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Evaluation and hazard identification process unit 3 operation of Gachsaran HAZOP technique

 

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The Dissertation of M.Sc. in Chemical Engineering Process

Design

Evaluation and hazard identification process unit
3 operation of Gachsaran HAZOP technique

 

ABSTRACT

 

Operation, crude oil, the raw material industries such as oil refineries and other parts extracted from the earth and sends to the factories and refineries, and general exploitation of oil industry is the starting point and feeder. The exploitation of oil and gas extraction and separation of H2S to control salt and oil products from some parts that must be prepared to be sent. During the actual operation of devices such as separation, public separation towers, pumps, turbines, heat exchangers and other system such that are used.

Growing public awareness and concern about the threat of industrial activities on human health and the environment, industrial management has been forced to increase their safety level. Risks and performance capabilities of the system (HAZOP) Hazard identification process is known as the most used method. The purpose of this study process to identify hazards and operational problems in order to reduce risks and improve system performance operation of unit 3 of Gachsaran. In this method, the 267 deveations has been reviewed by  the HAZOP team. 34 offer expertise derived from HAZOP results in order to reduce the likelihood of Consequences, which is generally related to the discussion process, is presented. Based on expertise, The main problem of the oil flow in the pipe inlet plant pressure because that is very high which is recommanded installing the discharge excess pressure safety valve to preventing from bursts and leakage from the flanges, which are causing environmental pullotion and fire. Process has offered undergraduate and HAZOP documentation is available in Appendix thesis.

 

Keywords : Separation of, Turbines, Gas Separation, Leaking flanges, Safety valve discharge

 

Index

 

Title                                                                                                                                Number

                                                                                                            

Chapter I:

Introduction to Safety

15

1-1- Introduction

16

1-2 – HSE History in Iran

17

1-3 – The general division of HSE

17

1-3-1 – HSE management system

18

1-3-2 – Engineering HSE

19

1-4 – the cost of lack of attention to safety issues and reduce the safety factor

19

1 -5 – safety impact on the organizations financial balance

19

1-6 – HSE Integrated Management System

19

1-6-1 – an audit

20

1-6-2 – Continual improvement

20

1-6-3 – Hazard

20

1-6-4 – identify risk

20

1-6-5 – Event

20

1-6-6 – non-compliance

20

1-6-7 – Risk

20

1-6-8 – risk tolerance

20

1-6-9 – risk assessment

21

1-7 – the most important elements of management systems

1-7-1 – leadership and commitment

21

1-7-2 – Policy and Strategic Goals

21

1-7-3 – organize, assign resources and documentation

22

1-7-4 – Risk management and assessment

22

1-7-5 – plan

23

1-7-6 – Implementation and Monitoring

23

1 -8 – to destroy or remove the risk

23

1-9 – limiting risk

23

1-10 – a variety of assessment methods and risk identification

24

1-11- Method HAZOP

24

1-12 – Introduction to Software

24

1-12-1-PHA Pro

25

1-12-2-FMEA

25

1-12-3-PHAST

1-13 – Conclusion

25

Chapter Two:

HAZOP recipes

26

2-1 – Introduction

27

2-2 – The risk of HAZOP studies

28

2-2-1 – identify the risks

29

2-2-2 – Qualitative Risk Analysis

29

2-2-3 – Quantitative Risk Analysis

29

2-2-4 – risk assessment

29

2-3 – risk analysis

29

2-4 – Statistical models and systematic methods for risk analysis

29

2-5 – decision-making process in risk management

30

2-6 – The optimal method for dealing with risks

30

2-7 – Follow-up results of previous steps in order to coordinate and exercise greater control

2-8 – Factors for Success in risk assessment

30

30

30

2-9 – the kind of results needed

31

2-10 – Parameters influencing the type of information for risk assessment studies

31

2-11 – characteristics of the units or processes

31

2-11-1 – type process

31

2-11-2 – Type of operation

31

2-11-3 – risks inherent in the process

32

2-12 – The two groups are required to perform risk assessments in the evaluation sessions

32

2-13 – decision making techniques for risk assessment

32

2-14 – The risk of HAZOP studies

33

2-14-1 – individual risk

33

2-14-2 – occupational risk

34

2-14-3 – Social Risk

34

2-15 – risk acceptance criteria

34

2-16 – Risk Matrix

34

2-17 – Definitions of Risk

35

2-18 – asymmetric risk matrix

36

2-19 – Analysis (HAZOP)

36

2-20 – The definitions in HAZOP

37

2-20-1 – nodes

37

2-20-2 – operational stage

37

2-20-3 – purpose or intent

37

2-20-4 – Guide word

37

2-20-5 – process parameters

37

2-20-6 – reasons

37

2-20-7 – Aftermath

38

2-20-8 – safety equipment

38

2-20-9 – recommendations or actions (Action / Recommendation)

38

2-21 – defining the objectives, issues and areas of study

39

2-22 – elected members of study team

39

2-23 – providing the necessary information for HAZOP studies

40

2-24 – planning meetings, HAZOP team

40

2-25 – Poor problem-solving tasks to minimize the group leader

40

2-26 – Methods of Reporting Results

41

2-27 – Conclusion

41

Chapter Three:

Overall understanding of the operation unit 3

of Gachsaran

42

3-1 – Introduction

43

3-2 – Utilities

44

3-3 – oil production

44

3-4 – production and gas injection

45

3-5 – Gachsaran facility operation unit 4 is divided

3-5-1-1 – Part I (separation)

45

3-5-1-2 – causes separation of application equipment

45

3-5-1-4 – Instrumentation and control devices installed on the separator

46

3-5-1-5 – mechanical equipment within the separator

47

3-5-1-5-1 – trays or misleading (DISH DEFLECTOR)

47

3-5-1-5-2 – bed sheets and direct elimination of the flow

48

3-5-1-5-3 – where large fluid

48

3-5-1-5-4 – horizontal separator pages

48

3-5-1-5-5-MIST EXTRACTOR

48

3-5-1-5-6 – Vortex breakers

49

3-5-2 – Part II (Instrumentation and Control products)

3-5-2-1 – Pressure gauge

49

3-5-2-2 – indicate the liquid level (LEVEL GAUGE)

3-5-2-3 – Pressure  reducing  agents

3-5-2-4 – pressure control

3-5-2-5 – LEVEL CONTROLLER

3-5-2-6 – control valves

3-5-3 – Part III

3-5-3-1 – Wellhead separators

3-5-3-2 – provide necessary pressure in the unit and prevention of pressure drop in pipe flow

3-5-3-3 – pump strength

3-5-3-4 – duplex filter

3-5-3-5 – Horizontal Pump

3-5-3-6 – device controller level too

3-5-3-7 – pressure in the pressure control device is too

3-5-3-8 – separator pressure control device

3-5-4 – Part Four

3-5-4-1 – (air system)

3-6 – Design and operation considerations Gachsaran unit

3-6-1 – Pumps

3-7 – Conclusion

Chapter Four:

Conclusion on HAZOP Studies Unit

3 operation Gachsaran

4-1 – Introduction

4-2 – recipe suggestions and recommendations

4-3 – General Discussion

4-4 – hardware suggestions and recommendations

4-5- The risk assessment method, WILLIAM FINE

4-6 – Matrix of risk and risk acceptance criteria

4-7 – as described in Table A-7 Node 4

4-7-1 – Turbine

4-7-2 – Types of turbines

4-7-3 – Fluid used in turbines

4-7-4 – Oil and gas turbines used in

4-7-4-1 – steam turbines

4-7-4-2 – Gas Turbine

4-8 – History of Gas Turbine

4-9 – How do gas turbines work

4-10 – In a special category of gas turbines can be classified in two categories

4-11 – The advantages of gas turbine

4-12 – disadvantages of gas turbine

4-13 – Ordering components of gas turbines (gas turbine layouts)

4-14 – the effects of turbine inlet temperature and pressure

4-15 – re-warming gases in the turbine

4-16 – Theory of processes in gas turbine to increase power and efficiency

4-17 – Gas Turbine unit Gachsaran

4-18 – The unit offers Gachsaran

4-18-1 – Node: 1; Deviation high pressure

4-18-2 – Node: 1; Deviation low pressure

4-18-3 – Node: 2; Deviation high-level liquid

4-18-4 – Node: 2; Deviation low level liquid

4-18-5 – Node: 2; Deviation high pressure

4-18-6 – Node: 3; Deviation high level

4-18-7 – Node: 4; Deviation low pressure

4-18-8 – Node: 4; Deviation high pressure fuel turbine inlet

4-18-9 – Node: 4; Deviation low pressure fuel turbine inlet

4-18-10 – Node: 6; Deviation high corrosion

4-19 – Conclusion

References

Attachments

Attachments: (Qualifications HAZOP)

 

 

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Table index

Number

32

33

35

35

35

38

40

60

60

61

67

74

75

76

79

86

90

93

100

103

Title

 

Table 2-1 – Comparison of the application of HAZOP Study, What-If & Checklist in different processes [6]

Table 2-2 – Risk assessment and method names and their symbol [6]

Table 2-3 – Definition of quality severely for the damage to humans [7]

Table 2-4 – The definition of quality [7]

Table 2-5 – Risk acceptance criteria [7]

Table 2-6 – AdWords Help using HAZOP [7]

Table 2-7 – Software HAZOP[7]

Table 4-1 Classification of risk or potential risk factors in ways detrimental WILLIAM FINE

Table 4-2 classifies severity of risk in WILLIAM FINE

Table 4-3 Risk matrix

Table 4-4 – Specification turbine operation Gachsaran

Table A -1. HAZOP team members listed

Table A – 2. List nodes in HAZOP studies

Table A- 3 lists the deviations in a HAZOP studies

Table A-4 nodes 1 unit of feed input

Table A-5- breakdown of the two favored

Table A-6 nodes separating three tanks

Table A-7 to strengthen the four pumps and turbines

Table A-8 nodes, five tanks of liquid turbine fuel consuming

Table A-9 the fourth stage 6 exhaust

 

 

 

 

 

 

 

 

Figure index

Number

53

 

Title

Figure 3-1 P & ID unit operation Gachsaran 3

 

 

 

 

 

 

 

 

 

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