Identification

of
Leak Sources of
Hydrocarbon Leakages
CONTENTS

1. Gasket Failures
2. Valve’s outflow to atmosphere
3. Sampling Operation
4. Rotating Equipment
5. Storage Tanks and Pressure Vessels
6. Loading – Unloading Operation
7. Mechanical Material Handling inside Plants
8. O.W.S. System and Process Drainage System
9. De-chocking, Filter/ Strainer cleaning
10. Wrong selection of MOC
Ignition Sources
 1. Gasket Failure

Probable Source Probable Cause

Corroded flange joints
Vibration on valves
Short bolts
Flanges and Valves
Bolts of different MOC used on same flange
Frequent temperature and pressure
variations
Hot & cold tighten joints
 2. Valve’s outflow to atmosphere
Probable Source Probable Cause
Inadvertent operation with handle type valve
Wrong MOC of valve cap on HPV
Damaged threads of HPV / LPD
Low Point Drain (LPD)
High Point Vent (HPV) Accumulation of high boils in HPV
Wrong MOC of LPD gasket
short bolting with end blind
Improper alignment of gasket at LPD
 2. Valve’s outflow to atmosphere

Probable Source Probable Cause

Not following SOP while draining storage
tanks
Frequent operation of valves increases the
probability of passing
Boot / Tank Draining Use of vulnerable hose
Hose MOC compatible with process fluid
Draining near hot work / hot surface
Leg drains
 3. Sampling Operation
Probable Source Probable Cause
Glass bottle Glass bottle breakage and spillage on hot
surface
Bladder Bursting of bladder
Sample Point Valve operation/ valve passing
Ferrule Ferrule leakage
Coupler Coupler leakage
Sample bomb Improper identification
Non availability of bomb stand
Block & bleed system Drain valve chocked /closed
Wrong sequence of valve operation
Not follow up SOP
Rupture disc Rupture disc failure due to overfilling
 4. Rotating Equipment
Probable Source Probable Cause
Leak of Mechanical seal due to process fluid
handling particulates
Low pressure of seal fluid
‘O’ ring failure
Pump Over pressure of sealant
Low level of seal fluid
Seals having failure > 5 in years
Malfunction of related alarm and trip
Surging
Compressor Lubrication Problem
Vibration
 4. Rotating Equipment
Probable Source Probable Cause
Belt failure
Friction due to guard

Centrifuge Vibration due to alignment

( Domino effect to flying Dynamic balancing
fragments )
Uneven feed rate

Varying slurry concentration

 4. Rotating Equipment
Probable Source Probable Cause
Seal failure and seepage in the insulation

Agitated vessel Coolants failure

High slurry concentration

 5. Storage Tanks and Pressure Vessels

Floating Roof Tank

Probable Source Probable Cause

Excessive Filling Rate

Floating Roof-Tank Oval formation of tank shell

Choking of rain water drainage system

Excessive withdrawal will cause formation of

Vapor space below roof
explosive gas mixture
 5. Storage Tanks and Pressure Vessels

Fixed Roof Tank

Probable Source Probable Cause

Tank Blanketing nitrogen control-valve stuck-up

Tank-Bottom Failure of bottom plate

Tank Nozzle Failure of first joint of tank nozzles

 5. Storage Tanks and Pressure Vessels

Pressure Vessels

Probable Source Probable Cause

Failure of PRV piping

PRV Assembly
Integrity of PRV installed during FCO
 6. Loading – Unloading Operation

Probable Source Probable Cause

Improper identification of piping connection
Piping and Bay
resulting into wrong destination of transfer
Over filling of tank
Tanker
Incompatible content in the tanker

Vessel piping Reverse flow from the receiving vessel

Mismatch of compartment capacity and
Tanker Compartment
filling
Tanker Hoses Driving away of vehicle with connected hose

Vapour Balance System Vapour balance line left out proper isolation
 7. Mechanical Material Handling

Probable Source Probable Cause

Parking of crane on collapsible ground
( e.g. Position of outrigger near drain or on
soft soil etc.)

Crane Outreaching to retrieve small objects by

extending crane operation beyond operating
limits
Reversing operation / safe distance for
counter balance weight
Forklift Shifting and stacking the materials in plants
 8. O.W.S. & Process Drainage System

Probable Source Probable Cause

Fire trap Failed baffle system

Level indicator malfunction

OWS Pit
ETP-side Valve Closed

Process drain Choked & damaged

 9. De-chocking, Filter/ Strainer cleaning

Probable Source Probable Cause

Line
Sudden release of material,
Equipment
Quantity of material not estimated.
Valve

Improper flushing and draining

Filter & Strainer
Valve-passing
 10. Wrong Selection of MOC

Probable Source Probable Cause

Wrong selection of MOC

Piping and Valves Use of unidentified material

Use of surplus material

 Sources of Ignition

1. Hot Work

2. Furnaces & Incinerators

3. Open hot surface of steams

4. Use of non flame-proof electrical gadgets/extension boards

5. Inadequately maintained field insulations

Thank You !