1 oleum and sulfuric acid pipeline safety maintenance presented by

1
OLEUM AND SULFURIC ACID
PIPELINE SAFETY
MAINTENANCE
PRESENTED BY:
•
Emar Leão
•
R d i Maçon
Rodrigo
M
2
PARANAPANEMA - CARAÍBA
The Caraiba Metais’ sulfuric acid
facility was designed by Natron
Engenharia with a initial capacity
of 1.870 t/day.
t/day.
The main porpouse of the facility is
to treat the gases from the copper
fundition..
fundition
1982:: H2SO
1982
SO44 facility startstart-up
up..
Actual production capacity
capacity::
2.475 t/day after debottlenecking
debottlenecking..
Caraíba
3
Background
1. The pipeline is in operation since 1993 and occurred one
oleum spillage happened in 1998
1998,, one chemical burn
accident and one acid spillage to the ground in 2003,
2003, during
preventive maintenance.
p
maintenance.
2. After 2003,
2003, more than 30 preventive interventions inside
and outside Caraiba without accidents.
accidents.
•
Two general painting and 15 pipeline sections paintings;
paintings;
•
Five pipeline sections replacements / external area valve
relocation;;
relocation
•
Eight pipeline sections inside Caraiba;
Caraiba;
•
Thickness measurement on semester basis and quarterly
vegetation cleanness.
cleanness.
4
System characteristics: 1- 12,000 meter long pipelines
5
System characteristics: 2- Height differences up to 30 m
1.
PROQUIGEL
2.
BRASKEM CPL
3.
PUMPING STATION CIBRAFERTIL
4.
CETREL ACCESS
5.
COPPER PUMPING STATION
6.
CARAIBA METAIS
7.
PUMPING STATION CARAIBA
6
System characteristics: 3- places with difficult access (height and vegetation
vegetation))
7
System characteristics: 4- places with difficult access (Pipe way inside complex)
8
MAIN OBJECTIVE
OBJECTIVE:: Pipeline
p
maintenance jjobs
without accidents and environmental events.
events.
MAIN STAGES
STAGES::
•
•
Job planning
planning::
•
Caraiba operation, Braskem and clients selling,
maintenance, safety and environmental areas has to work
t th ;
together;
together
•
Client autonomy less than 03 days;
days;
•
Police and environmental agency official notice.
notice.
Operational procedure:
procedure:
•
•
Pipeline drainage and start
start--up procedures;
procedures;
Task risk analysis.
analysis.
9
Operational procedure (resumed):
1. Acid transfer interruption
interruption;;
2 Pi
2.
Pipeline
li gravity
it drain
d i to
t storage
t
t k andd nitrogen
tanks
it
purge;;
purge
3. Depressurize and isolate the pipeline section;
section;
4. Open drains and collect the residual product with vacuum
truck;
truck;
5. Maintenance job execution and shut down the pipeline
section;
section;
6. Pipeline startstart-up and confirm that there are no leaks
leaks;;
7. The
h pipeline
i li is
i ready
d again
i for
f acid
id transfer.
transfer
f .
10
Labels
isolating Caraíba side
Labels and locks
isolating the client side
11
Non destructive testing
Non destructive testing
Non destructive testing
Non destructive testing
New screws and gasket
12
Task Risk Analysis:
Dangers::
Dangers
1 Sulfuric acid 98
1.
98%
% and oleum 28
28%
%;
Risks:
Risks:
1. Skin and/or eyes chemical burns
burns;;
2. Product spillage;
spillage
p g ;
3. SO3 inhalation
inhalation;;
Risks Mitigation (next slide):
slide):
13
Skin, eyes and respiratory protection
14
Skin, eyes and respiratory protection
15
Emergency drills: foam over oleum
16
Collecting tray
Sodium carbonate
Vacuum truck
Suction in progress
17
DIPHOTERINE
PLASTIC BAG
BOARD EYE WASH
500 mL
500 mL
PORTABLE DIPHOTERINE
5.000 mL
EYE WASH
MINI PD
MICRO PD
100 mL
200 mL
100 mL
18
30 min after the accident
After diphoterine use
After 6 hours
Next morning
19
04 years latter
04 years latter
20
Task Risk Analysis:
Dangers::
Dangers
2 Flammable products and/or heated products in nearby
2.
pipelines;;
pipelines
Ri
Risks:
Risks
k:
1. Explosion
Explosion;;
2. Heat burns
burns;;
Risks Mitigation (next slide):
slide):
21
Flammable atmosphere testing
anti--heating hut
anti
Huts
anti--heating cloth
anti
22
Thermal heat clothes
Thermal heat clothes
Thermal heat cloths
Thermal heat cloths
23
Task Risk Analysis:
Dangers::
Dangers
3 Confined area and poisonous animals
3.
animals;;
Risks:
Risks:
•
Asphyxia and/or poisoning
poisoning;;
•
Poisonous animals stings
stings;;
Risks Mitigation (next slide):
slide):
24
Eg: confined area and/or animals habitats
habitats
Bees
Snakes
Mitigation: cleaning, leg protection and boots
Mitigation: oxygen measurements; air; exhaust, ladders
25
Task Risk Analysis:
Dangers::
Dangers
4 Weather
4.
Weather;;
Risks:
Risks:
•
Drown e sudden illness
illness;;
Risk Mitigation (next slide):
slide):
26
Normal condition – ducts in both sides
Flooded location – vapor formation
Normal condition – duct depth
Flooded location – vapor formation
27
Task Risk Analysis:
Dangers::
Dangers
5 Road proximity,
5.
proximity weight lifting machinery;
machinery;
Risks:
Risks:
•
Vehicle crashes, running overs;
overs;
•
Equipment
q p
fall;
fall;
Risk Mitigation (next slide):
slide):
28
Automobile crashes
Traffic signs; blockage road and police help
Pipe
p section liftingg
Traffic signs; Industrial complex vigilance
29
Pipe ends are isolated to avoid acid droplets
Droplets events
30
Cramps to avoid leakages or pipeline drainage
Cold connection cramp
Hot pipeline drain
Pipeline leaks cramps
Stanch leakages near the drain
Drain containment
31
Example: Job inside Caraiba area
32
Resources are always available
Lifting truck
Emergency truck
Vaccum truck
Emergency KIT
33
Fire response team and operators are trained in several emergency situations
34
THE
END