M.ELAMARAN PNM-CG AGENDA A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT INTRODUCTION
BASICS
TYPES OF HAZARD
HAZARD CONTROL
VIDEOS AND ANIMATION
SPECIFIC TO COMMISSIONING INTRODUCTION A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT INTRODUCTION A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT INTRODUCTION A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Q1 . Do you believe that these incidents could have been prevented?
Q2. How many people could have prevented it? BASICS-Hazard A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT What is a Hazard?
A potential to cause harm or damage.
Damage to Life , Health , Environment and Property .
The potential to damage is realized with certain probability in the absence of its control. BASICS- Risk A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT What is Risk?
The likelihood that a specified undesired event will occur due to the realisation of a hazard by work activities, or during work activities or by the products and services created by work activities.
Risk = Hazard * Exposure
Risk = Severity * Likelihood BASICS- Personal and process safety A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Personal safety incidents Relatively high frequency low consequence incidents.- controlled by PPE, Work permit systems
Process safety incidents Relatively low frequency high consequence incidents. Controlled by Process safety management, Work permit system Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Basics- Spot the Hazards A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Hazard control -Principles A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT At its source. Along its path. (erect a barricade between the hazard and the worker.) At the worker. (remove the worker from the exposure, such as automated/remote controls, worker rotation, providing PPE when all options have been exhausted.) Monitoring activities (locate new hazards and assess the effectiveness of existing controls.) Hazard control - Hierarchy A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Hazard control Various stages A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT 18 CONCEPTUAL DESIGN SITE SELECTION PROCESS DESIGN DETAIL ENGINEERING START-UP OPERATION COARSE HAZOP, WHAT-IF, HAZARD RANKING, HAZID PRELIMINARY RISK ASSESSMENT, CONSEQUENCE ANALYSIS HAZOP, FMECA, SIL STUDY, SAFETY REVIEW DETAILED RISK ANALYSIS SAFETY AUDIT, EMERGENCY PLAN, HIRA SAFETY AUDIT, HAZOP, RA, RBM, HIRA Hazards in Refinery - Physical A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Fall from height , impact from tools , slips and trips , Objects falling from height
From Heat Hot burn , cold burns
From Light Eye damage due to looking at welding arc
From Sound Ear damage
From Pressure whiplash of hoses , danger during hydro jetting
Electrical Hazards. Static Electricity.
Impact Hazard.
Fire and Explosions.
Radiation. Hazards in Refinery - Chemical A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Uncontrolled runaway reaction
Asphyxiation
Gases H2S , Cl etc
Other catalyst and chemicals respiratory damages, carcinogens ,dusts
Uncontrolled release Air , water and land pollution.
Hazards in Refinery -Process A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Uncontrolled release.
Fire.
Explosion. Hazards Pre commissioning and Commissioning A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Layout Impact Hazards , Dangerous approaches and Hindrances, no escape routes- address in Format checking
Flushing - Mix up in flushing media , improper flushing .
Air blasting Rupture and blast , abrasion.
Box up improper box up , improper gasket leaks . Missed LPD, HPV , small bore piping box up.
Pressure test rupture dangerous with hydrogen
Inertisation improper. Vacuum pulling after steaming.
Fuel gas back up leaks , release through small piping's.
Utility charging Hammering , Nitrogen going to wrong place. Hazards Pre commissioning and Commissioning A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Lining up wrong line up , wrong blinding and deblinding
Equipment line up Missed PSV line up. Wrong sequence, inadequate adherence to procedure.
Pump/ equipment trials wrong line up, missed pre requisites , missed coupling guard, earthing from motor missing, improper junction box sealing.
Instrument points mix up, wrong control valve action, missed square rooting in flow, non line up, non calibration, junction box improper sealing, wrong interlock implementation.
First heating Constraints to expansion leading to rupture, line falling of support, fouling , unreleased expansion bellows and spring supports
Hot Bolting- wrong spanner material , leaks, gasket rupture Hazards Pre commissioning and Commissioning A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Start up improper adherence to procedure, wrong procedure, too quick heat up , bypassing safety interlocks, doing start up before the unit is ready.
Leaks small points like orifice flange spare tapings, bull plugs in NRVs, pump strainers, Valves, HPVs , LPDs , instrument tapping drain points etc
Operators Not familiar with the plant and operation, incomplete and inadequate training.
Major Hazards mix up in MOC, Design errors , wrong calculations etc. A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT