SAFETY IS

REALISATION

EXPLOSION IN SOUR WATER STORAGE TANK

22/03/2002

NITROGEN

Fuel gas
260 MMWC
SOUR WATER SURGE DRUM

TO INCINERATOR STACK

PVRV (-) 40 MMWC + 250 MMWC

SOUR WATER DAY TANK

SOUR WATER FROM UNITS

SCHEMATIC DIAGRAM FOR OPERATIONS SOUR WATER

SOUR WATER STORAGE TANK Provides a buffer storage for Sour water in case of any interruption in the processing of sour water in the down stream Storage capacity : 160 M3 40 45 Hrs

Provision on SW Storage tank

Overpressure release to SRU Incinerator stack PVRV with in and out to atmosphere Dead weight safety valve

EVENT RELATED OBSERVATIONS The tank roof lifted off and fell aside due to explosion The bolts of the tank foundation had moved up. The rank had slightly propelled up from the base due to the impact of the explosion. Earthing provision on the appeared intact. Dead weight safety valve blew off. PVRV out breathing line got uprooted from the support. Epoxy coating of the tank internal was intact. However, it was non-existent on dead weight internal face.

PROCESS RELATED OBSERVATIONS The tank was not in use since commissioning since 2002 due to limitations in the U loop water seal. Tank bypass arrangement was in use, however, it was floating on the system. At the time of incident, shutdown was in progress and the residual content was being pumped out. Tank pressure gauge was stuck at 100 MMWC. Nitrogen line PVC was found stuck in closed position & was not in commissioned condition Out breathing line of PVRV was in plugged condition. Overpressure control valve was on manual at about 60-65 % since the tank was taken in line.

ANALYSIS

With tank nitrogen blanketing system not in commissioned condition, the presence of PYROPHORIC substance could have led to the explosion.

WHAT IS PYROPHORIC SUBSTANCE

The word `PYROPHORIC is derived from the Greek word meaning `FIRE BEARING. Any material which ignite spontaneously in air when rubbed, scratched or struck is called Pyrophoric substance. Iron Sulphide is one such material which oxidizes exothermically when exposed to air. It is formed by conversion of iron oxide (rust) into iron sulphide in an oxygen free atmosphere where hydrogen sulphide gas is present. It is frequently found in solid iron sulphide scales in refinery units, particularly in Distillation columns. If this Pyrophoric Iron Sulphide (PIS) deposits are not removed properly, there is a likelihood of spontaneous burning of PIS.

CLEANING UP OF PYROPHORIC SUBSTANCE PIS can be cleaned up by the following methods :

Steaming

for about 20 24 hours

Hot water washing for about 15 20 hours

Cold water washing - for about 20 24 hours

Chemical treatment with KMnO4 , Hydrogen peroxide, Bleaching powder etc.

Note : Though KMnO4 has excellent oxidizing properties , Now

a days, it is is not preferred as removal of KmO2 produced after treatment is a problem. Moreover, it creates large volume of sludge. KMnO4 itself involves dangerous and explosive vapours.

GENERAL PRECAUTIONS TO AVOID PYROPHORIC IRON FIRES

The scrap and debris collected from cleaning of tanks/ filters/ pipelines must be kept wet and disposed of underground. Tanks, reactors, columns and exchangers, particularly in high sulphur feed must be properly blanketed.
All equipment and structured packing must be properly washed and kept wet when exposed to atmosphere. Care must be taken while unloading catalyst. Spent/coked catalyst might contain PIS. If the spent catalyst is warm and contacts with oxygen, PIS will ignite spontaneously.

LESSON LEARNT

Nitrogen blanketing and its reliability is the key issue for the safe operations of the sour water day tank.

Provide separate low pressure alarm for the tank.

Provide temperature indicator on overpressure release line to know the backflow of the flue gas. Ensure proper epoxy coating.

Thanks

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