chevron refinery pipe rupture
TRANSCRIPT
![Page 1: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/1.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 1/49
CSB Investigation:
Chevron Refinery Pipe Rupture and Fire
Richmond, California
Southern California Society For Risk Analysis
26th Annual Meeting
May 30, 2013
![Page 2: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/2.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 2/49
Chevron Refinery Pipe Rupture and FireRichmond, California
Background
Incident Review
Sulfidation Corrosion
Review of Findings and Recommendations
2
![Page 3: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/3.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 3/49
3
Chevron Richmond Refinery
![Page 4: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/4.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 4/49
Atmospheric
Crude Column
8-inch
“ 4-sidecut” line
Line Constructed
of Carbon Steel
Process Fluid is
Light Gas Oil
P = 55 psigT = 640 ⁰F
4
![Page 5: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/5.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 5/49
5
![Page 6: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/6.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 6/49
6
![Page 7: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/7.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 7/49
7
![Page 8: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/8.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 8/49
8
![Page 9: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/9.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 9/49
9
![Page 10: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/10.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 10/49
10
![Page 11: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/11.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 11/49
11
![Page 12: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/12.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 12/49
12
![Page 13: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/13.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 13/49
13
![Page 14: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/14.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 14/49
14
![Page 15: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/15.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 15/49
15
![Page 16: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/16.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 16/49
16
![Page 17: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/17.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 17/49
17
![Page 18: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/18.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 18/49
18
![Page 19: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/19.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 19/49
19
![Page 20: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/20.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 20/49
20
![Page 21: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/21.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 21/49
21
![Page 22: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/22.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 22/49
22
![Page 23: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/23.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 23/49
23
![Page 24: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/24.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 24/49
ccuMechanics of Sulfidation Corrosion
Occurs in high temperature process fluidSulfur Compounds React with Iron Contained in Steel
24
![Page 25: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/25.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 25/49
Sulfidation Rates of Various Alloys
25Curves can be found in API RP 939-C
![Page 26: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/26.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 26/49
Carbon Steel Corrosion Rate Variability
26Graph from API RP 939-C
![Page 27: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/27.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 27/49
Low-SiliconCarbon Steel
>.1% Silicon
Carbon Steel9-Chrome Stainless Steel
INHERENTLY SAFER
90 % Wall Loss 65% Wall Loss 9% Wall Loss < 1% Wall Loss
Chevron 4-sidecut
Material of Construction
27
Inherently Safer Materials of ConstructionThinning resulting from 15 years of operation (Estimated)
![Page 28: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/28.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 28/49
Corrosion Monitoring of Carbon Steel Piping
http://ftp2.bentley.com/dist/collateral/docs/plantspace_isometrics/PlantSpace_Isometrics_3D_Pipe.jpg
Measurement
Location
Straight-Run
Components
Elbow
Components
Generic Piping Configuration
28
![Page 29: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/29.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 29/49
http://ftp2.bentley.com/dist/collateral/docs/plantspace_isometrics/PlantSpace_Isometrics_3D_Pipe.jpg
Generic Piping Configuration
http://ftp2.bentley.com/dist/collateral/docs/plantspace_isometrics/PlantSpace_Isometrics_3D_Pipe.jpg
Measurement
Location
Measurement
Location
Measurement
Location
Measurement
Location
MeasurementLocation
Measurement
Location
Measurement
Location
Measurement
Location
Measurement
Location
29
100 Percent Component Inspection Identifies
Low-Silicon Components
![Page 30: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/30.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 30/49
Inherently Safer Metallurgy Reduces Hazard
http://ftp2.bentley.com/dist/collateral/docs/plantspace_isometrics/PlantSpace_Isometrics_3D_Pipe.jpg 30
![Page 31: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/31.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 31/49
Low-Silicon 4-Sidecut Component Not
Monitored
Measurement
Location
WeldHigh-Silicon
Elbow Component
Low-SiliconPipe Component
31
![Page 32: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/32.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 32/49
32
Low-Silicon 4-Sidecut Component Not
Monitored
![Page 33: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/33.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 33/49
33
![Page 34: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/34.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 34/49
34
![Page 35: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/35.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 35/49
35
![Page 36: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/36.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 36/49
36
![Page 37: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/37.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 37/49
37
![Page 38: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/38.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 38/49
Many Chevron Recommendations
to Inspect or Upgrade 4-Sidecut
2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Pipe Ruptures
Recommendations to 100 Percent Inspect 4-Sidecut
Recommendations to Upgrade Metallurgy of 4-Sidecut
38
![Page 39: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/39.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 39/49
Process Hazard Analysis
Process Hazard Analysis Required by OSHA PSM Program
– Enforceable by Cal/OSHA and City of Richmond
PHA team DID evaluate “leak or rupture” of 4-sidecut line
PHA team did not identify 4-sidecut Sulfidation vulnerabilities – PHA team not knowledgeable of 4-sidecut corrosion hazards
– PHA team did not seek out additional corrosion expertise
No PHA recommendations to improve 4-sidecut safeguards
39
![Page 40: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/40.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 40/49
Damage Mechanism Hazard Reviews
These hazard reviews:
– Analyze all process equipment failure mechanisms including:• Corrosion
• Cracking
– Identify potential safeguards to control or eliminate hazard
Not required by regulators or by current Chevron standards
May have prompted PHA team to recommend replacing 4-sidecut line
CSB recommended to Chevron and State of California to require
Damage Mechanism Hazard Reviews as part of PHA cycle
40
![Page 41: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/41.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 41/49
Adequacy of PHA Safeguards
Safeguard Evaluation Methodologies; accepted methods include:
– Quantitative, e.g., Quantitative Risk Analysis
– Semi-Quantitative, e.g., Layers of Protection Analysis, and
– Qualitative, e.g., NFPA Fire Codes
Chevron PHAs do not use these safeguard evaluation methodologies
– Reliability of safeguards were not adequately verified
– Rely on PHA team experiences, beliefs, and areas of expertise
CSB recommended to California Regulators to require a fullydocumented, rigorous analysis of safeguards using established
methods such as LOPA
41
![Page 42: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/42.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 42/49
Implementation of Inherently Safer Systems
(ISS)
Contra Costa County process facilities are required consider inherently
safer design opportunities in PHAs and for new construction
But many more opportunities exist:
– Management of Change (MOCs)
– Process Unit Rebuilds
– Major Repairs
– Corrective actions from incident investigation recommendations
Chevron did not document the analysis of ISS alternatives.
CSB recommended more rigorous ISS requirements by:
– City of Richmond / Contra Costa County
– State of California
42
![Page 43: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/43.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 43/49
Multi-Agency Regulatory Approach Needed
Program will improve public
accountability and process safety
performance
Sharing of data and operational
coordination will help regulators
prevent major incidents
Regulators have cited the need for
greater multi-agency cooperation
CSB recommended multi-agency
regulatory cooperation
![Page 44: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/44.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 44/49
Transparency Drives Process Safety
Transparency is the public disclosure of process safety information
Minimal transparency exists
between refineries, regulators,
and the public
The CSB recommended that
the multi-agency group
establish procedures for
greater transparency betweenlocal officials, regulators, the
workforce, and the public.
Tawanda Kanhema/Richmond Confidential
![Page 45: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/45.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 45/49
Many Factors Contributed to Incident
Immediate Causes
– Failure caused by sulfidationcorrosion in low-silicon carbon steel
– Chevron failed to shut down unit
when leak was found
Latent Causes
– Chevron never fully inspected or
replaced the 4-sidecut despite
many recommendations
– Chevron PHA process failed to
identify sulfidation corrosion hazard
45
![Page 46: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/46.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 46/49
Many Factors Contributed to Incident
Regulations did not require rigorous
ISS implementation
Regulations did not require damage
mechanism hazard review
Regulations did not require evaluation
of safeguard effectiveness
Multi-agency cooperation andtransparency needed in California
46
![Page 47: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/47.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 47/49
Additional Items Still Under Investigation
California
– Refinery regulatory regime
Chevron
– Safety culture
– Management system
– Mechanical integrity systems
– Emergency planning,
notification, and response
– Process safety indicators
47
![Page 48: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/48.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 48/49
48
![Page 49: Chevron Refinery Pipe Rupture](https://reader035.vdocuments.us/reader035/viewer/2022062504/577c84d01a28abe054ba765c/html5/thumbnails/49.jpg)
8/19/2019 Chevron Refinery Pipe Rupture
http://slidepdf.com/reader/full/chevron-refinery-pipe-rupture 49/49
CSB Investigation:
Chevron Refinery Pipe Rupture and Fire
Richmond, California
Southern California Society For Risk Analysis
26th Annual Meeting
May 30, 2013