Crude oil Sludge Handling safety procedure.ppt

suldge handing procedure

1. HSEGroup

2. OBJECTIVES
Understand the Hazards Associated with the Vessel
Cleaning Activities.
Understand How to control these Hazards.

3. Vessels
Test, HP & LP Separators.
Oil Surge Drum.
Degassing Drum.
Close Drain Drum-PDP.
Close Drain Drum-GIP.
HP & LP Flare Knock out Drums.
Fuel Gas Buffer Vessel.
Hot Water Expansion Vessel.

4. CONFINED SPACE DEFINITION
AN ENCLOSED AREA THAT HAS FOLLOWING
CHARACTERISTICS
LARGE ENOUGH AND SO CONFIGURED THAT AN
EMPLOYEE CAN BODILY ENTER AND PERFORM ASSIGNED
WORK, AND
ITS PRIMARY FUNCTION IS SOMETHING OTHER THAN
HUMAN OCCUPANCY I.E. NOT DESIGNED FOR CONTINUOS
HUMAN OCCUPANCY, AND
HAS LIMITED OR RESTRICTED MEANS FOR ENTRY OR
EXIT
MAY CONTAIN POTENTIAL OR KNOWN HAZARDS
FLAMMABLE GASES OR VAPOUR
OXYGEN LEVEL <19.5% OR >23%
TOXIC GASES/ VAPOURS

5. Steps Involved In Vessel Cleaning
PlantShutdown&De-pressurized
Isolation&Purging
GasTesting
VesselOpening&MechanicalVentilation
GasTesting&VesselEntry
RemovalofSludge&InternalStructures
ReassemblingofInternalStructures
Boxup

6. Isolation & Purging
Standard Isolation Procedure.
Flushing with Sea water & Purging with inert gas
Nitrogen.
Complete disconnection of all inlet & outlet pipelines,
level gauges & other instruments.
Blindsto be installed(Blinding on the flange).
Improper Isolation leads to release of Energy Sources

7. Vessel Access
Vertical –The entrance portal is located on the top of
vessel.
Horizontal–The portal is located on the side of the
vessel. For access –we need a scaffold.
Scaffold-should be properly constructed & supported.
Poor Scaffold causes injuries
Entry Portal

8. Vessel Opening
Use proper tools .
Proper usage of tools.
Follow safe methods –loosen the bolts one by one.
Improper usage of Tools
results in Injuries.

9. 9
Ventilation
Where practicable all the man-
ways of a vessel should be
removed to increase ventilation.
Mechanical (forced) ventilation is
normally quicker and safer than
natural ventilation.

10. Hazards of vessel Entry
Risk of Fire or Explosion.
Loss of Consciousness from Asphyxiation arising from Gas or Lack
of Oxygen.
Loss of Consciousness arising from an increase in Body
Temperature.
Slip & Trip Hazard.
Engulfment & Entrapment.
GIVEN THE USUAL ENCLOSED AND DARKENED NATURE OF A
CONFINED SPACE THIS ACTIVITY IDEALLY SHOULD NOT BE
CARRIED OUT BY PERSONNAL SUFFERING FROM
PHOBIAS(Claustrophobia) .

11. 11
In addition to the hazards associated with the
confined space, confined space entries can also
involve the following additional hazards:
Limited body movement .
High Temperatures (Heat Stress).
Noise (High Decibels).
Restricted (limited) vision.
Impact injuries.
Note:All of these additional factors can result in work
taking longer than would normally be expected and must
be considered during the planning phase of the confined
space work.
Additional Hazards

12. Symptoms of O2 Deficiency
Decreased ability to work.(15-19%).
Impaired coordination.(10-15%).
Increased Respiratory rate & Poor judgment.(8-10%).
Vomiting, Fainting.(6-8%).
Coma.(4-6%).

13. Effects of H2S
0.01-0.1ppm –Beginning of Rotten egg smell.
10ppm -Beginning of Eye irritation.
100ppm -Loss of sense of smell.
200-300ppm-Irritation of Respiratory Tract.
500-700ppm-Rapid loss of consciousness.
700-1000ppm-Asphyxiation.

14. 14
Conduct gas test readings to be taken in the following
order:
Oxygen
Flammable vapors
Toxic vapors
Continuous gas testing should be undertaken
whenever personnel are performing work inside a
confined space.
Gas Testing for Entry

15. You need a Permit

16. HP Separator-Man hole opened

17. HP Separator-Baffle Plate

18. HP Separator-Sludge

19. PPE requirement
Mandatory.
 Safety helmet, Safety glass, Safety foot wear,
Gloves & Chemical resistant overalls.
Additional.
 RPE (BA/Filter type), personal gas monitor,
Rubber gloves , Torch.

20. Sludge PPE

21. Vessel entry
Vessel Entry Team –Authorized Entrants &
Authorized Attendants.
Authorized Entrant –an employee who is
authorized by the employer to enter a vessel.
Authorized Attendant -an individual stationed
outside the vessel who monitor the authorized
entrants.

22. 22
The Entry Watch attendants’ must be adequately
trained in their duties and responsibilities, which
includes:
Control Entry into the confined space.
Maintain contact with people inside the space.
Clear the personnel from the confined space if the
site conditions change or facility alarm sounds
Raise the alarm if a problem occurs inside of the
confine space
Ensure gas testing results are within acceptable
limits and properly taken at recorded as required
by permit.
Be aware to changing conditions that may present
a hazard and clear the space if unsafe conditions
arise.
Confined Space Attendant

23. Removal of Sludge
NORM–QPD’s sludge is free from NORM
Spillage–may lead to environmental pollution, Fire,
slip hazard. Avoid spillage.Use drums with proper lids,
polythene sheets, oil absorbent pads.
Ingestion –Mercury, Arsenic, Chromium & Lead
Use Proper PPE & Good Personal Hygiene.

25. Waste Disposal
Sludge –Plastic Drum with tight lids.
Oily Cotton rags, Gloves, Disposable coveralls,
Polythene sheets & Absorbent pads.

26. Removal of Internal Structures
Internal structures –Baffle plate, Coalescing Plate
Pack ,Mesh Pad.
Hazards-hand injury –sharp edges, Improper tools,
manual handling injuries.

27. HP Separator-weir plate & Oil chamber
Weir Plate

28. HP Separator-After Cleaning

29. LP Separator-Coalescing Plate Pack
Coalescing Plate Pack

30. Coalescing Plate pack

31. Mesh Pad

32. Coalescing Plate Pack Unit

33. LP Separator-After Cleaning

34. HP Flare Knock Out Drum

35. Box Up
Thoroughly check the vessel compartment for any
tools, cotton rags ,etc before box up.
Use tools in a safe manner.

36. Let us work safely.