Marcio AbreuNovember 14, 2014

Marcio AbreuNovember 14, 2014

World Chlorine Council Global Safety Workshop

Process Safety Management

World Chlorine Council Global Safety Workshop

Process Safety Management

Unipar

Carbocloro

Cubatao Plant

• 1,000 metric ECU/day

• Plant start up: April 1964

• Products:

. Chlorine

. Caustic soda

. Hydrogen

. Hydrochloric acid

. Sodium hypochlorite

. EDC

ABS Quality Evaluations, Inc.

1

1

1

1994

19992007

2005

Overall Management System

Why a PSM program is so important

for the chlor-alkali industry?

Major Operational ConcernsCommandments of Chlorine Production

Hydrogen in

ChlorineIgnition of Metals

Ignition of

Titanium

Cleaning

Equipment and

Piping

Nitrogen

Trichloride (NCL3)

Moisture in Dry

ChlorineLiquid Chlorine

Expansion

Mechanical

Integrity for Liquid

Chlorine Systems

Oxygen in

Hydrogen

Cell Room

Electrical SafetyImpurities in Brine

Safety Devices and

Interlocks

Chlorine

Neutralization

Systems

Dilution of

caustics or acids

with water

Cold Temperature

and Carbon Steel

Stress Corrosion In

Stainless Steel

�MI is one of the most important elements of PSM

�MI program is intended to ensure equipment does not fail in a way that causes or affects a release of HHC

�Although maintenance is a major part of an MI program, MI is not just maintenance

Mechanical Integrity Program

MI covers the proper design,

fabrication, construction/installation

and operation of equipment

throughout the entire process life

cycle.

MECHANICAL INTEGRITY PROGRAM

MECHANICAL INTEGRITY PROGRAM

• Written procedures

• Training for maintenance

activities

• Inspection, testing, and repair

• Equipment deficiencies

management

• Quality assurance

Rotating

equipment

Relief

devices and

vent systems

Electrical

equipment

and systems

Emergency

shutdown

systems,

controls

systems and

alarms

Pressure

vessels

Storage

tanks

Piping

systems

MECHANICAL INTEGRITY PROGRAM

Plant procedures establishes the MI program requirements for key items

Mechanical Integrity ProgramPreventive Practices

Mechanical Integrity ProgramPreventive Practices

Pressure Vessel

(frequency of inspections)

Liquid chlorine storage tank

Chlorine Institute Pamphlet

Other pressure vessel

Brazilian Regulation (NR-13)

Plant inspection plan

1 year External visual inspection

2 years Pressure relief valves PM

6 years

Internal visual inspection

Thickness measurement

Other ND test

Replace tank block valves.

Frequency

Liquid chlorine storage tank

Pressure vessel(except chlorine storage tank)

NR-13: Brazilian regulation for

pressure vessels

• Frequency of inspection

defined according to the vessel

category

• Hydrostatic test performed

after equipment fabrication or

repair

• ND tests also recommended

Vessel Category External inspection Internal inspection

I 1 year 3 years

II 2 years 4 years

III 3 years 6 years

IV 4 years 8 years

V 5 years 10 years

Pressure Vessel

StandardsAPI, CI, NR-13

Inspection program frequency:

Liquid chlorine piping: 5 years;

Chlorine gas piping: 5 years;

Chlorine pipeline: 1 year (CI recommendation)

ServiceAPI

570

EXTERNAl

INSPECTION

(years)

Chlorine Gas I 5

Liquid Chlorine I 5

Ethylene I 5

Hydrocarbon II 5

Natural Gas /LPG II 5

Hydrogen II 5

Caustic soda II 5

Sulfuric acid II 5

Hydrochloric acid II 5

Sodium Hypochlorite - 5

Piping systems

� Visual inspection

� Thickness measurement

� ND tests

Corrosion Under Insulation

Control ClassClassification Table

Maintenance Frequency

0 • Inspect, calibrate and repair as needed

1 • Routine maintenance do not exceed 8 years.

2• Function test do not exceed 3 years.

• Routine maintenance do not exceed 5 years.

3• Function test do not exceed 1 year.

• Routine maintenance do not exceed 3 years.

4

• Inspect, calibrate and repair

• In the absence of a requirement or technical reason:

o Function test do not exceed 6 months

o Routine maintenance do not exceed 2 years

5

• Pressure relief devices

• Inspect and calibrate

• Routine maintenance and applicable function tests for Relief Devices

in HHC service not to exceed 2 years.

• Routine maintenance and applicable function tests for other Relief

Devices as per NR13 requirements

Emergency Shutdown and Controls Systems

Maintenance

program for

devices related

to HHC service

Pressure Relief Devices

Pressure relief valves maintenance

inspection and pre-pop test.

Rotating equipment summary

• MI equipment priorities based on ABC classification

• Predictive and preventive maintenance program

• Monthly inspection routine

• Vibration monitoring

• Oil analysis

ABC classification

TAG# DescriptionCriticality

classG4-AG-327 Agitador Tanque Remoção de Pesados A

G4-BC-217 Bomba Alimentação Torre Remoção Leves A

G4-BC-218 Bomba de Remoção Solido Sobrenadante B

G4-BC-234 Bomba de Bissulfito de Sódio B

G4-BC-236 Bomba de Distribuição Ácido Clorídrico C

G4-BC-237 Bomba de Distribuição Ácido Clorídrico C

Rotating Equipment

Rotating Equipment

Vibration monitoring

Oil Analysis

Electrical Equipment

Equipment Maintenance activity

Outdoor Substation and Equipment Disconnect Switches

ThermographyOutdoor Capacitors

MCC Equipment (Low voltage switchgear)

Rectifiers

Lightning Protection System Detailed Inspection

Power or Rectifier transformers Visual Inspection, Oil analysis, Electrical tests,

Thermography

UPS Visual Inspection

Battery Chargers/DC Power Supply Visual Inspection

Battery Systems Cleaning and Visual Inspection

Battery tests

Ex classified equipment and systems Visual Inspection and detailed inspection

Thermography during

Electrical Inspections

ThermographicAnalysis

Electrical Equipment

,

Quality Assurance

Inspection of materials

• Visual;

• Dimensional;

• Surface roughness;

• Thickness Measurement

• Liquid Penetrant Inspection (LPI);

• Hardness measurement;

• PMI (positive material identification).

CS cracked pipe found during the material

inspection before use in chlorine service

MI Program Management

• Monthly report of MI metrics (KPI’s)

• Management of change: an important tool to manage MI

program deviation

• MI program audits

• PSM plant committee to follow up program items and gaps

• IT tools supporting the PSM/MI program: SGI, SAP

� Painting program is an important issue for the success of the MI program

� Corrosion under insulation is another important concern

� MI must be a plant priority to keep the operation reliable and safe

� Dedicated PSM engineer is also recommended

� PSM: a commitment for the entire organization

� Top management must support the overall PSM program

Final Comments

Thank you!

marcioabreu@uniparcarbocloro.com.br

www.uniparcarbocloro.com.br

Back upBack up

1. Hydrogen concentration in chlorine gas streams must be monitored and controlled to

prevent forming an explosive mixture. Hydrogen must be kept below the lower

explosive limit (LEL) of hydrogen in chlorine at all times.

2. Nitrogen trichloride (NCl3) is an unstable compound that can self detonate at relatively

low concentrations. Very small quantities can detonate with tremendous force. Systems

where NCl3 may accumulate or concentrate must be actively monitored and managed

to maintain NCl3 at safe levels.

3. Chlorine will react violently with many different chemicals and materials. It is essential

that all equipment, piping, and valves be properly cleaned and dried for chlorine

service before introducing any chlorine into the system.

4. Chlorine will react with many metals, especially at elevated temperatures. It is critical

that the material of construction be consistent with the operating conditions and that

excessive external heat is not applied to chlorine containing systems.

5. Dry chlorine will react violently with titanium. Systems must be in place to protect

titanium equipment from exposure to dry chlorine and insure titanium is not used in

dry chlorine service.

Commandments of Chlorine ProductionCommandments of Chlorine Production

6. Many grades of carbon steel can be become brittle when exposed to temperatures

below -20 °F. It is essential that low temperature carbon steel or a suitable alloy is used

for continuous operation below -20°F.

7. Moisture in dry chlorine systems will increase carbon steel corrosion rates which can

become dangerously rapid at high levels. Additionally the possibility of generating

hydrogen exists. Moisture concentrations must be continuously monitored and

controlled using moisture analyzers and drying systems.

8. Oxygen in hydrogen systems must be monitored and controlled to prevent forming an

explosive mixture. Extreme care must be used around hydrogen compressors to ensure

air is not pulled into the system during operation.

9. Liquid chlorine has a high coefficient of expansion. Any system where the threshold

amount of liquid chlorine can be trapped must have expansion protection.

10. An electrolytic cell line has the capability to produce a fatal electrical shock. Cell line

working procedures must be clearly understood and followed by everyone entering the

“Cell Line Working Zone”.

Commandments of Chlorine ProductionCommandments of Chlorine Production