major accidents in oil and gas, petrochemicals slide presentations
TRANSCRIPT
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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
PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
Loss of containment
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ACCIDENTS CAUSES CONSEQUENCES RELIEF MEASURES
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.
PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
Loss of containment
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PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
Reactive Incident
ACCIDENTS CAUSES CONSEQUENCES RELIEF MEASURES
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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PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
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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PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
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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ACCIDENTS CAUSES CONSEQUENCES
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.
PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
Ignition source: dust explosion
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ACCIDENTS CAUSES CONSEQUENCES
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
PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
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
PHENOMENA ASSOCIATED WITH MAJOR ACCIDENT
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.