Achieve Safe Operations

in Chemical Storage Terminal

Lessons Learned from Cases

Anthony Su
Mar 12-13, 2008

Content
• The Data – Statistic of the Relevant Accidents
• Cases:
− Case-1: LPG Truck Fire
− Case-2: Tank Overflowed…Fire & Blast
− Case-3: Explosion in Storage Tank
− Case-4: Naphtha Storage Tank Fire
− Case-5: Fire in Flammable Liquid Tank
− Case-6: Vacuum Damage
− Case-7: Fire due to Service Change
• Summary

1
 Hardware associated with largest losses

Source: A Thirty-Year Review of One Hundred of the Largest Property Damage Losses
in the Hydrocarbon-Chemical Industries (Marsh Inc., 1987)

Source: The 100 Largest Losses1972-2001 Large Property Damage Losses in the Hydrocarbon-Chemical Industries. (Marsh Inc., 2003)

2
 Breakdown of Tank Incident by Causes

Note: picture source - Process Safety Booklet Published by BP, 2004

Key Elements of
Process Safety Management
• Process Safety Information (PSI)
• Process Hazard Analysis (PHA)
• Operating Procedures
• Contractor
• Management of Change (MOC)
• Training
• Employee Participation
• Trade Secret
• Hot Work Permit
• Emergency Planning and Response
• Incident Investigation
• Mechanical Integrity（
（MI）
（PSSR） Compliance Audit
）
• Pre-Startup Safety Review

3
Case-1: LPG Truck Fire

After 2/3 of the LPG truck

was loaded, the loading arm
detached from the truck
tanker nozzle and propane
was released and ignited…

Weakened connection:

Deformed

Wear of 1 to 2 mm in
diameter, …minor thread overlap

Interference of the driver: uncertain

Possible sources of ignition:

Mechanical spark from
wrench tool

Mechanical spark from the
loading arm hitting a metal
casing during backswing
movement

Electrostatic ignition

4
Lessons Learned

Mechanical Integrity

• Periodical measuring of the threads of box nut and tank

truck male connections, assure timely replacement;
• Avoid deformation of the brass box nut and tank male
connections;

Lessons Learned

• Avoid the use of a variety of unauthorized adapters

carried by the tank trucks (use only certified adapters
belong to the loading site);
• Loading site shall be equipped with non-sparking
spanner;
• Train operators NEVER try to tighten the connection
during loading (shall shutdown and initial ESD system).

5
Similar Case – Collapsed Sphere

• The 2000m3 LPG

sphere was
approximately 80% full
of fresh water…
• the steel legs had
thickness reductions of
up to 8mm, with
pitting holes of up to
10cm2.

Case-2: Tank Overflowed…Fire & Blast

• A gasoline tank overflowed

outside normal working
hours…
• The smell from the spill was
detected by a security guard…
• Two operators were sent to
investigate. They approached
the scene by car…
• One person in a building some
20 km from the scene ‘felt’ the
subsequent bang.

6
Tank Overflowed…Fire & Blast
• The fire spread from one tank to four
others…
• It eventually destroyed five storage
tanks, an administration building,
maintenance workshop, store,
engineering office, and medical centre
suffered fire and/or blast damage;
• the fire station and three fire fighting
trucks were also damaged, due to being
located too close to the tank farm;
• A total of 8 people were killed and 13
serious injuries.

Causes & Lessons Learned

• Tank overflow prevention
(no pump interlock with
level controller…engineering,
Process Hazard Analysis);

• Quick fire spread to adjacent 4 tanks (safety distance and

prevention of domino effect…layout, Process Hazard
Analysis);
• Presence of ignition source (employee drove car to the
site…Training);
• Fire Station including fire trucks were damaged (located
too close to the tank farm…Emergency Response)

7
Similar Case: … Overflow in Road Tanker

Source: Process Safety Booklet Twelve – Tankfarm and (Un)Loading Safe Operations

Case-3: Explosion in Storage Tank

• Tanks contained
mixtures of waste
hydrocarbons and
water…
• A welding operation
was in progress on a
service stairway located
between two waste
liquid storage tanks…

8
 Potential Vapor & Ignition Sources

Source: EPA Chemical Incident Investigation Report, EAP-550-98-001

Causes & Lessons Learned

• Inadequate preparation for hot work: nearby storage
tanks with flammable were not completely isolated
(open manways, open swingline valve, open hose);
• A lack of awareness of the impact of changing
conditions …
• Content change: the tanks were primarily intended to
store waste water rather than to handle flammable
materials;
• Corrosion: the tanks failed along their bottom seams,
releasing their entire contents - evidence of corrosion
along the bottom seam;
• No secondary containment around tanks.

9
Case-4: Naphtha Storage Tank Fire
• Sunk Floating Roof due to
Heavy Rain …

Causes & Lessons

• Extremely heavy rainfall … amount of rain equates to

112 mm of water depth at the center well on the roof of
Tank – External Factors … Process Hazard Analysis
• Hydrocarbon product was unable to displace the water
seal and flow onto the roof – Maintenance … Mechanical
Integrity
• The most likely ignition source: friction sparks
subsequent to the mechanical failure of the pole support.

10
Similar Case
… Roof Sinks Due to No Maintenance

In 1992, a floating roof of a catalyst distillate tank sank

during heavy rains:

After receiving complaints of odor, operators began to look for the

source and discovered product escaping from the tank roof
drainage system … the floating roof was found having sunk out
of sight.

Source: Process Safety Booklet Twelve – Tankfarm and (Un)Loading Safe Operations

• An open top single deck pontoon floating roof: to carry

at least a load of 10 inch (254mm) of rain water before it
will sink (API-650);
• Rust and debris on floating roof could block the internal
drain.

11
Case-5: Fire in Flammable Liquid Tank

Ignition Sources!!!

• Activated carbon drums were used in the vent system to

control hydrocarbon emissions and odors;
• Flame arrestor and a foam fire protection system were
NOT installed before filling the tanks;
• When organic materials pass through activated carbon, a
chemical reaction occurs that can cause significant
amounts of heat... Fire and Explosion!

Similar Case
… Fire in Road Tanker during Loading

12
Case-6: Vacuum Damage

Case-7: Fire due to Service Change

• Tank level was low and the

incoming discharge into the
vapor space of the tank;
• High flow rate caused a static
electric discharge in the
FLAMABLE vapor space;
• Without thoroughly cleaning
the tank and purging the The Tank Was Changed:
vapor … flammable vapor Gasoline  Diesel Oil
space exists!

13
Similar Case – due to Process Change

Liquid ethylene tank venting arrangement

Summary
• Effective management system and its implementation are
helpful in preventing accidents;
• Process Hazard Analysis (PHA) is an important tool to identify
hazards with the process facilities;
• Mechanical Integrity (MI) is the basis for material containment;
• Ignition sources: not only apparent as flame…may hide
somewhere;
• External factors: heavy rain? think of your floating roof;
• Hot work: gas testing, be aware of “the dynamic…the change of
the environment”;
• Management of Change: change to facilities, as well as service
change;
• Vacuum: the tank … weaker than an egg!

14
Thanks!
Anthony Su （粟镇宇）
粟镇宇）
anthony.su@rmscn.com
MP: +86 135 6428 8299

15