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A Sunrise Project for a Sunshine Future

PARADEEP REFINERY PROJECT


M.ELAMARAN
PNM-CG
AGENDA
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
INTRODUCTION

BASICS

TYPES OF HAZARD

HAZARD CONTROL

VIDEOS AND ANIMATION

SPECIFIC TO COMMISSIONING
INTRODUCTION
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
INTRODUCTION
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
INTRODUCTION
A Sunrise Project for a Sunshine Future
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Q1 . Do you believe that these incidents could have
been prevented?




Q2. How many people could have prevented it?
BASICS-Hazard
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What is a Hazard?

A potential to cause harm or damage.

Damage to Life , Health , Environment and Property .

The potential to damage is realized with certain probability in the
absence of its control.
BASICS- Risk
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What is Risk?

The likelihood that a specified undesired event will occur due to the
realisation of a hazard by work activities, or during work activities or by
the products and services created by work activities.

Risk = Hazard * Exposure

Risk = Severity * Likelihood
BASICS- Personal and process safety
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Personal safety incidents Relatively high frequency low consequence
incidents.- controlled by PPE, Work permit systems



Process safety incidents Relatively low frequency high consequence
incidents. Controlled by Process safety management, Work permit system
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Basics- Spot the Hazards
A Sunrise Project for a Sunshine Future
PARADEEP REFINERY PROJECT
Hazard control -Principles
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At its source.
Along its path. (erect a barricade between the hazard and the worker.)
At the worker. (remove the worker from the exposure, such as automated/remote controls, worker rotation,
providing PPE when all options have been exhausted.)
Monitoring activities (locate new hazards and assess the effectiveness of existing controls.)
Hazard control - Hierarchy
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Hazard control Various stages
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18
CONCEPTUAL
DESIGN
SITE SELECTION
PROCESS DESIGN
DETAIL
ENGINEERING
START-UP
OPERATION
COARSE HAZOP, WHAT-IF, HAZARD
RANKING, HAZID
PRELIMINARY RISK ASSESSMENT,
CONSEQUENCE ANALYSIS
HAZOP, FMECA, SIL STUDY, SAFETY
REVIEW
DETAILED RISK ANALYSIS
SAFETY AUDIT, EMERGENCY PLAN, HIRA
SAFETY AUDIT, HAZOP, RA, RBM, HIRA
Hazards in Refinery - Physical
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Fall from height , impact from tools , slips and trips , Objects falling from height

From Heat Hot burn , cold burns

From Light Eye damage due to looking at welding arc

From Sound Ear damage

From Pressure whiplash of hoses , danger during hydro jetting

Electrical Hazards. Static Electricity.

Impact Hazard.

Fire and Explosions.

Radiation.
Hazards in Refinery - Chemical
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Uncontrolled runaway reaction

Asphyxiation

Gases H2S , Cl etc

Other catalyst and chemicals respiratory damages, carcinogens ,dusts

Uncontrolled release Air , water and land pollution.

Hazards in Refinery -Process
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Uncontrolled release.

Fire.

Explosion.
Hazards Pre commissioning and Commissioning
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Layout Impact Hazards , Dangerous approaches and Hindrances, no escape
routes- address in Format checking

Flushing - Mix up in flushing media , improper flushing .

Air blasting Rupture and blast , abrasion.

Box up improper box up , improper gasket leaks . Missed LPD, HPV , small
bore piping box up.

Pressure test rupture dangerous with hydrogen

Inertisation improper. Vacuum pulling after steaming.

Fuel gas back up leaks , release through small piping's.

Utility charging Hammering , Nitrogen going to wrong place.
Hazards Pre commissioning and Commissioning
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Lining up wrong line up , wrong blinding and deblinding

Equipment line up Missed PSV line up. Wrong sequence, inadequate
adherence to procedure.

Pump/ equipment trials wrong line up, missed pre requisites , missed coupling
guard, earthing from motor missing, improper junction box sealing.

Instrument points mix up, wrong control valve action, missed square rooting in
flow, non line up, non calibration, junction box improper sealing, wrong interlock
implementation.

First heating Constraints to expansion leading to rupture, line falling of
support, fouling , unreleased expansion bellows and spring supports

Hot Bolting- wrong spanner material , leaks, gasket rupture
Hazards Pre commissioning and Commissioning
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Start up improper adherence to procedure, wrong procedure, too quick heat
up , bypassing safety interlocks, doing start up before the unit is ready.

Leaks small points like orifice flange spare tapings, bull plugs in NRVs, pump
strainers, Valves, HPVs , LPDs , instrument tapping drain points etc

Operators Not familiar with the plant and operation, incomplete and
inadequate training.

Major Hazards mix up in MOC, Design errors , wrong calculations etc.
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PARADEEP REFINERY PROJECT