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Safety in Petroleum Refineries - Coggle Diagram
Safety in Petroleum Refineries
Hazards in Refinery Units
Crude Oil Pre-treatment
Scheduled maintenance is required to prevent salt fouling and corrosion.
Hydrogen sulphide, hydrogen chloride and salts in the desalter are the main causes of corrosion in the unit.
Crude Oil Distillation
Sour crude distillation, especially at a high temperature of 232 °C (450 °F), causes severe corrosion
Anti-corrosive chemicals and sufficient wash water are injected to avoid corrosion.
Catalytic Reforming
Hydrogen chloride and ammonium chloride may form in the unit pre-heater which can lead to fouling and corrosion
Scheduled maintenance is required to prevent corrosion and ensure the temperature is controlled to avoid hot spots in the reactor.
Thermal Cracking
Hydrogen sulphide corrosion may occur in the furnace, coking drums and reactors.
Scheduled maintenance is required to ensure that the temperature control units are working properly.
Water jets used for coke removal from the coke drum should be drained properly and completely to avoid explosion when fresh coke forms again during operation
Hydrotreating and Hydrocracking
Fine particulates may result in a dust explosion.
Since hydrogen sulphide is present regular maintenance is required to avoid corrosion.
Fluid Catalytic Cracking
Hydrocyclones must be carefully operated, otherwise catalyst fines will be carried out over to the distillation column.
Oil coating the spent catalyst should be stripped out in the stripper section of the reactor before sending it to the regenerator
Alkylation
In the alkylation unit, two systems are used, either sulphuric acid or hydrofluoric acid, which are both considered hazardous chemicals.
Material handling with extreme care is required especially the hydrofluoric acid during cleaning processes in which water is used.
Hydrogen Production
Scheduled maintenance is required to prevent corrosion and ensure that temperature and pressure are controlled.
Low boiling point hydrocarbons released from a leak may lead to a fire and/or an explosion.
Inspections for piping and connections should be done regularly to assure hydrogen production quality.
Safety Programs and Regulations
OSHA US
CFR 1910
14 elements
UK COMAH 2015
Malaysia
FMA 67
CIMAH 1996
Ageing Mechanism
Management of Ageing
Plant ageing should be managed as part of a well structured Health, Safety and Environment Management Systems (HSEMS) or Process Management System (PSM).
A well structured and maintained HSEMS document is a means of identifying and setting down a commitment to how a business will manage health, safety and environmental issues
