oleum and sulfuric acid pipeline safety...

11

OLEUM AND SULFURIC ACID OLEUM AND SULFURIC ACID PIPELINE SAFETY PIPELINE SAFETY

MAINTENANCEMAINTENANCEMAINTENANCEMAINTENANCE

PRESENTED BY:PRESENTED BY:

•• EmarEmar LeãoLeão

R d iR d i MM

PRESENTED BY:PRESENTED BY:

•• RodrigoRodrigo MaçonMaçon

22

PARANAPANEMAPARANAPANEMA CARAÍBACARAÍBAPARANAPANEMA PARANAPANEMA -- CARAÍBACARAÍBATheThe CaraibaCaraiba Metais’Metais’ sulfuricsulfuric acidacidfacilityfacility waswas designeddesigned byby NatronNatronEngenhariaEngenharia withwith aa initialinitial capacitycapacity Caraíba

ofof 11..870870 t/dayt/day..

TheThe mainmain porpouseporpouse ofof thethe facilityfacility isisTheThe mainmain porpouseporpouse ofof thethe facilityfacility isistoto treattreat thethe gasesgases fromfrom thethe coppercopperfunditionfundition..

19821982:: HH22SOSO44 facilityfacility startstart--upup..

ActualActual productionproduction capacitycapacity::22 475475 t/dayt/day afterafter debottleneckingdebottlenecking22..475475 t/dayt/day afterafter debottleneckingdebottlenecking..

33

BackgroundBackgroundBackgroundBackground

1.1. TheThe pipelinepipeline isis inin operationoperation sincesince 19931993 andand occurredoccurred oneoneoleumoleum spillagespillage happenedhappened inin 19981998 oneone chemicalchemical burnburnoleumoleum spillagespillage happenedhappened inin 19981998,, oneone chemicalchemical burnburnaccidentaccident andand oneone acidacid spillagespillage toto thethe groundground inin 20032003,, duringduringpreventivepreventive maintenancemaintenance..pp

2.2. AfterAfter 20032003,, moremore thanthan 3030 preventivepreventive interventionsinterventions insideinsideandand outsideoutside CaraibaCaraiba withoutwithout accidentsaccidentsandand outsideoutside CaraibaCaraiba withoutwithout accidentsaccidents..

•• TwoTwo generalgeneral paintingpainting andand 1515 pipelinepipeline sectionssections paintingspaintings;;

•• FiveFive pipelinepipeline sectionssections replacementsreplacements // externalexternal areaarea valvevalverelocationrelocation;;

•• EightEight pipelinepipeline sectionssections insideinside CaraibaCaraiba;;

•• ThicknessThickness measurementmeasurement onon semestersemester basisbasis andand quarterlyquarterlyThicknessThickness measurementmeasurement onon semestersemester basisbasis andand quarterlyquarterlyvegetationvegetation cleannesscleanness..

44

System characteristics:System characteristics: 11-- 12,000 meter long pipelines12,000 meter long pipelines

55

System characteristicsSystem characteristics:: 22-- Height differences up to 30 mHeight 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

66

System characteristics:System characteristics: 33-- places with difficult access (height and vegetationplaces with difficult access (height and vegetation))

77

System characteristics:System characteristics: 44-- places with difficult accessplaces with difficult access (Pipe way inside complex)(Pipe way inside complex)

88

MAINMAIN OBJECTIVEOBJECTIVE:: PipelinePipeline maintenancemaintenance jobsjobs

MAINMAIN STAGESSTAGES::

pp jjwithoutwithout accidentsaccidents andand environmentalenvironmental eventsevents..

MAINMAIN STAGESSTAGES::

•• JobJob planningplanning::

•• CaraibaCaraiba operation,operation, BraskemBraskem andand clientsclients selling,selling,maintenance,maintenance, safetysafety andand environmentalenvironmental areasareas hashas toto workworkt tht thtogethertogether;;

•• ClientClient autonomyautonomy lessless thanthan 0303 daysdays;;

•• PolicePolice andand environmentalenvironmental agencyagency officialofficial noticenotice..

•• OperationalOperational procedureprocedure::•• OperationalOperational procedureprocedure::

•• PipelinePipeline drainagedrainage andand startstart--upup proceduresprocedures;;

•• TaskTask riskrisk analysisanalysis..

99

Operational procedure (resumed):Operational procedure (resumed):Operational procedure (resumed):Operational procedure (resumed):

1.1. AcidAcid transfertransfer interruptioninterruption;;

22 Pi liPi li itit d id i tt tt t kt k dd itit2.2. PipelinePipeline gravitygravity draindrain toto storagestorage tankstanks andand nitrogennitrogen purgepurge;;

3.3. DepressurizeDepressurize andand isolateisolate thethe pipelinepipeline sectionsection;;

4.4. OpenOpen drainsdrains andand collectcollect thethe residualresidual productproduct withwith vacuumvacuumtrucktruck;;

5.5. MaintenanceMaintenance jobjob executionexecution andand shutshut downdown thethe pipelinepipelinesectionsection;;;;

6.6. PipelinePipeline startstart--upup andand confirmconfirm thatthat therethere areare nono leaksleaks;;

hh i lii li ii dd ii ff idid ff7.7. TheThe pipelinepipeline isis readyready againagain forfor acidacid transfertransfer..

1010

Labels and locksLabels and locksLabels Labels

isolating the client sideisolating the client sideisolating Caraíba sideisolating Caraíba side

1111

Non destructive testingNon destructive testing Non destructive testingNon destructive testing

Non destructive testingNon destructive testing Non destructive testingNon destructive testing

New screws and gasketNew screws and gasket

1212

Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:

DangersDangers::

11 SulfuricSulfuric acidacid 9898%% andand oleumoleum 2828%%;;1.1. SulfuricSulfuric acidacid 9898%% andand oleumoleum 2828%%;;

RisksRisks::

1.1. SkinSkin and/orand/or eyeseyes chemicalchemical burnsburns;;2.2. ProductProduct spillagespillage;;p gp g3.3. SOSO33 inhalationinhalation;;

RisksRisks MitigationMitigation (next(next slide)slide)::

1313

Skin, eyes and respiratory protectionSkin, eyes and respiratory protection

1414

Skin, eyes and respiratory protectionSkin, eyes and respiratory protection

1515

Emergency drills:Emergency drills: foam over oleumfoam over oleum

1616

Collecting trayCollecting tray Sodium carbonateSodium carbonate

Vacuum truckVacuum truck Suction in progressSuction in progress

1717

DIPHOTERINEDIPHOTERINE

PLASTIC BAG PLASTIC BAG

500 mL500 mLBOARD EYE WASH BOARD EYE WASH

500 mL500 mL

PORTABLE DIPHOTERINE PORTABLE DIPHOTERINE

5.000 mL5.000 mL

EYE WASHEYE WASH

100 mL100 mL

MINI PD MINI PD

200 mL200 mL

MICRO PDMICRO PD

100 mL100 mL

1818

30 min after the accident30 min after the accident30 min after the accident30 min after the accident

After diphoterine useAfter diphoterine use

After 6 hoursAfter 6 hours Next morningNext morning

1919

04 years latter04 years latter

04 years latter04 years latter

2020

Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:

DangersDangers::

22 FlammableFlammable productsproducts and/orand/or heatedheated productsproducts inin nearbynearby2.2. FlammableFlammable productsproducts and/orand/or heatedheated productsproducts inin nearbynearbypipelinespipelines;;

Ri kRi kRisksRisks::

1.1. ExplosionExplosion;;2.2. HeatHeat burnsburns;;

RisksRisks MitigationMitigation (next(next slide)slide)::

2121

Flammable atmosphere testingFlammable atmosphere testing HutsHuts

antianti--heating hutheating hut antianti--heating clothheating cloth

2222

Thermal heat clothesThermal heat clothes Thermal heat clothsThermal heat cloths

Thermal heat clothsThermal heat clothsThermal heat clothesThermal heat clothes

2323

Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:

DangersDangers::

33 ConfinedConfined areaarea andand poisonouspoisonous animalsanimals;;3.3. ConfinedConfined areaarea andand poisonouspoisonous animalsanimals;;

RisksRisks::

•• AsphyxiaAsphyxia and/orand/or poisoningpoisoning;;

•• PoisonousPoisonous animalsanimals stingsstings;;PoisonousPoisonous animalsanimals stingsstings;;

RisksRisks MitigationMitigation (next(next slide)slide)::

2424

Eg: confined area and/or animals habitatEg: confined area and/or animals habitatss BeesBees SnakesSnakes

Mitigation: cleaning, leg protection and boots Mitigation: cleaning, leg protection and boots

Mitigation: oxygen measurements; air; exhaust, laddersMitigation: oxygen measurements; air; exhaust, ladders

2525

Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:

DangersDangers::

44 WeatherWeather;;4.4. WeatherWeather;;

RisksRisks::

•• DrownDrown ee suddensudden illnessillness;;

RiskRisk MitigationMitigation (next(next slide)slide)::

2626

Normal condition Normal condition –– ducts in both sidesducts in both sides Flooded location Flooded location –– vapor formationvapor formation

Normal condition Normal condition –– duct depthduct depth Flooded location Flooded location –– vapor formationvapor formation

2727

Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:Task Risk Analysis:

DangersDangers::

55 RoadRoad proximityproximity weightweight liftinglifting machinerymachinery;;5.5. RoadRoad proximity,proximity, weightweight liftinglifting machinerymachinery;;

RisksRisks::

•• VehicleVehicle crashes,crashes, runningrunning oversovers;;

•• EquipmentEquipment fallfall;;q pq p ;;

RiskRisk MitigationMitigation (next(next slide)slide)::

2828

Automobile crashesAutomobile crashes Pipe section liftingPipe section liftingp gp g

Traffic signs; blockage road and police helpTraffic signs; blockage road and police help Traffic signs; Industrial complex vigilanceTraffic signs; Industrial complex vigilance

2929

Pipe ends are isolated to avoid acid dropletsPipe ends are isolated to avoid acid droplets

Droplets eventsDroplets events

3030

Cramps to avoid leakages or pipeline drainageCramps to avoid leakages or pipeline drainage

Cold connection cramp Cold connection cramp Pipeline leaks crampsPipeline leaks cramps

Hot pipeline drainHot pipeline drain Stanch leakages near the drainStanch leakages near the drain Drain containmentDrain containment

3131

Example: Job inside Caraiba area Example: Job inside Caraiba area

3232

Resources are always availableResources are always available

Lifting truckLifting truck Emergency truckEmergency truck

Vaccum truckVaccum truck Emergency KITEmergency KIT

3333

Fire response team and operators are trained in several emergency situationsFire response team and operators are trained in several emergency situations

3434

THETHETHE THE ENDENDENDEND