Petroleum Process Hazard Control

K P Pandey

The primary Variables in the process are

Flow Pressure Temperature Composition Quantity

Process load may arise from disturbance of the following

Feed stream quality and rate

Service stream quality and rate Equipment malfunction Process operating condition Ambient condition Material properties and behavior

Deviation in the variables can cause deviation in the process. Deviation from accepted conditions are the fundamental Source of Process Hazard

The Success of the process control depend on the integrity of the control system. The integrity means that the control strategies and hard ware are adequate,reliable for the job at hand

Important safety aspect in the control system

The control loops, should have failsafe action as far as possible, particularly on loss of instrument air or electrical power to the control valves Important instrument should be checked regularly, by pass of alarm, trips and ultimate protective devices should be through proper documented procedure. Instrument containing glass such as rotameter can break and give rise to serious leaks and should be avoided, where possible for toxic and corrosive chemicals Instrument should not be the potential source of ignition and should conform to hazardous area classification requirements

Flow hazards
Low flow Flow can be interrupted or reduced by factors related to process , equipment or operations . These factors may act independently or in combination and include (1) Blockage(2) Vapor lock (3) Cavitation in pump(4) Mechanical failure of the prime mover ( 5) Leakage
Excess flow A primary cause is an open valve which should be either either partially open or closed. Reverse flow can occur when down stream pressure exceeds upstream pressure. A common cause of reverse flow is pump failure or failure or directly pressured fluid transport system

Pressure Hazard
Over pressure and under pressure can increase the probability of accidental chemical release. Either can cause physical failure of the process equipment or storage equipment. Over pressure can cause the opening of a relief device, thereby allowing a toxic chemical to enter in the environment. Potential consequences ranges from a small release of hazardous material through leakage to a large,sudden release through the total and rapid failure of containment.

Generally overpressure are considered more hazardous than underpressures but process under pressure can also cause equipment failure by collapse or back flow of incompatible materials.

Temperature hazards
High temperatures are usually more hazardous than low temperatures but both must be considered in evaluating the temperature's contribution to process hazards. Often a low temperature will slow down or quench the reaction. This may be hazardous if an unreacted feed stream is incompatible with down stream operation.

Level hazards

Equipment hazard control

Vessels
Piping ( Including Valves) Process Machinery Process Instrumentation

General equipment failure mode

Process upset causing pressure or temperature to exceed design limits of the equipment. Faulty fabrication Faulty repair or installation

Corrosion
Erosion Mechanical failure.

Corrosion
General corrosion Exfoliation

Intergranular corrosion
Galvanic corrosion Corrosion pitting

Crevice corrosion
Hydrogen imbritlement External corrosion Stress corrosion