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  3. Evaluation and identification of process hazards of Utility unit of fifth refinery of South Pars gas complex using HAZOP technique

Evaluation and identification of process hazards of Utility unit of fifth refinery of South Pars gas complex using HAZOP technique

Number of pages: 158 File Format: word File Code: 31791
Year: 2016 University Degree: Master's degree Category: Chemical - Petrochemical Engineering
Tags/Keywords: Gas industry - Gas refinery - Hazap - Knick HAZOP - Risk identification - Utility unit - Water vapor unit
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  • Summary of Evaluation and identification of process hazards of Utility unit of fifth refinery of South Pars gas complex using HAZOP technique

    Dissertation

    To obtain a master's degree

    in the field of chemical engineering

    Abstract

    Attention to the issue of safety in industrial and chemical facilities is very important. According to statistics and figures, the amount of human, economic and environmental damages caused by industrial accidents every year in the world is very high. In addition, some of these damages are basically irreparable. Therefore, in order to prevent these injuries and to discover the risks that lead to accidents, as well as to analyze the risk of the industrial unit, special measures and a systematic method are needed. In this study, risk assessment and risk analysis of the Utility unit of the fifth refinery of South Pars Gas Complex has been investigated. To identify the risks of this unit, the technique (HAZOP) has been used, in which process problems are also discovered. In this regard, the existing deviation has been investigated by the HAZOP team. The result of this research is to provide expert suggestions from the HAZOP method to reduce risk and increase the safety and operational factor of the unit. According to the experts, the efficiency of the utility unit is strongly dependent on the flow and the pressure caused by it in the unit, because the flow entering the unit is first stored in the tank and then distributed according to the pressure of the unit, so these parameters can be controlled and their increase and decrease should be prevented. The current circulates in the system with a normal operating pressure, and possible damages, such as lines breaking due to sensitivity to high stresses, pump stoppage, and unit out of service due to reduced flow, can be prevented. The most important suggestions presented in this study include the installation of temperature and pressure alarms in the unit. Also, based on the results of this study, the instructions for setting up the unit were revised.

    Keywords: Identification of hazards, water vapor unit, HAZAP, gas refinery

    Foreword: 

    Today, creating a safe environment in which all harmful factors are identified, evaluated, removed or controlled to ensure the health of people and facilities is one of the priorities of industrial management, safety science has also been reactive like the traditional approach to safety, that is, managers did not think of finding problems and fixing them until accidents occurred. In recent decades, the conscientious and moral considerations of industrial owners, along with legal requirements and insurance obligations, have placed attention on safety science in a special place. In the meantime, the great impact of safety on profitability and increasing competition with colleagues should not be neglected. Therefore, attention to safety with a preventive attitude towards accidents, especially in the oil, gas and petrochemical industries, which have a high potential to cause human and environmental accidents, has been the focus of attention. 

    The gas industry in Iran is of special importance due to the existence of huge gas reserves in this country. Gas refineries are one of the most important parts of this industry, and the need to increase safety in these parts is one of the most important issues that everyone cares about, because the smallest problem in this industry, in addition to huge environmental and human disasters, may impose irreparable economic problems on the country. 

    Several methods are used to increase the current processes in the gas industry, and the study of risks and process management is one of the best methods. The use of this method is a requirement in industrialized countries. The implementation of this system is highly recommended in developing countries and is used in many oil, gas and petrochemical industries. The implementation of the HAZOP system in Iran's refineries in order to increase the safety of the systems has become one of the most important tasks that can be done in these factories and has been used in many industries related to oil, gas and petrochemicals. 

    The works done in these industries include HAZOP study and risk assessment for urea unit of Shiraz Petrochemical Complex, sweetening units of Razi Petrochemical Complex, ethylene oxide production unit of Arak Petrochemical Complex, fluor-UCF Isfahan production unit, sodium bicarbonate units of Shiraz Petrochemical Complex, LPG recycling unit of Kangan Gas Refinery, polystyrene production unit of Tabriz Petrochemical, He pointed out the upstream units of Dehran and Danan region, water extraction unit from the sea in Mobeen Petrochemical and Izomax unit of Bandar Abbas Oil Refining Company. Of course, the activities carried out in this field are many and progressing, and every day more units of the petrochemical complex are subjected to this study [1]. 

    The reasons for the necessity and justification of the project implementation in the Utility unit of the fifth refinery of South Pars Gas Complex:

    1. Considering that more than 5 years have passed since the installation and commissioning of this unit, while there are no available HAZOP studies in the Utility unit, and after the operation of the unit, hazard identification studies have not been conducted through HAZOP studies. 

    2. The high volume of investment along with the importance of the strategic dimension of continuous and continuous fuel and energy supply requires the identification of risky factors and factors that reduce the production rate or disturb the quality of the product and take the necessary measures to eliminate them. 

    3. Government centers and individuals always show resistance to changes. Providing scientific, documented and substantiated solutions through an expert and elite group with the help of the experiences of the complex's own personnel paves the way to improve the safety and operational level of the system as quickly as possible. 

    The direct and indirect costs caused by accidents each year cause significant financial and life damage to the country's industries, especially the gas refining industry, due to the nature of the activities of this industry as one of the country's high-risk industries, therefore, in order to prevent such accidents from occurring, it is necessary to use a systematic method to identify the hidden risks in industrial units and its continuous review. 

    Many managers and experts consider paying attention to safety issues to save time and money. Implementing safety programs in industrial units, identifying risk potentials and providing practical solutions to prevent and reduce injuries caused by accidents, can bring many benefits in terms of economy and optimal use of time. Among these benefits, the following can be mentioned:

    ? Reducing costs related to:

    • Equipment destruction

    • Interruption in work

    • Restarting and reaching a uniform state in continuous processes

    • Waste of materials

    • Absence of employees injured in accidents

    • Transfer and treatment of the injured

    • Training of new people

    ? Increasing efficiency in the use of resources and consequently increasing the economic profitability of the company

    • Increasing production efficiency

    • Raising the quality of products

    ? Showing the commitment of the organization's management towards safety and continuous improvement

    ? Increasing the credibility of the organization regarding compliance with occupational health and safety principles

    This thesis consists of 5 chapters, in the first chapter definitions related to safety And there is a brief description of different and conventional methods of hazard identification. In the second chapter, the HAZOP method is fully explained in accordance with the existing standards and in order to familiarize the readers and colleagues of the project. In the third chapter, the utility process of the fifth refinery of the South Pars gas complex is described in detail along with the description of the input section of the unit and their control topics. In the fourth chapter, the method of conducting HAZOP studies in the utility unit of the fifth refinery of the South Pars Gas Complex and the assumptions and considerations of the work are described, and in the fifth chapter, the conclusions and suggestions of the entire project are described in detail.

  • Contents & References of Evaluation and identification of process hazards of Utility unit of fifth refinery of South Pars gas complex using HAZOP technique

    List:

    Chapter One: An introduction to safety and hazard identification methods. 5

    1-1- History of safety in industry. 6

    1-1-2- Health and safety movement, from past to present. 6

    1-1-3- Basic safety improvements. 7

    1-1-4- Accidents and their effects in the industry. 8

    1-1-5- Expenses of accidents. 8

    1-2- An overview of huge industrial disasters in the past. 9

    1-2-1- The huge accident of the Chernobyl nuclear power plant. 9

    1-2-2- Fire in the Petrochemical Complex of Pardis Ik Assalouye. 11

    1-2-3- France Ficin explosion: 11

    1-2-4- Fire and explosion in the North Sea oil production platform, Piper Alpha 11

    1-2-5- Bhopal incident in India. 12

    1-2-6- Explosion in Khark Petrochemical Complex. 12

    1-3 Definitions. 13

    1-3-1- Risk. 13

    1-3-2- Risk 13

    1-3-3- Event. 13

    1-3-4- accident. 14

    1-3-5- Safety. 14

    1-3-6-tolerable risk. 14

    1-4- Risk measurement criteria. 14

    1-4-1- Risk index. 14

    1-4-2- Average severity of losses. 15

    1-4-3- Personal risk. 15

    1-4-4- collective risk. 15

    1-5- Risk assessment. 15

    1-6- Risk identification. 16

    1-6-1- safety review. 17

    1-6-2-checklist analysis. 18

    1-6-3- Question analysis. 18

    1-6-4- Analysis of materials in the process and critical conditions. 19

    1-6-5-Preliminary risk analysis (PHA) 19

    1-6-6- Hazard study and management (HAZOP) 20

    1-6-7- Risk analysis. 20

    1-6-8- Analysis of defects and effects. 21

    1-7- Consequence modeling. 21

    1-9- Calculation of risk. 22

    1-9-1- F-N curve 22

    1-9-2- Risk acceptance criteria. 24

    1-10- Risk reduction. 25

    1-11- Conclusion. 26

    Chapter Two: Risk Analysis and System Management. 28

    2-1- Introduction. 29

    2-2- Definition of HAZOP. 29

    2-3- The reasons for the widespread use of the HAZOP method. 29

    2-4- Description of activities in the HAZOP method. 30

    2-5- Start-up information 30

    2-6- HAZOP steps. 31

    2-7- HAZOP group. 31

    2-8- HAZOP table. 34

    2-8-1- HAZOP table entries. 35

    2-9- Application software and reasons for using them. 38

    2-10- Major disadvantages of the HAZOP method. 40

    2-11- Risk matrix. 40

    2-12 - Mathematical model integration as a suggested solution to improve the disadvantages of the HAZOP method. 42

    2-13- Conclusion: 42

    Chapter 3: general understanding of the utility unit of South Gazpars complex. 44

    3-1- Introduction. 45

    3-1-1- South Pars Gas Complex Company: 46

    3-2-1- Unit 100: flood trap, receiving equipment and HP separator 47

    3-2-2- Unit 101: Gas sweetening 49

    3-2-3- Unit 102: Glycol recovery. 49

    3-2-4- Unit 103: stabilization of gas condensate. 50

    3-2-5- Unit 104: Dehumidification and removal of mercury 50

    3-2-6- Unit 105: Ethane recycling. 51

    3-2-7- Unit 106: Gas export 52

    3-2-8- Unit 107: Liquid gas separation. 53

    3-2-9- Unit 108: Sulfur recycling. 53

    3-2-9-1- Clause stage 54

    3-2-9-2- Degassing stage. 54

    3-2-9-3- Incinerator 55

    3-2-10- Unit 109: Separation of acid gases and hydrocarbons from water. 55

    3-2-11- Unit 110: Support unit 103. 56

    3-2-12-Unit 111: Propane cooling 56

    3-2-13- Unit 113: Caustic regeneration. 57

    3-2-14- Unit 114: Propane processing. 58

    3-2-15- Unit 115: Butane processing. 59

    3-2-16- Unit 116: Ethane processing. 59

    3-2-16-1- Absorber section 60

    3-2-16-2- Regeneration section 60

    3-2-16-3-Dehydration section 60

    3-2-17- Unit 121: Steam production. 61

    3-2-18- Unit 122: Fuel gas 62

    3-2-19- Unit 123: Air production of precision instruments. 63

    3-2-20- Unit 124: Nitrogen production. 64

    3-2-21- Unit 125: Water supply. 65

    3-2-22- Unit 126: Water desalination. 66

    3-2-23- Unit 127: Production of water without solvents. 67

    3-2-24- Unit 128: Production of potable water 67

    3-2-25- Unit 129: Industrial wastewater treatment. 68

    3-2-25-1- Treatment of oily water and hydrocarbons68

    3-2-25-1- Treatment of oily water and hydrocarbons 68

    3-2-25-2- Treatment of chemical water. 68

    3-2-25-3- Treatment of human sewage. 69

    3-2-26- Unit 130: Fire fighting water. 70

    3-2-27- Unit 131: Fuel supply for diesel consumers. 71

    3-2-28- Unit 132: Water cooler. 71

    3-2-29- Unit 140: Flares 72

    3-2-30- Unit 141: Drain tank. 72

    3-2-31- Unit 142: Burn Pit 73

    3-2-32- Unit 143: Gas condensate tanks. 73

    3-2-33- Unit 144: Sulfur solidification. 74

    3-2-34- Unit 145: Propane storage for cooling. 74

    3-2-35- Unit 146: Storage of chemicals. 74

    3-2-36- Unit 147: Export propane storage. 75

    3-2-37- Unit 148: Butane export storage. 76

    Chapter 4: HAZOP studies of the Utility Unit of the Fifth Refinery of South Pars Gas Complex. 77

    4-1- Introduction. 78

    4-2- Documents of HAZOP studies of Utility Unit of the fifth refinery. 79

    4-2-1- HAZOP team members. 79

    4-2-2- The list of map numbers used in HAZOP. 79

    4-2-3- List of nodes 80

    4-2-4- Checking deviations in each node 83

    4-2-5- HAZOP tables: includes all finalized tables. (Worksheet) 83

    4-2-5-1- Interpretation of Table A-61-Reduction/interruption of flow in the sea water inlet system to tank 101. 84

    4-2-6- List of proposals presented in HAZOP meetings. 85

    4-3- Assumptions and considerations in conducting HAZOP studies. 85

    4-4- Effective solutions to reduce risk in the Fifth Refinery Utility Unit. 86

    4-4-1- Personal protective equipment. 86

    4-4-2- Process materials. 86

    4-4-3- Labor health 87

    4-4-4- Accidents. 87

    4-4-5- Education. 87

    4-4-6- Repairs and maintenance. 87

    4-4-7- Process. 88

    4-4-8- Safety. 88

    4-4-9- Management. 88

    4-5- Conclusion. 88

    Chapter: Fifth conclusion and suggestions. 89

    5-1- Introduction. 90

    5-2- General suggestions. 90

    5-3- The results of hazard and management study (HAZOP) 91

    5-3-1- Hardware suggestions. 92

    5-3-2- Guideline suggestions and recommendations 95

    5-3-3- Study and research suggestions. 97

    5-4- Suggestions for future works 97

    References. 98

    Appendices 101

    Appendix (A): HAZOP documents. 102

    Appendix (b): The knotting done on the p&id maps of the Fifth Refinery Utility Unit. 132

    Appendix (c): HSE questionnaire. 139

     

    Source:

     

    Kazemi B., Occupational Safety and Health (Industrial Protection), second edition, Pashtun 1382.

    Spanalo K., New Approach to Safety, Nuclear Safety Research and Development Department, First National Conference on Safety Engineering and HSE Management, Sharif University of Technology, Tehran, March 1384.

    Goharrokhi M., Qualitative and quantitative risk assessment in process units, incident investigation methods and flare network simulation with Aspen flare net software, Danesgaran Sanat Pajoh Publications, 2018.

    Gogol M., Risk identification and qualitative risk analysis in process industries by PHA-pro software, Danesgaran Sanat Pajoh Publications, 2013.

    Kletz, T., Learning from Accidents, Third ed., Gulf Professional Publishing, Oxford, 2001.

    Arendt, J. S. and Lorenzo, D. K., Evaluating Process Safety in the Chemical Industry, American Institute of Chemical Engineers, New York, 2000.

    Drs. P. L. B. A Van Geel, Guidelines for Quantitative Risk Assessment, 2005.

    Guideline for Risk Based Process Safety, center for chemical process safety, John Wiley&Sons, 2005.

    Mannan S., Lee's Loss Prevention in the Process Industries, Third ed., Vol. 1, Elsevier Inc, 2005.

    Tixier, J., Dusserre, G., Salvi, O., Gaston, D., Review of 62 risk analysis methodologies of industrial plants. Journal of Loss Prevention in the Process Industries, Vol. 15, NO. 4, pp. 291-303, 2002.

    Dennis, P., Nolan, P. E., Application of HAZOP and What-If safety reviews to the petroleum, New Jersey, USA, petrochemical & chemical industries, 1994.

    Guideline for Hazard Evaluation Procedure, Center for Chemical Process Safety, Wiley Interscience, New York, 2008.

    Keletz, T., Hazop and Hazan, 4th ed.

Evaluation and identification of process hazards of Utility unit of fifth refinery of South Pars gas complex using HAZOP technique
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