Process Safety Management im Refinery.pptx

Process safety management

1. Process Safety Management Case study “ Byco refinery fired heater incident” Presanted by : M. Muhayminullah Khan Presanted to : Dr. Zahoor

2. About Refinery Refineries where crude oil distilled into various product such as gasoline, kerosene, diesel etc having high potential of hazard during its process. Almost every country in the world operates a refinery( ies ) to provide its industrial, transportation , commercial , housing, and other sectors with the required fuel .

3. Byco and its incident Byco newly name as Cnergyico has Pakistan's largest crude refining capacity of 156,000 barrels a day, company engaged in the businesses of oil refining, petroleum marketing, and petroleum logistics.  On the day of October 27, 2015 incident of fired heater explosion and fire reported which has been controlled by Refinery’s Emergency Response Team.

4. Fired Heater ( furance )

5. Activities before incident Plant is going to start up Activities perform by field operator before startup of fired Heater Line up checked Control valve stroke checked Damper opening checked Physical inspection checked LEL from bottom checked Status Informed to DCS operator GO head to pilot the burner from DCS

6. Activities cause incident Neglected or Bypass activities Check list not filled SOP for LEL check not followed properly (top and bottom ) field Operator Oxygen level not check by DCS Operator Forced Draft fan is not running (general practice)

7. Cause of fire Hydrocarbon Composition in heater Control valve passing Blast / explosion as 1st pilot burner torched

8. Reason “SOP violations” Trainee operator DCS Shift Engineer (absent) Oxygen Level analyzer overlook Maintenance violation control valves passes Bad practice of of LEL check and FD fan close .

9. Conclusion “This incident could have been avoided with commitment toward safety “ Although no Casualty , no injury Property loss only

10. THANK YOU & JAZAKALLAH