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By:
Gerard B. Hawkins
Managing Director, CEO
 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
 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?
 Gas leaks
◦ Invisible H2 flames
◦ Personal gas monitors
 Site maintenance
◦ Energy isolation methods (electrical, pressure)
◦ Locked! “LOTO”
 Working at height
◦ Tie off policy
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.
1. Column lift
2. Welding methanol column
3. Instrument maintenance
4. Chimney plume and CO leak
5. Grating and guard rails
6. Scaffold condemned
7. Steam valve removal
8. Utility boiler explosion
9. Hydrogen leak
10. Pneumatic testing
Safety Officers
nearby- no action
Debris on temporary
scaffold platform
Sideways crushing
incidents-
If it moves, let it go.
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!
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
LPOxo plant Ammonia plant
Weather pattern
Heavies
CO
“Sit in conference room with the A/C on!”
Gratings and railings move during
construction activities-
there one minute, gone the next!!
Hold on to them!
Site Safety Awareness
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.
S.E. Asia
Site Safety Awareness
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
Site Safety Awareness
Site Safety Awareness
Status of valves after accident
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.
High pressure hydrogen,
160# pipe rating
Pressure gauge
Plate hid contact during
normal inspection
Site Safety Awareness
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.
Site Safety Awareness
Site Safety Awareness
Site Safety Awareness
Site Safety Awareness
• Putting hand over pipe to see if flow had started
• Welding near syngas leak
• Operating machinery without guards
• Arc eye
Site Safety Awareness
Site Safety Awareness
Site Safety Awareness
Site Safety Awareness

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Site Safety Awareness

  • 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.
  • 6. 1. Column lift 2. Welding methanol column 3. Instrument maintenance 4. Chimney plume and CO leak 5. Grating and guard rails 6. Scaffold condemned 7. Steam valve removal 8. Utility boiler explosion 9. Hydrogen leak 10. Pneumatic testing
  • 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
  • 19. Status of valves after accident
  • 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.
  • 21. High pressure hydrogen, 160# pipe rating Pressure gauge Plate hid contact during normal inspection
  • 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