Confined Space Entry
Hazardous Substances In Refineries
Hazards of Air and Oxygen
Hazards of Electricity and Static Electricity
Hazards of Nitrogen and Catalyst Handling
Hazards of Steam
Hazards of Trapped Pressure and Vacuum
Hazards of Water
Hotel Fire Safety
Liquid Hydrocarbon Tank Fires
Safe Handling of Light Ends
Safe Furnace and Boiler Firing
Safe Tank Farms and (Un)loading Operations
Safe Ups and Downs for Process Units
Control of Work
2. Confined Space Entry
Hazardous Substances In Refineries
Hazards of Air and Oxygen
Hazards of Electricity and Static Electricity
Hazards of Nitrogen and Catalyst Handling
Hazards of Steam
Hazards of Trapped Pressure and Vacuum
Hazards of Water
Hotel Fire Safety
Liquid Hydrocarbon Tank Fires
Safe Handling of Light Ends
Safe Furnace and Boiler Firing
Safe Tank Farms and (Un)loading Operations
Safe Ups and Downs for Process Units
Control of Work
3. Construction
◦ Crane lifts
◦ Trenches, overhead work, pits, scaffold
Steam blowing
◦ Roped off discharge
◦ Safety Officer?
◦ Noisy
Hydraulic testing
◦ Pneumatic for water sensitive areas
◦ Warnings
◦ Done after hours?
4. Gas leaks
◦ Invisible H2 flames
◦ Personal gas monitors
Site maintenance
◦ Energy isolation methods (electrical, pressure)
◦ Locked! “LOTO”
Working at height
◦ Tie off policy
5. CONFINED SPACE ENTRY
◦ Highly hazardous activity- multiple deaths.
Controlled by permit to work system
◦ Only valid for a certain time period
◦ Energy isolation
◦ Gas sampling (must be suitable for inert atmospheres?)
◦ Buddy system (count in, count out)
◦ Tied off
◦ Rescue equipment, BA sets nearby
Myths: “I promise you it’s ok”
◦ “No gases/N2 on site yet”
◦ “We were in there yesterday”
◦ “The valves are shut” X even if locked.
7. Safety Officers
nearby- no action
Debris on temporary
scaffold platform
Sideways crushing
incidents-
If it moves, let it go.
8. Steam leak from
t-t weld line
Welded onto live
column base,
under column
skirt (confined
space, fire?)
Venting steam,
but if column
dumped-
methanol!
First welder in
hospital, but
Second finished
job!
9. Instrument fitter
opened live level
bridal to
atmosphere.
Venting H2,
propylene and
alcohol.
5 bar, 100°C
Sent operator into
plume to close
isolation valve,
wearing cotton
overall (+ BA set).
Used fire hose to
‘fog’ area
LI
10. LPOxo plant Ammonia plant
Weather pattern
Heavies
CO
“Sit in conference room with the A/C on!”
11. Gratings and railings move during
construction activities-
there one minute, gone the next!!
Hold on to them!
13. Undid steam
valve flanges with
temperature and
pressure in line:
Too impatient to wait for line to cool
Spoke to operators: still opened line
but were cautious. Got away with it.
16. On 9 Dec at about 2:30am, three personnel were trying
to re-start the boiler when an explosion occurred inside
the furnace of the boiler.
The three personnel were badly injured with more than
50% 2nd degree burns on their bodies.
Two of them subsequently passed away later in the
hospital:
• Deceased 1 - Technician/ Male / 23 yrs old
• Deceased 2 - Technician/ Female / 21 yrs old
20. Gulf Coast Refinery 12:10:00 PM
During inspection of K-XYZ H2 make up compressor
it was discovered that a bolt resting on the 4th stage
suction piping had worn a hole in the pipe and
caused the release of make up hydrogen. The
compressor was taken off line.
23. Incident happened in a South American
Plant during a pneumatic test of the
tank associated piping.
A blind was NOT installed to isolate the
piping – only block valves were closed.
28. • Putting hand over pipe to see if flow had started
• Welding near syngas leak
• Operating machinery without guards
• Arc eye