TITLE OF ASSIGNMENT:
APPLICATION OF INTRISNSICALLY
SAFE DESIGN PRINCIPLES AND
STRATEGIES
TEAM MEMBERS:
MOHAMMED AL-KAABI
COURSE NAME:
SAFE DESIGN AND OPERATION AECH6101
1
Section 1: Identification and Description of
Hazards
Chemical Process: Natural Gas Processing Plant
Natural gas processing involves the extraction of hydrocarbons and impurities from
natural gas to produce pipeline-quality dry gas. This process is critical for energy
production but presents significant hazards.
Hazards:
Flammability and Explosiveness: Natural gas is highly flammable, and leaks can
lead to explosive atmospheres.
Toxicity of Hydrogen Sulfide (H2S): Natural gas contains H2S, which is highly
toxic and can pose severe health risks.
High Pressure: Processing operations occur under high pressure, increasing the
risk of leaks and equipment failure.
Cryogenic Temperatures: In some processes, such as liquefied natural gas (LNG)
production, extremely low temperatures can lead to cryogenic burns or equipment
failure.
Previous Major Hazard Accidents:
San Bruno Pipeline Explosion (2010): A significant incident involving a natural gas
pipeline explosion, emphasizing the risks associated with leaks.
Gulf Coast Chemical Plant Explosion (2019): Highlighted the dangers of processing
hydrocarbons and the need for robust safety measures.
Section 2: ISD Checklists for Main Processes
2
Process Unit 1: Acid Gas Treatment
Checklist Items:
H2S Removal Systems: Ensure effectiveness of amine treating systems.
Regular Maintenance: Schedule routine checks to prevent equipment failure.
Gas Monitoring Systems: Verify functionality of continuous H2S monitoring.
Justification: Gas sweetening is crucial for removing toxic compounds from natural
gas, making it safe for transport and use.
Process Unit 2: Sales Gas/ Compression Unit
Checklist Items:
Pressure Relief Devices: Confirm that pressure relief valves are operational and
properly maintained.
Vibration Monitoring: Implement monitoring systems to detect abnormal vibrations
that could indicate equipment failure.
Emergency Shutdown Systems: Ensure emergency shut-off systems are functional
and tested regularly.
Justification: The compression unit increases gas pressure for transportation, and
its safe operation is essential to prevent catastrophic failures.
Section 3: Inherently Safer Design
Alternatives
Alternative 1: Use of Non-toxic Sweetening Agents
3
Justification: Employing non-toxic amine alternatives for gas sweetening reduces
health risks associated with H2S exposure.
Alternative 2: Advanced Leak Detection Systems
Justification: Implementing enhanced gas detection technologies can provide early
warnings for gas leaks, minimizing the risk of explosions.
Alternative 3: Lower Operating Pressures
Justification: Designing processes to operate at lower pressures can significantly
reduce the risk of catastrophic failures and leaks.
Section 4: Evaluation Methods for ISD
Alternatives
Method 1: Fault Tree Analysis (FTA)
Justification: FTA can identify potential failure pathways in the processing system,
allowing for the evaluation of how ISD alternatives may mitigate these risks.
4
Method 2: Safety Integrity Level (SIL) Assessment
Justification: Assessing the SIL of safety systems can help determine the adequacy
of safety measures related to the proposed ISD alternatives.
Method 3: Cost-Benefit Analysis (CBA)
Justification: CBA evaluates the financial implications of implementing ISD
alternatives, helping to ensure that safety enhancements are economically feasible.
Section 5: Discussion on Proposed Changes
The proposed inherently safer design changes primarily focus on enhancing safety.
For instance, using non-toxic sweetening agents and advanced leak detection
systems directly improves safety by reducing the likelihood of exposure to
hazardous materials. However, modifications such as lowering operating pressures
may lead to increased process times or changes in production capacity. It is
essential to conduct a thorough risk assessment to evaluate the potential trade-offs
between enhanced safety and operational efficiency.
Section 6: References
5
1. Center for Chemical Process Safety (CCPS). (2005). Guidelines for Process Safety
Fundamentals in Natural Gas Processing.
2. American Institute of Chemical Engineers (AIChE). (2012). Inherently Safer
Chemical Processes: A Life Cycle Approach.
3. Occupational Safety and Health Administration (OSHA). (n.d.). Natural Gas
Processing Safety Standards.
4. National Transportation Safety Board (NTSB). (2011). San Bruno Pipeline
Explosion Report.
5. American Petroleum Institute (API). (2018). Recommended Practices for Natural
Gas Processing.
