Global Congress on Process Safety 2012 - Topical Conference at the 2012 AIChE Spring Meeting and 8th Global Congress on Process Safety | Year: 2012
This work aims to present, in a practical approach, the application of Process Safety basics principles and management elements to the major turnaround of an Olefins Plant in the year 2011. This application can be understood and emphasized in the various stages of a turnaround: planning, pre-turnaround, shutdown and decontamination, maintenance itself, commissioning and startup of the plant.
6th CCPS Latin American Conference on Process Safety 2014, LACPS 2014 | Year: 2014
The objective of this project done in Braskem Company, that has 25 sites in Brazil, 5 sites in USA and 2 sites in Germany was analyze the current stage of identification, control and management of the main process accidental scenarios (Major Hazard) that can happen at Braskem Units. It was done during 2 years. This evaluation is based on process safety standards and Braskem risk criteria, as well as good practices in process safety. The focus is to understand the main scenarios and hazards (Major Accident Hazards) and how its controls are being managed, in order to allow for operation of the units under acceptable risk conditions. The motivation for this study is the identification of some conditions in Braskem that indicates the need of a more in deep knowledge of the main scenarios related to process safety from Braskem units. Among this factor, some as indicated below: a) Units in different stages of knowledge of its scenarios with major damage, their risk levels and barriers condition; b) Accelerated non organic growth, incorporating assets with different knowledge and culture related to process safety and knowledge of their risks and barriers integrity; c) Large number of scenarios with level of consequences critical or catastrophic, with potential to cause important damage to plants and reach externally of the units (residential population or other companies); d) Occurrence of accidental scenarios over the last months, indicating the need of a better understanding of those scenarios and their barriers; e) Need to increase visibility of major hazards to the high levels of leadership in Braskem to show their importance for the decisions related to the sustainability of the business. In this project were involved 35 sites, raw material units and resins sites more than 650 process Scenarios and more than 5,000 preventive and mitigating barriers were audited. A very rich information and statistics data were generated. Below are the phases that show all phases since selection of scenarios until quantitative studies. Methodology developed in all four phases: In phase 1, were asked the following main information from each plant: a) Risk Studies (qualitative and quantitative) in the units in the last 5 years b) If there are no studies in the last 5 years, previous studies c) Process flow diagram of the plant d) Inventory list of products e) Layout of the units f) Aerial photos with the region around the unit g) PMP scenario (maximum loss related to process scenario) In Phase 2 a) For each scenario defined previously, the protection and mitigation barriers will be identified, through studies of risk information and validation with the teams of the plants involved; b) The Audit of Barriers methodology applied at Braskem will be used for monitoring the condition of each barrier, proposing recommendations to improve the barrier integrity condition, if necessary; c) It will set a frequency for monitoring of these barriers, for keeping the integrity of them. If necessary LOPA and SIL studies can be applied to better support these settings; d) In the monitoring phase, the recommendations generated in risk studies will also be evaluated, regarding the status of implementation; e) For the scenarios which have their barriers audited in less than one year, only the status of recommendations will be evaluated. In phase 3 a) Information and indicators will be established to be used for monitoring the condition of the scenarios, considering the different processes of governance, defined in the element 02, the organizational synergy SEMPRE (plant, the industrial unit and the Executive Committee); b) The frequency of monitoring, form of governance and information flow will be set. In Phase 4 - Quantitative Studies a) Prepare, or complement, quantitative studies of the units, so for the units in which there is no complete or recent study, in the selection of scenarios included in the previous steps will be validated/added the new scenarios identified. b) For road transport: the calculation will be done for up to 30 scenarios, each one defined by product and location of leakage. c) For pipelines: the calculation will be done for up to 10 different points of leakage. d) For processing plants and terminals: accidental scenarios which have potential to achieve residential or industrial areas, not Braskem, with effect of 1% fatality or lower flammable limit, will be included. e) Initially the LOPA study must be applied for all PHRs (Potential High Risk) identified in the plant, complementing the other scenarios, as requirements of Risk Matrix and Five-Year Plan. Final Comments This project was an important opportunity for Braskem to improve the process safety system and culture, considering that the results showed how to manage the major hazard scenarios and how to assure the commitment of leaders and the participation of all related areas as maintenance, operation, process and design engineer, logistics, supply and others.
Control | Year: 2013
Daniel Morales, Automation Manager, Braskem, suggests that electronic marshalling can provide extra time for modernizing and building new facilities. Daniel Morales has overseen a control system modernization project for one of the company's polypropylene production facilities. Enter Emerson Process Management and its Electronic Marshalling technology has played a key role in helping the company achieve its objectives. The migration team tested everything on the new DeltaV system out before undertaking the project. Electronic Marshalling solution has allowed the team to design and install the new system in 50% less time compared with conventional I/O approaches. Emerson's focus on human-centered design (HCD) is visible in the smallest implementation details that can streamline system installation and commissioning tasks, while Electronic Marshalling represents a conceptually different approach to doing automation projects.
Ohlweiler D.R.,Braskem |
12AIChE - 2012 AIChE Spring Meeting and 8th Global Congress on Process Safety, Conference Proceedings | Year: 2012
The application of Process Safety basics principles and management elements to the major turnaround of an Olefins Plant in the year 2011 is presented. This application can be understood and emphasized in different stages of a turnaround, i.e., planning, pre-turnaround, shutdown and decontamination, maintenance itself, commissioning and startup of the plant. This is an abstract of a paper presented at the 2012 AIChE Spring Meeting and 8th Global Congress on Process Safety (Houston, TX 4/1-5/2012).
Eckhard N.,Braskem |
11AIChE - 2011 AIChE Spring Meeting and 7th Global Congress on Process Safety, Conference Proceedings | Year: 2011
Braskem manufacturers monomers, resins, and chemicals specialties. On February 2009, during the high pressure boil-off compressor startup, an explosion incident occurred. A gasket in the discharge cooler flange and several pieces of the piping system failed. An investigation was undertaken to understand the potential causes of the incident and to determine whether the startup procedures or the system design require any improvement for safety reasons. The investigation took place with personnel interviews, inspection of the damage material, physical and chemical laboratory analysis, and survey under potential contamination, as well as ethylene decomposition mechanisms. An ethylene decomposition occurred during the startup pressurization at a low pressure due to a diatomic gas presence with ethylene. Several measures were implemented to avoid a recurrence of the event. The safety process protection system of the ethylene and propylene storage tanks are being updated. This is an abstract of a paper presented at the 2011 AIChE Spring Meeting & 7th Global Congress on Process Safety (Chicago, IL 3/13-17/2011).