World Chlorine Council Global Safety Workshop

Process Safety Management

Marcio Abreu
November 14, 2014
 Cubatao Plant
Unipar
Carbocloro
• 1,000 metric ECU/day
• Plant start up: April 1964
• Products:
. Chlorine
. Caustic soda
. Hydrogen
. Hydrochloric acid
. Sodium hypochlorite
. EDC
 Overall Management System

ABS Quality Evaluations, Inc.

1994

2007
1

1
1999

2005
Why a PSM program is so important

for the chlor-alkali industry?

 Major Operational Concerns
Commandments of Chlorine Production

Cleaning
Hydrogen in Ignition of
Ignition of Metals Equipment and
Chlorine Titanium
Piping

Nitrogen Moisture in Dry Mechanical

Liquid Chlorine
Trichloride (NCL3) Chlorine Integrity for Liquid
Expansion
Chlorine Systems

Oxygen in Cell Room Safety Devices and

Hydrogen Electrical Safety Impurities in Brine Interlocks

Chlorine Dilution of
Cold Temperature Stress Corrosion In
Neutralization caustics or acids
and Carbon Steel Stainless Steel
Systems with water
 Mechanical Integrity Program

MI is one of the most important elements of PSM

MI program is intended to ensure equipment does not

fail in a way that causes or affects a release of HHC

Although maintenance is a major part of an MI

program, MI is not just maintenance
 MECHANICAL INTEGRITY PROGRAM

MECHANICAL INTEGRITY
PROGRAM
MI covers the proper design, • Written procedures
fabrication, construction/installation • Training for maintenance
and operation of equipment activities
throughout the entire process life • Inspection, testing, and repair
cycle. • Equipment deficiencies
management
• Quality assurance
 MECHANICAL INTEGRITY PROGRAM

Plant procedures establishes the MI program requirements for key items

Pressure
Emergency vessels
shutdown
Electrical
systems,
equipment
controls
and systems
systems and
Relief alarms
devices and
vent systems
Rotating Storage
equipment tanks

Piping
systems
Mechanical Integrity Program
Preventive Practices
 Pressure Vessel
(frequency of inspections)

Liquid chlorine storage tank

Chlorine Institute Pamphlet

Other pressure vessel

Brazilian Regulation (NR-13)
 Liquid chlorine storage tank

Plant inspection plan

Frequency

1 year External visual inspection

2 years Pressure relief valves PM

Internal visual inspection

Thickness measurement
6 years
Other ND test
Replace tank block valves.
 Pressure Vessel

Pressure vessel
(except chlorine storage tank)

NR-13: Brazilian regulation for

pressure vessels

• Frequency of inspection
defined according to the vessel
category Vessel Category External inspection Internal inspection
• Hydrostatic test performed I 1 year 3 years
after equipment fabrication or II 2 years 4 years
repair III 3 years 6 years
• ND tests also recommended
IV 4 years 8 years
V 5 years 10 years
 Piping systems

Standards
API, CI, NR-13

Inspection program frequency:
Visual inspection

Liquid chlorine piping: 5 years;
Thickness measurement
Chlorine gas piping: 5 years;
ND tests
Chlorine pipeline: 1 year (CI recommendation)

EXTERNAl
API
Service INSPECTION
570
(years)
Chlorine Gas I 5
Liquid Chlorine I 5
Ethylene I 5
Hydrocarbon II 5
Natural Gas /LPG II 5
Hydrogen II 5
Caustic soda II 5
Sulfuric acid II 5
Hydrochloric acid II 5
Sodium Hypochlorite - 5
Corrosion Under Insulation
 Emergency Shutdown and Controls Systems

Classification Table
Control Class
Maintenance Frequency
0 • Inspect, calibrate and repair as needed
1 • Routine maintenance do not exceed 8 years.
• Function test do not exceed 3 years.
2
Maintenance • Routine maintenance do not exceed 5 years.

program for • Function test do not exceed 1 year.

3
• Routine maintenance do not exceed 3 years.
devices related
• Inspect, calibrate and repair
to HHC service • In the absence of a requirement or technical reason:
4
o Function test do not exceed 6 months
o Routine maintenance do not exceed 2 years

• Pressure relief devices

• Inspect and calibrate
• Routine maintenance and applicable function tests for Relief Devices
5
in HHC service not to exceed 2 years.
• Routine maintenance and applicable function tests for other Relief
Devices as per NR13 requirements
 Pressure Relief Devices

Pressure relief valves maintenance

inspection and pre-pop test.
 Rotating Equipment

Rotating equipment summary

• MI equipment priorities based on ABC classification

• Predictive and preventive maintenance program
• Monthly inspection routine
• Vibration monitoring
• Oil analysis

ABC classification
Criticality
TAG# Description
class
G4-AG-327 Agitador Tanque Remoção de Pesados A
G4-BC-217 Bomba Alimentação Torre Remoção Leves A
G4-BC-218 Bomba de Remoção Solido Sobrenadante B
G4-BC-234 Bomba de Bissulfito de Sódio B
G4-BC-236 Bomba de Distribuição Ácido Clorídrico C
G4-BC-237 Bomba de Distribuição Ácido Clorídrico C
 Rotating Equipment

Vibration monitoring

Oil Analysis
 Electrical Equipment

Equipment Maintenance activity

Outdoor Substation and Equipment Disconnect Switches

Outdoor Capacitors
Thermography
MCC Equipment (Low voltage switchgear)

Rectifiers
Lightning Protection System Detailed Inspection

Visual Inspection, Oil analysis, Electrical tests,

Power or Rectifier transformers
Thermography

UPS Visual Inspection

Battery Chargers/DC Power Supply Visual Inspection
Battery Systems Cleaning and Visual Inspection
Battery tests
Ex classified equipment and systems Visual Inspection and detailed inspection
 Electrical Equipment

Thermographic
Analysis

Thermography
during
Electrical
Inspections
 Quality Assurance

Inspection of materials

• Visual;
,
• Dimensional;
• Surface roughness;
• Thickness Measurement
• Liquid Penetrant Inspection (LPI);
• Hardness measurement;
• PMI (positive material identification).

CS cracked pipe found during the material

inspection before use in chlorine service
 MI Program Management

• Monthly report of MI metrics (KPI’s)

• Management of change: an important tool to manage MI
program deviation
• MI program audits
• PSM plant committee to follow up program items and gaps
• IT tools supporting the PSM/MI program: SGI, SAP
 Final Comments

 Painting program is an important issue for the success of the MI program

 Corrosion under insulation is another important concern

 MI must be a plant priority to keep the operation reliable and safe

 Dedicated PSM engineer is also recommended

 PSM: a commitment for the entire organization

 Top management must support the overall PSM program

 Thank you!
marcioabreu@uniparcarbocloro.com.br

www.uniparcarbocloro.com.br
Back up
 Commandments of Chlorine Production

1. Hydrogen concentration in chlorine gas streams must be monitored and controlled to

prevent forming an explosive mixture. Hydrogen must be kept below the lower
explosive limit (LEL) of hydrogen in chlorine at all times.
2. Nitrogen trichloride (NCl3) is an unstable compound that can self detonate at relatively
low concentrations. Very small quantities can detonate with tremendous force. Systems
where NCl3 may accumulate or concentrate must be actively monitored and managed
to maintain NCl3 at safe levels.
3. Chlorine will react violently with many different chemicals and materials. It is essential
that all equipment, piping, and valves be properly cleaned and dried for chlorine
service before introducing any chlorine into the system.
4. Chlorine will react with many metals, especially at elevated temperatures. It is critical
that the material of construction be consistent with the operating conditions and that
excessive external heat is not applied to chlorine containing systems.
5. Dry chlorine will react violently with titanium. Systems must be in place to protect
titanium equipment from exposure to dry chlorine and insure titanium is not used in
dry chlorine service.
 Commandments of Chlorine Production

6. Many grades of carbon steel can be become brittle when exposed to temperatures
below -20 °F. It is essential that low temperature carbon steel or a suitable alloy is used
for continuous operation below -20°F.
7. Moisture in dry chlorine systems will increase carbon steel corrosion rates which can
become dangerously rapid at high levels. Additionally the possibility of generating
hydrogen exists. Moisture concentrations must be continuously monitored and
controlled using moisture analyzers and drying systems.
8. Oxygen in hydrogen systems must be monitored and controlled to prevent forming an
explosive mixture. Extreme care must be used around hydrogen compressors to ensure
air is not pulled into the system during operation.
9. Liquid chlorine has a high coefficient of expansion. Any system where the threshold
amount of liquid chlorine can be trapped must have expansion protection.
10. An electrolytic cell line has the capability to produce a fatal electrical shock. Cell line
working procedures must be clearly understood and followed by everyone entering the
“Cell Line Working Zone”.