Professional Documents
Culture Documents
EMERGENCY ISOLATION OF
CHEMICAL PLANTS
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
CONTENTS
1 Introduction
References
Glossary
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Many serious fires have occurred in the oil and chemical industries
because leaks of highly flammable gases or liquids could not be
contained. For example, the serious fire at Feyzin in France in 1966
started while water was being drained from a tank of liquefied petroleum
gas. The drain valves could not be shut, LPG flowed out and was ignited
by a car on a motorway 500 feet away. Many fires have occurred as a
result of gland leaks on pumps handling very cold liquefied hydrocarbons.
Appendix I describes some incidents that could have been prevented
by the installation of emergency isolation valves. They were all the result
of leaks of flammable gases or liquids. On other plants equipment failure
or human failure has led to leaks of toxic gases or vapors or corrosive
liquids, but these do not seem to be so well documented.
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
(a) The equipment is particularly liable to leak for example, very hot or
cold pumps.
(b) The equipment is less likely to leak but if it does leak a very large
quantity of material will run out and there is no way of stopping it,
for example, the bottom pump on a still containing more than, say,
50 tons, of flammable Liquid.
(C) The equipment is less likely to leak but if It does so, the rate of
leakage will be very large For example, a very large pump.
In addition, if the inventory between the emergency isolation valve and the leak is
large, or if the isolation valve is unlikely to give a good shut off, then an
emergency blow-down valve may be needed as well as an emergency isolation
valve.
The following illustrates the kind of argument that may be used to decide whether
or not emergency isolation is justified in a particular case:-
Suppose a leak on the equipment being protected could lead to damage and loss
of profit worth $1,650,000.
Then if the chance of a leak of this size is greater than 1 in 1,000 in the life of the
plant (or in 10,000 per year) the expenditure is justified as an insurance policy,
quite apart from any risk to life.
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
If, however, our experience tells us that the chance of a fire is about 1 in 1,000
(say, between 1 in 100 and 1 in 10,0001 in the lifetime of the plant then it is
worthwhile expending some effort in trying to obtain more accurate data on the
frequency of pump fires.
In some cases, particularly where toxic or corrosive materials are concerned, the
chance of damage to equipment is small but there is a significant risk of injury to
people. The methods of hazard analysis can be used in these cases. It is
necessary to estimate:
(b) The chance that a man will be near enough to be injured at the time - this
can be estimated by measuring the 'population density' in the area. For
corrosive liquids, we also need to know the chance that the man will be In
the line of fire, i.e. what is the solid angle of the leak.
From these figures the probability that a man will be injured can be estimated
and compared with the usual criteria (Refs. 1,2 and 3).
Finally; the need to isolate the feed to a plant in an emergency must not
be overlooked. An emergency valve on the feed line may be desirable.
Remotely operated isolation valves are better than excess flow valves as
the latter operate only when the leak rate is 50% or more above the
normal flow; heavy leaks can occur without them operating.
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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3.2 Actuators
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Electrically operated
Pneumatically operated
In most cases emergency isolation valves are held open by air pressure or
electric power and they will close when the pressure falls or the current is
isolated. If operators forget to operate these valves, and a fire occurs, then
the impulse lines will be burnt through and the valves will close. (A fusible
section in a mechanical linkage behaves similarly)
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
If the suction vessel is some distance from the likely point of leakage then
a hand-operated emergency valve may be acceptable. It must be possible
to reach it when a leak occurs, without exposing the operators to undue
risk. A man should not be expected to go upstairs to operate an
emergency valve. These hand-operated emergency valves must also be
exercised regularly or they will be too stiff to operate when required In
anger. Note that moving the emergency valve further away from the point
of leakage increases the quantity of material that will continue to leak out
after the valve is closed and may strengthen the case for a blow down
valve, this is particularly Important if the liquid is above its atmospheric
pressure boiling point so that a lot of it has to flash to reduce the pressure.
In a few cases mechanical linkages have been used instead of electric or
pneumatic means to operate valves from a distance.
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Care should be taken that the operating buttons for emergency isolation
valves are not so close to the likely point of leakage that they cannot be
reached when a leak or fire occurs. One serious fire occurred because this
point had been overlooked. Motorized suction valves had been installed
on a pump, primarily for process convenience, and the operating buttons
placed close to the pump. The fact that the valves might be required in an
emergency had been overlooked (Ref 5).
Of course, the operating buttons should not be too far away or there will
be delay before they can be operated. On many installations there is one
button about 30 feet away and another in the control room.
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Several accidents have occurred (Ref 12) because motorized valves were
used to isolate equipment which was under maintenance and power was
accidentally isolated or restored.
If power opens the valve, then the power must he disconnected before
equipment is given to maintenance, i.e., on electrically operated valves the
fuses must he withdrawn, on pneumatically or hydraulically operated
valves the impulse lines must be vented and the vent valves locked open.
If power keeps the valve closed then it must be held shut by a locked
clamp strong enough to withstand the loss of power Simple clamps which
give a little when power is removed, thus allowing the valve to open
slightly, are not suitable
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
8 Report No. 0.21, 100/B, 'Report on a Fire on No.2 Crude Oil Distillation
Plant', TA Kletz, 7.7.69.
12 The tolerability of risk from nuclear power stations HSE Books 1992 ISBN
0 11 886368 1
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
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15 Safety signs and signals. The Health and Safety (Safety Signs and
Signals) Regulations 1996. Guidance on Regulations L64 HSE Books
1996 ISBN 0 7176 0870 0
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Glossary
blank flange (blind) a component for closing an open end of pipe work,
which is suitably rated to maintain the pressure rating of the pipe and of an
appropriate material to withstand the contents of the line.
bleed or vent valve a valve for draining liquids or venting gas from a
pressurized system.
block valve a valve which provides a tight shut-off for isolation purposes.
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
intolerable risk: risk at an unacceptably high level. Until the risk has been
reduced, activity should not be started (or continued). If the risk cannot be
reduced, even with unlimited resources, the proposed activity should not
go ahead.
isolation envelope that part of the pipe work system which is within the
isolation points forming the boundary within which intrusive work can be
performed. Where a valved isolation allows a physical isolation to be
effected, it is the physical isolation point that forms the boundary of the
isolation envelope.
own isolation: isolation where the same person both installs the isolation
and carries out the intrusive work. Such isolations may be carried out
under PTW or procedural control.
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short-duration work: work which does not extend beyond one operating
shift.
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Except where stated, the following accidents are taken from reference 10.
Leakage from the seals of cold duty pumps on European Olefin Plants has
been a not uncommon occurrence. One of the leaks which fired was on
a Olefin Plant and it was a fortunate circumstance on this occasion that
other plant above the pump was screened from the fire by a solid concrete
floor. On another Olefin Plant there has been severe leakage from the
seals of the C2 splitter reflux pumps on a number of occasions, giving rise
to a cloud of vapor which, prior to the installations of the firewall and
steam curtain in 1968, created a hazard on a Works road on 35 ft away.
The vapor cloud from a major seal failure on one of the pumps in 1969
was contained and dispersed by means of the steam curtain.
Another Company reported three major leaks from seals of cold ethylene
pumps which occurred on different plants in 1968. The first resulted from
the failure due to stress corrosion of one of two bolts which held the seal
in position, allowing a large outflow of liquid which vaporized immediately
and generated a large volume of Vapor. The vapor cloud was fortunately
carried clear of adjacent flares and heaters by the wind blowing at the
time, and did not ignite. It was estimated that 90,000 ft3 of vapor (3 tons)
escaped in 20 minutes. The other two leaks both ignited near the pumps,
apparently due to discharge of static electricity, the escape occurring in
each case as a jet of vapor containing entrained droplets of liquid.
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
The compound wall was provided with a steam curtain which was
actuated, and tests with a combustible gas detector on the roadway
beyond the wall gave negative results In the second incident an amount of
butadiene estimated at several tons was found in the bund round a stock
tank. This had come from the drain of a torque tube, which had most
probably been blocked open by a piece of ice or hydrate which
subsequently melted.
The disaster at the Rhone Alpes refinery at Feyzin in January 1966 (Ref 8)
started with a blockage in the drain line from a propane storage sphere,
which was almost certainly due to ice or hydrate. The drain line had two
valves, and the open end pointed straight down to the ground below the
sphere. The standing Instruction on the draining operation was to open the
valve next to the tank fully, and control the draining with the second valve,
so leaving the opportunity to isolate the lank by the fist valve in the event
of any trouble with the second. On this occasion the operator, from
another refinery, controlled the draining on the first valve with the second
one wide open. When the first valve blocked he opened It wider, until the
obstruction gave way, and a jet of propane issued full bore through the 2
in line, striking the ground below and rebounding into the operators f, and
also so knocking the handle off the valve. Subsequent attempts to replace
the handle of the first valve, and to shut the second valve failed. The
resultant cloud of vapor was ignited at a point some 500 ft. away, and the
flame flashed back to the sphere and continued to burn under it until the
stock, originally 348 tons, was almost exhausted. Because of lack of
experience of the fire brigade combined with shortage of firewater, the
sphere was left without any cooling water in the belief that the relief valves
would prevent over pressuring. In the event the metal of the sphere failed
due to overheating, and the vessel ruptured, spreading the fire to
neighboring storage spheres. In all, 18 people were killed and 81 injured.
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Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
As the pump glands were liable to leak, the leaking oil was above its
autoignition temperature and the inventory was large, the case for an
emergency Isolation valve was good and one was fitted on the rebuilt
plant. (Ref. 11).
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
1 LPG Storage
2 An Olefin Plant
The attached table lists all the likely sources of leakage on a European
Olefin Plant, the nature of the material, its temperature and pressure
and the inventory which will leak out if a leak occurs and it cannot be
isolated. It also shows whether or not an emergency isolation valve has
been fitted. The column headed 'A or B' refers to page 2 of the main
report. 'A' indicates that the equipment is particularly liable to leak, for
example very hot or cold pumps. In assigning this classification
experience in the industry as a whole is taken into account, and not just
experience on this plant. 'B' indicates that the equipment is less likely to
leak, but if it does leak, a very large quantity of material will run out,
and unless there is an emergency isolation valve, there will be no way of
stopping it.
Unless otherwise stated, emergency isolation valves are fitted only on the
suction lines of pumps and other items of equipment. Delivery lines are
normally protected by non-return valves.
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
The attached table lists all the likely sources of leakage on a European
Aromatics Plant, the nature of the material, its temperature and
pressure and the inventory which will leak out if a leak occurs and it
cannot be isolated. A and B have the same meaning as in (2) above.
All the points where emergency isolation valves are fitted, have been
listed.
In addition, a number of points where they are not fitted, and there is no
intention to fit them, are noted for comparison.
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
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2 Pipelines often have long sections of pipe between valves. You may need
to use techniques such as pipe plugs or pipe freezing to enable the
isolation of intermediate sections of pipe for maintenance purposes, when
it is not reasonably practicable to use primary devices (see Table
below). Such techniques are not appropriate for standard use on process
plant and should be subject to task-specific risk assessment and senior-
level authorization.
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The model list below should be tailored to suit your own isolation systems.
It should not be assumed to be a comprehensive model.
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Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
This checklist provides a basis (structured around the HSG653 model) for
reviewing the adequacy of your safety management system (SMS) for isolation
activities. Select the questions appropriate to your site and its hazards. You
should also assess whether any additional questions will be appropriate for your
operation.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries