Leak in the high-pressure inlet pipeline for heavy oil hydrogenation
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Accident scenario: During the production process, a leak occurred in the high-pressure pipeline between the heat exchanger for the reaction products and raw materials and the high-temperature separator, which led to a massive fire. The DCS indicated that the instruments and valves located near the high-temperature separator were no longer functional for monitoring or control. Discussion: 1. What is the primary task of an indoor operator? 2. How should outdoor operators respond? 3. What should be noted in accident handling? 4. What should be contacted first with the outside world?
1. First, consider implementing an emergency shutdown: stop the new hydrogen and recycle hydrogen compressors in the control room, as well as the feed pump; shut down the heating furnace. Inform the hydrogen production unit to cease hydrogen supply, and notify the workshop supervisors, production department managers, and the fire department. 2. Outdoor operators should work together with indoor operators to shut down all pumps (it may be possible to keep the high-pressure water injection pumps running temporarily, following the instructions of the supervisors). Close the isolation valves for each pump, and open the fresh water and steam lines of the unit so that they can be used in case the equipment overheats. 3. During accident handling, it is necessary to follow the instructions of the supervisors in an organized manner. Adhere to the principles of not causing harm to others, putting personnel first, then equipment, and catalysts last. Special attention should be paid to the combustion characteristics of hydrogen and to preventing sulfur poisoning.
What was said upstairs wasn’t quite appropriate. The first ones to handle an accident are the employees on duty; by the time the managers arrive, the on-duty employees must already know the principles for dealing with accidents and bring them under control.
A couple of days ago, the company informed us that we needed to conduct a drill related to leaks in high-temperature and high-pressure pipelines. The specific scenario for the drill hadn’t been determined yet, and company leaders would be attending it. Feeling uncertain, I wanted to discuss this with everyone and learn a bit more about it secretly. Thank you all! :lol
1. The on-site operator should immediately activate the emergency pressure relief interlock and check its operation. Call the fire department and inform relevant management personnel such as those in the workshop and dispatch department. 2. Fu Cao should wear a portable hydrogen sulfide detector and an air respirator when entering the site, in order to check the operation of the interlock valves. Set up a perimeter to prevent other unauthorized persons from entering the area. Close the fuel gas valve of the heating furnace and the outlet valve of the feed pump. Remove new hydrogen and follow instructions to adjust the process. Responsible for providing first aid to the injured on site. After the reaction pressure drops below the pressure in the nitrogen pipeline network, nitrogen is introduced at the outlet of the recycle hydrogen compressor for displacement. 3. During accident handling, attention should be paid to preventing hydrogen sulfide poisoning, cross-contamination between high and low pressures, poisoning, providing aid to injured persons, and preventing further injuries and poisonings. 4. First, contact the fire department and emergency services. The nitrogen supply must be ensured.
The team responsible for handling the incident immediately should, in addition to reporting it, promptly activate the emergency shutdown plan. First, cut off the material and the heat source (heating furnace). Then the team leader organized the fire extinguishing.