosion : confined space or atmosphere such as vessel and chamber,

part of manufacturing plant and equipment

- Secondary explosion: involve dust clouds of flammable dust, finely distributed in

contact with the oxygen & ignition source which cause wide explosion

ACCIDENTS CAUSES CONSEQUENCES

Masterton Dust Explosion

(1965)

Plastic dusts which has

accumulated under the

floor of the button

ornamenting room

short circuit of an

under floor electrical

socket

Demolished a locker

room

Four people died and

six were injured in the

incident


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Kinston Accidents(2003)

West

Pharmaceutical

explosion

ExplosionFailure on behalf of facility management to

conform the standards that would reduce or

prevented the effects of explosion to NFPA

(National Fire Protection Agency).

Failures to identified dust explosion hazards or

recommend protective measures by company

personnel, government standards enforcement

officials, insurance underwriters and health andsafety professionals that inspecting the

facilities.

The housekeeping procedure was inadequate

for the unsafe accumulations of combustible

dust in the facilities.

Lack of awareness on dust explosion hazards

among workers and managers.

The elimination or control combustible dust

hazards procedures and training were

inadequate.

The causes of previous fires and other warning

events were not identified and resolved.

The maintenance and designed of dust

collectors to minimize explosions were

inadequate.

6 employee werekilled and 38

people suffered

from injuries

The shattered glass

from more than

half a mile away

injured a student

at a school. two 7,500-gallon

plastic tanks of

mineral oil

collapsed

The flaming debris

caused the forest

on fire.

The rubber storagewarehouse was

burned for more

than two days and

many buildings are

collapsed.

loss of jobs in

Kinston.


Ignition source: dust explosion


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Flixborough

Accidents - 1974

Vertical crack on the reactor which caused a leak of

a flammable substance, cyclohexane.The substance found a source of ignition thus

caused the explosion.

28 employee were killed & 36

were badly injured 53 injuries outside facility &

hundreds more mild injuries

Risk from combustion fumes of

chemicals substances

Property damage

Buildings, house & retail

business were destroyed &

damaged Environment pollution

Buncefield, UK

2005

Overpressure of liquid contributes to high

magnitude concentration of vapour cloud under

stable wind conditions

failure of automatic safety switch alarm causes

the tank to fill twice its maximum capacity

High speed rotating machine in the pump house

is identified as the source of ignition.

Explosion radius of 2 km.

43 reported injuries

Damage of property


Ignition source: vapour cloud explosion

Vapour cloud explosion: due to rupture or crack in vessel and pipes which

released combustible substance such as gasses, highly flammable exposed toignition source.

Similar to dust explosion except the consequences are more catastrophic.


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RELIEF MEASURES: Segregating dust-producing operations, sealing walls, ceilings,

and partitions to prevent the accumulation of dust.

Only the electrical equipment that are suitable for potentially

explosive atmospheres can be used Regular training on the combustible dust hazards.

Conduct educational outreach programme to avoid future

accidents

Encourage training of North Carolina fire and building codeofficials on combustible dust

Improve the material safety review procedures


Ignition source


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Instillation design

Control room must be located away from hazardous region

Limit hazard potential present onsite

Management of facility modification, personnel interventions

and maintenance

Use official standards on construction, designs andmodifications

Mechanical Lessons

Structural reliability must always be inspected

Human Factor

High skilled workers are important

Technical knowledge prevents accident

Responsibility for Environmental Issues

LESSONS LEARNTMechanical (Loss of containment)


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Technical Aspects

Sealed ceilings at area which contain hazardous dust

Monitor not to accumulate and reach explosive

environment

Dust Control

Effective and Efficient Filtration System

Cleaning methods that inhibit accumulation of explosive

dust

Training to the employees on HSE

Proper cleanouts Require high skilled workers

Always implement systematic documentations

Importance of Waste Generator

Satellite Accumulation Area (SAA)

LESSONS LEARNTChemical


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Health & Safety Awareness

Long Term Investment

Create a safe environment

Standard Safety Board for Chemical and Dust Explosion

LESSONS LEARNTIgnition source


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CONCLUSION

The case study in context is something that we and people all around the globe as

industrial workers face throughout our daily lives and all these accidents are very real andtook place around us. Via observation and analysis of some examples of major accidents

that involved the industry, we can see these potential hazards certainly pose a lot of risks to

the safety of the workers. We have been able to outline the causes of these catastrophic

events, the consequences that had been resulted from the accidents and relief measures

taken in order to cope with such events.

Throughout the analysis of these case studies, we have enlisted few lessons that are learnt

via coping with these accidents. We came to conclude that solutions that have been

suggested before can really contribute in minimizing the risk of accidents in the industry.

At the end of the day, it is still up to the efforts, responsibility and integrity of the

management especially and also the workers to ensure a safe working environment of theoil and gas, petrochemicals, and pharmaceutical industries.

Major Accidents in Oil and Gas, Petrochemicals Slide Presentations

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