2_B RAJEEV

B RajeevChief Engineer (Production)

Oil and Natural Gas Corporation Ltd.

Safety in Natural Gas Processing

PETROFED Seminar

“Safety in Hydrocarbon Sector : Drilling to Dispensing”

New Delhi

12 August 2010

Introduction

Safety in Natural Gas Processing –B Rajeev, CE(P), ONGC2

Our industry has brought great benefits to the

mankind but also exposed it to great hazards.

An Obvious hazard is posed by the gases and

vapours associated with upstream production and

downstream processes.

This necessitates that Safe Systems of Work are

in place to minimize such hazards.

Safety Management

Safety in Natural Gas Processing –

B Rajeev, CE(P), ONGC3

Proper safety management results in reduced Losses, Accidents and damages, Lawsuits, Penalties, Public liability claims, and Insurance premiums.

Other intangible benefits include retention ofcorporate image.

The principles of PSM apply throughout the lifecycleof a plant or installation to ensure that the facilitiescan be managed safely and achieve acceptable levelsof business risk overall.

Statutory Requirements



Safety Management is mandatory as per

Statutory legislations.

Statutory Monitoring Bodies

OISD

DGMS

CCE

PCB

Electrical Inspectors

Boiler Inspectors

Applicable Legislations



Health & Safety:

1. The Factories Act,1948

2. Mines Act, 1952

3. Oil Mines Regulations, 1984

4. The Indian explosives Act,1884

5. The Indian explosive Rules,1983

6. The Static & Mobile Pressure Vessels (Unfired) Rules, 1981

7. The Gas Cylinders Rules,1981 (amended 2004)

8. The Petroleum Act-1934

9. The Petroleum Rules, 2002

10. Inflammable Substances Act 1952

11. Petroleum & Natural Gas Rules,1959

12. The Indian Electricity Act,1910 (amended 2007)

13. The Indian Electricity Rules, 1956

14. The Indian Boiler Act, 1923 (amendment 2007) (IBA_GazetteNotification_27May2008)

15. The Indian Boiler Regulations,1950

16. The Motor Vehicle Act,1988




Health & Safety:

17. The Motor Vehicles (Central) Rules, 1989

18. The Atomic Energy Act,1962

19. The Atomic Energy (Factories) Rules,1996

20. The Public Liability Insurance act, 1991 The Public Liability Insurance

Rules, 1991, amended 1993

21. The Chemical Accidents(Emergency Planning, Preparedness and

Response) Rules, 1996

22. Gujarat State Disaster Management, Act 2003

23. Gujarat State Disaster Management Rules, 2006

24. Noise Pollution _Regulation and Control_ Rules_ 2000. (amended 2002),

(amended 2006)

25. Municipal Solid Wastes (Management and Handling) Rules, 2000.

26. PNGRB Act, 2006

27. PNGRB(Code of Practices for ERDMP) Regulations, 2010




Environment:

1. Environment protection Act 1986

2. Environmental Protection Rules,1986

3. The water (Prevention and Control of Pollution) Act 1974 (Chapters- 1 , 2,

3, 4, 5, 6, 7, 8)

4. Water Prevention and Control of Pollution Rules, 1975

5. The Air (Prevention and Control of Pollution ) Act 1981

6. The Air (Prevention and Control of Pollution) Rules, 1982

7. The water (Prevention and Control of Pollution) Cess Act 1977.

8. WATER (PREVENTION AND CONTROL OF POLLUTION) CESS RULES,

1978

9. Manufacture storage and import of hazardous Rules 1989. (amended

2000)

10. Bio-medical waste (M & H) Rules, 1989 (amended 2000) (amended 2003)




Environment:

11. Battery Management & handling Rules 2001

12. Hazardous Waste ( Management & Handling ) Rules, 1989 (Amend 2000)

& (Amend 2003) & (amended 2008)

13. Emission regulations DG Sets; Stack height

14. The Noise Pollution (Regulation and Control) Rules, 2000

15. Ozone Depleting Substances (Regulation & Control) Rules, 2000

16. Ambient noise standards

17. Vehicular exhaust emission standards.

18. Biological Diversity Act, 2002

19. Biological Diversity Rules, 2004

20. National Ambient Air Quality Standards

21. The National Environment Appellate Authority Act, 1997

22. Environmental Impact Assessment Notification-2006. (amended 2007)




Other Acts & Rules:

1. Right to Information Act 2005

2. CENVAT Rules, 2002

3. Arms Act,1959.

4. Arms Rules, 1962

5. Poison Act, 1919

Process Safety



Process Safety Management is a part of Safety Management.

Incidents occur in Natural Gas Processing due to Properties of the medium handled Toxic, Reactive, Flammable, Explosive

Process upsets Temperature, Pressure, Level, Composition etc.

Process Safety Management is intended to Prevent any process related hazardous event.

Management of hazards related with processing.

Process Safety Management



“Prevention is better than cure” – an age old maxim

The major aims are

To develop plant systems and procedures to prevent

unwanted releases, which may ignite and cause toxic

impacts, local fires, or explosions in plants - effecting

nearby communities.

To address issues related to the Operability, Productivity,

Stability, and Quality output of processes, leading to the

specification of safeguards against undesirable events.

Recognition of Hazards



Identify unsafe acts and conditions.

Determine the corrective actions.

Implement corrective actions.

Risk Analysis


People Property Environment

Harm

Hazard

Likelihood Consequence

R I S K

ACCIDENT

Risk Assessment & Analysis



Various tools are available for risk assessments and analysis

HAZID – Hazards Identification studies Early Identification of hazards at design stage

HAZOP – Hazards and Operability studies Provides the most incisive design review, covering safety, environment,

operations, and maintenance

QRA – Quantified Risk Assessment Provides input on safety issues during the design, operation and regulation

of hazardous activities

PSI – Process System Integrity Identifies operational fatigue based damages in the system

RBI – Risk Based Inspection Identifies, assesses and maps risks (due to corrosion and stress cracking),

which can compromise equipment integrity in both pressurized equipment

and structural elements

Risk Perceptions in a Gas Processing Unit


Leakage of hydrocarbons with acid gas.

Leakage of hydrocarbons.

Hydrocarbon vapour clouds.

Fire & Explosion

Boiling liquid expanding vapour Explosion (BLEVE).

Sabotage / Bomb Threat or terrorist activities.

Plant Safety System



Plant safety system consists of Process Safety Equipment safety Fire Safety Personnel Safety Storage Safety Product Loading Safety Electrical Safety Chemical Safety H2S Safety Construction Safety Pipeline Safety Document and Data Safety

Process Safety-Key Ingredients



Basic Process Design scrutinized through Risk Assessment Tools/studies.

Equipment selection as per Hazardous Area Classification.

Process Interlocks with logics.

Preventive Maintenance.

All PSVs with closed discharge to the flare.

Process Safety-Key Ingredients



Fixed Hydrocarbon and Hydrogen SulphideDetectors at strategic locations.

Continuous Flare monitoring.

Emergency Shut Down Systems (ESDS)

Fire Proofing of all process vessels and supporting structures.

Fire Detection and Fighting System

Process Safety – Other Measures



Availability of Standard Operating Procedures

(SOPs).

Availability of Material Safety Data Sheets

(MSDS) for each hazardous chemical.

Availability of safe Work Procedures for each

critical job.

Management of Change Procedures.

Pre-start up safety Reviews.

Availability of Plant specific HSE information.

Process Safety – Other Measures



Availability of Disaster Management Plan.

Accident / Incident reporting, investigation &

analysis system.

HSE Auditing system.

HSE Training.

Occupational Health & Hygiene.

Personal Protecting Equipments.

Safety Critical System Inhibition (Bypass)


All process areas are equipped with primary andsecondary Critical safety systems.

The function of the Safety Critical System is toprevent loss of containment of hydrocarbon by controlof pressure, temperature, level, etc.

These Safety critical systems are interlocked andfunction automatically.

These systems are sometimes inhibited for thepurpose of maintenance activities which can triggertheir inadvertent operation.

Objective should be to define safeguards andoperations that are necessary if one wishes to inhibitany of the Safety Critical Systems.

Safety System in LPG Storage


LPG Storage

& Handling

Level, Pressure

& Temp. switches

Vapour balance

system

Fire-proof

structures

Insulation

Level Alarms

at 60% & 80 %

Drenchers

PSVs & TSVs

with closed

discharge

Automatic

Sprinkler

System with

Fusible Plugs

Fixed Gas Detection

System

Filling restricted

upto 80%

Double Mechanical

Seals in Pumps

Safety System for Loading area


Fixed Gas Detection

System

Product Loading

Operations

Sick Tanker

Unloading Bay

Emergency

Shut- off System

Non-sparking

tools

Computerised

Weigh bridge

CCE approved

Spark arrester in

tankers

Batch

Controlled

Loading System

Sprinkler

System

Fire Alarms &

Explosion proof

telephones

Earthing

Interlock

Hazardous Area


Hazardous area

may be defined as an area in which an explosiveatmosphere is, or may be expected to be, present inquantities such as to require special precautions forthe construction, installation and use of electricalapparatus.

Area classification

is a method of analysing and classifying theenvironment where explosive gas atmospheres mayoccur so as to facilitate the proper selection andinstallation of apparatus to be used safely in thatenvironment, taking into account gas groups andtemperature classes.

Hazardous Area – reasons for classification


The main reasons for classifying the installation intohazardous areas are as follows:

To help in selection of suitable equipments.

To ensure that sources of ignition are segregated fromsources of flammable gas or vapour.

To assist in the appropriate location of air inlets and outletsfor ventilation systems or combustion equipment.

To define the extent of flammable gas level from vents

To ensure that life saving appliances, radioactive storesand emergency control points are located in non-hazardous areas.

To determine the location of flammable gas detectors

To determine the maximum allowable surface temperaturefor particular areas.

To assist in the location of escape routes.

Hazardous Area Classification


There are three zones for gases and vapours underBritish system:

Zone-0 : Flammable atmosphere highly likely to be present -

may be present for long periods or evencontinuously

Zone-1 : Flammable atmosphere possible but unlikely to be

present for long periods.

Zone-2 : Flammable atmosphere unlikely to be present

except for short periods of time - typically as a resultof a process fault condition.

Recommended Electrical Equipment in Various Zones


Zone 0:

Use of any electrical equipment including lighting fittings is prohibited under

law.

Zone 1:

All motors, transformers and switch gears to be of flame proof types (refer IS

2148 - 1968).

All light fittings to be of flame proof type (ref : IS 2148 – 1968 and IS - 2200 -

1976).

Telephones and other communication equipment should be of intrinsically safe

type.

Zone 2:

All motors, transformers and switch gears to be of either flameproof or

increased safety or pressurized type.

All light fittings should be of flame proof type.

Telephone and other communication equipment should be of intrinsically safe

type.

Gas Testing & Detection


Gas Testing An integral part of establishing a Safe System of

Work.

Testing of Oxygen, toxic & flammable gases to confirm the working environment to be safe.

Gas Detection An integral part of the Process to detect the

presence of any gas, vapour in operational area.

Fixed gas detectors at vantage points (ex- flanges, pump seals) to detect and raise alarms about any leakages.

Safe Gas Limits


The Lower Explosive Limit (LEL) - the smallest

amount of gas that will support a self propagating

flame when mixed with air (or oxygen) and

ignited.

The Upper Explosive Limit (UEL) – the highest

concentration of a gas in atmosphere, which

results in a combustible mixture.

The region between LEL and UEL is referred to

as the Flammable or Explosive Range.

Typical LEL values


Typical LEL values of gases

Hydrogen H2 100% LEL = 4.0 % by volume in air.

Methane C2H4 100% LEL = 5.0 % by volume in air.

Ethane C2H6 100% LEL = 3.0 % by volume in air.

Ethylene C2H4 100% LEL = 2.7 % by volume in air.

Pentane C5H12 100% LEL = 1.5 % by volume in air.

Propane C3H8 100% LEL = 2.2 % by volume in air.

Typical setting for the alarm circuits is 20% for low alarm and 40% for

the high alarm.

As the temperature increases, the LEL decreases and hence explosion

hazard increases.

H2S Handling


H2S poses a potential risk in petroleum refining

particularly Natural Gas Processing. Deadly, Extremely Toxic Gas

Colourless

Highly Soluble in Water, Crude Oil or Petroleum Fractions.

Heavier than air-tends to settle in low lying areas

Burns with a Blue flame, producing SO2,which is also a Toxic Gas.

Odour of rotten eggs only in very low concentrations (<5ppm, rapidly

deadens sense of smell

Threshold Limit Value (TLV) – 5 ppm for 8 hours

Short Term Exposure Limit (STEL) (Safe for 15 minutes) – 10 ppm

Loss of consciousness , death in 30 minutes – 500 to 700 ppm

Immediate unconsciousness, death in few minutes - >1000 ppm

Highly Corrosive and can cause extreme metal embrittlement.


Operators need to be regularly trained and updated on the risks involved.

Proper PPEs to be provided.

Buddy System.

Safe Working Procedures.

Operating areas to be properly ventilated.

Wind direction indicators at prominent places.

Fixed Gas detectors at likely places of leakages.

Portable gas detectors.

Confined area entry only after proper gas testing and availability of PPEs.

H2S Handling

Chemical Safety


For the purpose of chemical safety management,various raw materials (sour natural gas and sourcondensate) and products including the value addedproducts must be considered.

In addition, for processing of the sour gas and othervalue added products, different types of utilitychemicals are also used.

Material safety Data Sheets (MSDS) for all thechemicals must be available. MSDS provides all therelevant information about a particular chemical thathelps the users to safely handle such chemicals.

PPE-Personal Protective Equipments



PPE is defined as „all equipment (including

clothing affording protection against the

weather) which is intended to be worn or held

by a person at work and which protects him

against one or more risks to his health or

safety‟.

eg. safety helmets, gloves, eye protection, high

visibility clothing, safety footwear and safety

harnesses.HSE - A short guide to the Personal Protective Equipment at Work Regulations 1992

Maintenance Strategies


Plant Turnaround (once in four years)

Equipment Maintenance Pro-Active Maintenance

Predictive Maintenance (Based on Condition Monitoring)

Preventive maintenance (Periodic Checks, Safety Checks)

Overhauling (OEM recommended & periodic)

Reactive/Breakdown Maintenance.

Work Permit System

Spare Parts Management

Failure Analysis

Maintenance History

Statutory Inspections (Boilers, Cranes, etc.)

Maintenance Classification


Maintenance Classification

Mechanical

Electrical

Instrument / Electronics

Equipment Classification Rotary Pumps, Engines, Compressors, Fans, etc.

Semi-Rotary Safety valves, Control valves, Shutdown

valves, etc.

Static Pressure vessels, Heat Exchangers,

Columns, Furnaces, Boilers, Flare

stacks, Piping, etc.

Safety Measures during Maintenance


De-pressurize and purge the equipment free of

hydrocarbons.

Isolate the equipment electrically by taking out

the circuit breaker out of its switchgear in sub-

station.

Positive blinding of all process and associated

piping is necessary if the equipment is to be

under maintenance for longer period or man

entry is required.

Safety Measures during Maintenance


Before man entry, the vessel should be

purged of hydrocarbons, sufficient provision

for air supply should be made.

Hot jobs inside the battery limits should be

avoided as far as possible and if necessary,

maximum precaution should be taken in

consultation with safety department.

Maintenance- Work Permit System


The basic purpose of the work permit system is to

ensure that work is carried out in the safest

possible manner to prevent injuries to personnel,

protect property from damage, avoid fire etc.

Based on the nature of work to be performed, the

following three types of work permits shall be

used. Cold Work Permit

Hot Work / Entry to Confined Space Permit (Composite

Permit)

Electrical isolation and Energisation permit

Fire Detection & Fighting Systems


Fire &

Emergency

Management

Periodic Checking Of

Fire & Safety

Equipment

Disaster

Management Plan

Mock Drills

24 hrs Manned Fire

Stations

Mutual -

Aid

Fire OrderProcess

Emergency Manual

Life Saving

Equipment

Fire Training

Fire Safety Appliances


Fire Pumps

with Jockey

Fire Tenders

Hollow Jet

Monitors

DCP

Trolleys

Sprinkler

Systems

Halon

FloodingFIXED MOBILE

Drenchers

Fire Header

Network

Raw Water

Storage

CO2

Flooding

Fire

Extinguishers

Foam

Pourers Fire Water

Storage

Appliances

Fire Safety

Management of Change



Why Change?

Operational flexibility.

Energy conservation.

Technological up-gradation.

Capacity augmentation.

Improvement of product specification.

Compliance with Statutory rules and regulations

concerning to safety, health & environment.

Hazards connected with any change are to be identified

and controlled efficiently through an appropriate hazard

assessment and mitigation system.

Management of Change



The following are to be properly approved, documented and

conveyed to all

Equipment changes like addition, alteration or removal of an

equipment or a part of it from the plant.

Modifications in piping system and process equipment.

Change in normal operating procedure, start-up, shutdown

and emergency handling procedures.

Change in instrument which may include operating and

control parameters.

Accident Investigation & Reporting


Accident is an undesired event that results in harm topeople, damage to property and/or loss to process.

"All Accidents and Incidents must be reported".

ACCIDENT /INCIDENT INVESTIGATION

Investigation of accidents and incidents involves themethodical examination of an undesired event that didor could result in physical harm to people, damage toproperty or loss to process. Investigation activities aredirected toward defining the facts and circumstancesrelated to the event, determining the causes anddeveloping remedial actions to control the risks.

Accident Investigation & Reporting


OBJECTIVES OF ACCIDENT INVESTIGATION

To arrive at an accurate statement of what really happened.

To determine the basic causes responsible for the

happening. Fixing responsibility will not be the objective of the

investigation.

Cost estimation for every accident/incident is to be made and

reported based on the information from the field.

Deciding the likelihood of recurrence and the potential for major

loss for the accident or incident.

The basic aim of investigation is to have a means to avoid its

recurrence.

To have a control measure to minimise or eliminate the problem.

HSE Audits


Audit is a systematic, independent and documented processfor obtaining "audit evidence" and evaluating it objectively todetermine the extent to which "audit criteria" are fulfilled.

Audits are conducted at planned intervals to:

Determine whether the HSE management system conforms toplanned arrangements including the requirements of ISO9001, ISO 14001, OHSAS 18001 standards, legal & otherrequirements, which a Company subscribes to.

To review and evaluate the performance and effectiveness ofQHSE management system; and

To provide information on the results of audits to management

HSE Audits


Types of audits:

Internal audits:

QHSE internal audits

Loss control tours & inspections

Internal audits through Sectoral HSE

Special internal audits like Hygiene audits, ETP audit, Fire audit, pipeline audit etc.

External audits

OISD

Deptt. of Industrial safety & Health (safety inspection)

State Pollution control boards

Third party

HSE Audits


Audit Procedure

initiating the audit

conducting document review and

preparing for the audit

conducting the audit

preparing and communicating the audit

report

completing the audit and conducting audit

follow-up

Training


Training is the best tool for

Increasing Safety Consciousness

Keeping the work-force abreast with the latestdevelopments.

Disseminating the reports of accidentinvestigations and corrective measures.

Major tool in the Management of Change.

Accordingly, training need of each employee needsto be identified and training directed towardsknowledge and skill improvement.

Training Need Analysis


Training Need Analysis

Accident

Analysis

Disaster Management


Disaster

Disaster is a sudden calamitous event, bringing

great damage, loss or destruction of men,

machine and material.

Disaster Management Plan

It is the most comprehensive type of plan which

states who does what, when and how –before,

during and after a disaster.



Purpose Of The Plan

To visualize the possible emergency scenarios that

are likely to occur.

To evolve a preplanned methodology of carrying out

various emergency-combating plans.

To lay down clear-cut procedures to rescue and

rehabilitation.

To prepare detailed responses for each type of

emergency.



Purpose Of The Plan

To train the operating personnel, by means of

exercises and drills, so as to make them well

acquainted with the response actions such that

these can be performed with the greatest efficiency

in minimum possible time.

To minimize the damage to the environment during

emergency.

To provide relief and rehabilitation to the affected

personnel.



Ingredients of a typical DMP

Disaster Scenarios

Requirements of Mock Drills

Guidelines on Conducting Mock-exercises

Siren System

Assembly Point & Wind Socks Locations

Some Emergency Actions

Roles & Responsibility of Emergency Coordinator

Bomb Threat Plan

Rescue and Evacuation Planning

All Clear & Re-entry procedures

Local Authorities

Off Site Disaster Plan

Guidelines for Updating The Plan

Conclusion


Safe Operations Requires

Risk Assessment and follow-up

Correct selection of equipments as per the hazardous area classification

Laid down procedures for

Operations and Maintenance

Toxic gases and Chemical handling

Storage and dispatch

Personnel Safety

Environment Protection

Gas Testing and Detection

Fire Detection and fighting systems

Accident Investigations and Reporting

Inspections and Audits

Training

Management of change


Safety is everybody’s job

THANK YOU

Documents

2_B RAJEEV