Transcript PID_Safety_No_Narr

P&ID Safety Case Study
Texas City Refinery Disaster
Narrated by Kevin Lin and Eric Gauthier
www.chron.com
www.chron.com
Plant Background
460,000 barrels/day
11 million gallons
Texas City
1800 employees
1200 acres
Operation Unit
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
Operation Unit
Raffinate Splitter
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
Operation Unit
Relief Valves
Raffinate Splitter
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
Operation Unit
Stack
Relief Valves
Raffinate Splitter
Blowdown Drum
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
Disaster Strikes
• Isomerization Unit
• Overflow of Distillation
Tower
www.wikipedia.org
– Overpressurization
– Flooding with hydrocarbons
• 15 workers killed
• 180 injured
www.economist.com
What Went Wrong?
Stack
Relief Valves
Raffinate Splitter
Blowdown Drum
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
What Went Wrong?
Stack
Relief Valves
Raffinate Splitter
Blowdown Drum
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
What Went Wrong?
Stack
Relief Valves
Raffinate Splitter
Blowdown Drum
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
What Went Wrong?
Stack
Relief Valves
5x9000 gallon
tanker trucks
Raffinate Splitter
Blowdown Drum
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
What Went Wrong?
Stack
Relief Valves
Raffinate Splitter
Blowdown Drum
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_appendix_01_08.pdf
Pg A-11
http://www.bp.com/liveassets/bp_internet/us/bp_us_english/STAGING/local_assets/downloads/t/final_report.pdf
pg 4
www.economist.com
Blog.kir.com
www.weldreality.com
Prevention Measures—Engineering
• Improve Process Control
– Automated emergency shutdown system
• Location of Relief Valve
– Top of tower for greater control of vaporization
• Blowdown/Stack Flare Relief System
Prevention Measures—Human
Control
• Positive Work Enviroment
• Management Enforcement Of:
– Process safety
– Operations performance
– Systematic risk reduction
• Training
Remember, YOU
are responsible for
maintaining a safe
workplace!!