OLEUM AND SULFURIC ACID PIPELINE SAFETY...
Transcript of OLEUM AND SULFURIC ACID PIPELINE SAFETY...
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OLEUM AND SULFURIC ACID OLEUM AND SULFURIC ACID PIPELINE SAFETY PIPELINE SAFETY
MAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCE
PRESENTED BY:PRESENTED BY:
•• EmarEmar LeãoLeão
R d iR d i MM
PRESENTED BY:PRESENTED BY:
•• RodrigoRodrigo MaçonMaçon
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PARANAPANEMAPARANAPANEMA CARAÍBACARAÍBAPARANAPANEMA PARANAPANEMA -- CARAÍBACARAÍBATheThe CaraibaCaraiba Metais’Metais’ sulfuricsulfuric acidacidfacilityfacility waswas designeddesigned byby NatronNatronEngenhariaEngenharia withwith aa initialinitial capacitycapacity Caraíba
ofof 11..870870 t/dayt/day..
TheThe mainmain porpouseporpouse ofof thethe facilityfacility isisTheThe mainmain porpouseporpouse ofof thethe facilityfacility isistoto treattreat thethe gasesgases fromfrom thethe coppercopperfunditionfundition..
19821982:: HH22SOSO44 facilityfacility startstart--upup..
ActualActual productionproduction capacitycapacity::22 475475 t/dayt/day afterafter debottleneckingdebottlenecking22..475475 t/dayt/day afterafter debottleneckingdebottlenecking..
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BackgroundBackgroundBackgroundBackground
1.1. TheThe pipelinepipeline isis inin operationoperation sincesince 19931993 andand occurredoccurred oneoneoleumoleum spillagespillage happenedhappened inin 19981998 oneone chemicalchemical burnburnoleumoleum spillagespillage happenedhappened inin 19981998,, oneone chemicalchemical burnburnaccidentaccident andand oneone acidacid spillagespillage toto thethe groundground inin 20032003,, duringduringpreventivepreventive maintenancemaintenance..pp
2.2. AfterAfter 20032003,, moremore thanthan 3030 preventivepreventive interventionsinterventions insideinsideandand outsideoutside CaraibaCaraiba withoutwithout accidentsaccidentsandand outsideoutside CaraibaCaraiba withoutwithout accidentsaccidents..
•• TwoTwo generalgeneral paintingpainting andand 1515 pipelinepipeline sectionssections paintingspaintings;;
•• FiveFive pipelinepipeline sectionssections replacementsreplacements // externalexternal areaarea valvevalverelocationrelocation;;
•• EightEight pipelinepipeline sectionssections insideinside CaraibaCaraiba;;
•• ThicknessThickness measurementmeasurement onon semestersemester basisbasis andand quarterlyquarterlyThicknessThickness measurementmeasurement onon semestersemester basisbasis andand quarterlyquarterlyvegetationvegetation cleannesscleanness..
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System characteristics:System characteristics: 11-- 12,000 meter long pipelines12,000 meter long pipelines
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System characteristicsSystem characteristics:: 22-- Height differences up to 30 mHeight differences up to 30 m
1. PROQUIGEL
2. BRASKEM CPL
3. PUMPING STATION CIBRAFERTIL
4. CETREL ACCESS
5. COPPER PUMPING STATION
6. CARAIBA METAIS
7. PUMPING STATION CARAIBA
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System characteristics:System characteristics: 33-- places with difficult access (height and vegetationplaces with difficult access (height and vegetation))
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System characteristics:System characteristics: 44-- places with difficult accessplaces with difficult access (Pipe way inside complex)(Pipe way inside complex)
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MAINMAIN OBJECTIVEOBJECTIVE:: PipelinePipeline maintenancemaintenance jobsjobs
MAINMAIN STAGESSTAGES::
pp jjwithoutwithout accidentsaccidents andand environmentalenvironmental eventsevents..
MAINMAIN STAGESSTAGES::
•• JobJob planningplanning::
•• CaraibaCaraiba operation,operation, BraskemBraskem andand clientsclients selling,selling,maintenance,maintenance, safetysafety andand environmentalenvironmental areasareas hashas toto workworkt tht thtogethertogether;;
•• ClientClient autonomyautonomy lessless thanthan 0303 daysdays;;
•• PolicePolice andand environmentalenvironmental agencyagency officialofficial noticenotice..
•• OperationalOperational procedureprocedure::•• OperationalOperational procedureprocedure::
•• PipelinePipeline drainagedrainage andand startstart--upup proceduresprocedures;;
•• TaskTask riskrisk analysisanalysis..
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Operational procedure (resumed):Operational procedure (resumed):Operational procedure (resumed):Operational procedure (resumed):
1.1. AcidAcid transfertransfer interruptioninterruption;;
22 Pi liPi li itit d id i tt tt t kt k dd itit2.2. PipelinePipeline gravitygravity draindrain toto storagestorage tankstanks andand nitrogennitrogen purgepurge;;
3.3. DepressurizeDepressurize andand isolateisolate thethe pipelinepipeline sectionsection;;
4.4. OpenOpen drainsdrains andand collectcollect thethe residualresidual productproduct withwith vacuumvacuumtrucktruck;;
5.5. MaintenanceMaintenance jobjob executionexecution andand shutshut downdown thethe pipelinepipelinesectionsection;;;;
6.6. PipelinePipeline startstart--upup andand confirmconfirm thatthat therethere areare nono leaksleaks;;
hh i lii li ii dd ii ff idid ff7.7. TheThe pipelinepipeline isis readyready againagain forfor acidacid transfertransfer..
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Labels and locksLabels and locksLabels Labels
isolating the client sideisolating the client sideisolating Caraíba sideisolating Caraíba side
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Non destructive testingNon destructive testing Non destructive testingNon destructive testing
Non destructive testingNon destructive testing Non destructive testingNon destructive testing
New screws and gasketNew screws and gasket
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Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:
DangersDangers::
11 SulfuricSulfuric acidacid 9898%% andand oleumoleum 2828%%;;1.1. SulfuricSulfuric acidacid 9898%% andand oleumoleum 2828%%;;
RisksRisks::
1.1. SkinSkin and/orand/or eyeseyes chemicalchemical burnsburns;;2.2. ProductProduct spillagespillage;;p gp g3.3. SOSO33 inhalationinhalation;;
RisksRisks MitigationMitigation (next(next slide)slide)::
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Skin, eyes and respiratory protectionSkin, eyes and respiratory protection
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Skin, eyes and respiratory protectionSkin, eyes and respiratory protection
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Emergency drills:Emergency drills: foam over oleumfoam over oleum
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Collecting trayCollecting tray Sodium carbonateSodium carbonate
Vacuum truckVacuum truck Suction in progressSuction in progress
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DIPHOTERINEDIPHOTERINE
PLASTIC BAG PLASTIC BAG
500 mL500 mLBOARD EYE WASH BOARD EYE WASH
500 mL500 mL
PORTABLE DIPHOTERINE PORTABLE DIPHOTERINE
5.000 mL5.000 mL
EYE WASHEYE WASH
100 mL100 mL
MINI PD MINI PD
200 mL200 mL
MICRO PDMICRO PD
100 mL100 mL
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30 min after the accident30 min after the accident30 min after the accident30 min after the accident
After diphoterine useAfter diphoterine use
After 6 hoursAfter 6 hours Next morningNext morning
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04 years latter04 years latter
04 years latter04 years latter
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Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:
DangersDangers::
22 FlammableFlammable productsproducts and/orand/or heatedheated productsproducts inin nearbynearby2.2. FlammableFlammable productsproducts and/orand/or heatedheated productsproducts inin nearbynearbypipelinespipelines;;
Ri kRi kRisksRisks::
1.1. ExplosionExplosion;;2.2. HeatHeat burnsburns;;
RisksRisks MitigationMitigation (next(next slide)slide)::
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Flammable atmosphere testingFlammable atmosphere testing HutsHuts
antianti--heating hutheating hut antianti--heating clothheating cloth
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Thermal heat clothesThermal heat clothes Thermal heat clothsThermal heat cloths
Thermal heat clothsThermal heat clothsThermal heat clothesThermal heat clothes
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Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:
DangersDangers::
33 ConfinedConfined areaarea andand poisonouspoisonous animalsanimals;;3.3. ConfinedConfined areaarea andand poisonouspoisonous animalsanimals;;
RisksRisks::
•• AsphyxiaAsphyxia and/orand/or poisoningpoisoning;;
•• PoisonousPoisonous animalsanimals stingsstings;;PoisonousPoisonous animalsanimals stingsstings;;
RisksRisks MitigationMitigation (next(next slide)slide)::
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Eg: confined area and/or animals habitatEg: confined area and/or animals habitatss BeesBees SnakesSnakes
Mitigation: cleaning, leg protection and boots Mitigation: cleaning, leg protection and boots
Mitigation: oxygen measurements; air; exhaust, laddersMitigation: oxygen measurements; air; exhaust, ladders
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Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:
DangersDangers::
44 WeatherWeather;;4.4. WeatherWeather;;
RisksRisks::
•• DrownDrown ee suddensudden illnessillness;;
RiskRisk MitigationMitigation (next(next slide)slide)::
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Normal condition Normal condition –– ducts in both sidesducts in both sides Flooded location Flooded location –– vapor formationvapor formation
Normal condition Normal condition –– duct depthduct depth Flooded location Flooded location –– vapor formationvapor formation
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Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:
DangersDangers::
55 RoadRoad proximityproximity weightweight liftinglifting machinerymachinery;;5.5. RoadRoad proximity,proximity, weightweight liftinglifting machinerymachinery;;
RisksRisks::
•• VehicleVehicle crashes,crashes, runningrunning oversovers;;
•• EquipmentEquipment fallfall;;q pq p ;;
RiskRisk MitigationMitigation (next(next slide)slide)::
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Automobile crashesAutomobile crashes Pipe section liftingPipe section liftingp gp g
Traffic signs; blockage road and police helpTraffic signs; blockage road and police help Traffic signs; Industrial complex vigilanceTraffic signs; Industrial complex vigilance
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Pipe ends are isolated to avoid acid dropletsPipe ends are isolated to avoid acid droplets
Droplets eventsDroplets events
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Cramps to avoid leakages or pipeline drainageCramps to avoid leakages or pipeline drainage
Cold connection cramp Cold connection cramp Pipeline leaks crampsPipeline leaks cramps
Hot pipeline drainHot pipeline drain Stanch leakages near the drainStanch leakages near the drain Drain containmentDrain containment
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Example: Job inside Caraiba area Example: Job inside Caraiba area
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Resources are always availableResources are always available
Lifting truckLifting truck Emergency truckEmergency truck
Vaccum truckVaccum truck Emergency KITEmergency KIT
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Fire response team and operators are trained in several emergency situationsFire response team and operators are trained in several emergency situations
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THETHETHE THE ENDENDENDEND