Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluor

GRD Journals- Global Research and Development Journal for Engineering | Volume 5 | Issue 8 | July 2020 ISSN- 2455-5703

Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride Pawan Kumrawat Student Department of Industrial Engineering Shiv Kumar Singh Institute of Technology & Science, Indore Nisha Kushwaha Assistant Professor Department of Industrial Engineering Shiv Kumar Singh Institute of Technology & Science, Indore

Pravin Tathod Assistant Professor Department of Industrial Engineering IES, IPS Academy, Indore

Abstract In this study we have calculated the threat zones for the oil and gas industries using Hydrogen fluoride to extract petroleum oil and gas, with the help of ALOHA software. One of the most essential part of the loss prevention strategy is Emergency Planning. This is a pre planning to handle any emergency situation suitably and effectively. Emergency planning is an integral part of the overall loss control program and is essential for any organization. The same is vital for effective management of an accident /incident to attenuate losses to people and property, both in and round the facility. The important aspect in emergency management is to stop by technical and organizational measures, the unintentional escape and ignition of hazardous materials like Hydrogen fluoride (HF) and minimize accidents and losses. Not only unrecognized hazardous conditions which could aggravate an emergency situation be discovered, the emergency planning process also brings to light deficiencies such as lack of resources necessary for effective emergency response. Emergency planning also demonstrates the organization’s commitment to the safety of employees and increases the organization’s safety awareness.

Keywords- Hydrogen Fluoride, ALOHA Emergency Management for Oil and Gas Manufacturing Industries, Safe Handling of Hydrocarbons, Disaster Management in Oil and Gas, Strategy during Emergency Response

I. HAZARD IDENTIFICATION (RISK CALCULATION) For research purpose we have taken here a petroleum refinery industry that is being using hydrogen fluorides (Hydrofluoric acid or HF) to extract oil and gas. In this study we will calculate the toxicity and harmful effects of HF if there’s been a leak in the storage tank.

Fig. 1: Safety Instruction for HF

Hydrogen fluoride is a fuming liquid or gas with a strong, irritating odor and it is colorless, usually it is stored in a steel cylinder as a compressed gas. Its readily dissolves in water to form colorless hydrofluoric acid solution. To identify the risk factor for HF leakage we have to first get to the physical and chemical properties of HF.

Fig. 2: Hazard Classification for HF

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Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride (GRDJE/ Volume 5 / Issue 8 / 002)

Health rating (4) - Can be lethal under emergency conditions.

Fire rating (0) - Can burn under typical fire conditions.

Instability rating (1) - HF in themselves is normally stable but that can become unstable at elevated temperatures and pressures.

A. Worst Case Scenario Formulization 1) Chemical and Physical Properties for Hydrofluoric Acid Chemical formula – HF Molecular mass – 20.0064 g/mol Boiling point of HF– 19.40C or 67°F @ 760 mm of Hg and Density of HF is 0.98 kg/ltr.

Vapour pressure - 917 mm of Hg @ 25 °C 2) Atmospheric Conditions Atmospheric conditions present at the site as : Wind speed – 4.5 m/s Wind direction – East to West Wind temperature -280C Affective height taken – 3mt.

Fig. 3: Atmospheric conditions at the site taken

Figure 4: Atmospheric conditions at site taken

3) Storage After atmospheric conditions are entered we have to then input the source of leakage i.e. tank specifications with leak measurement as follows: Tank diameter – 10’ Tank shape – Spherical Chemical state in tank – gas only Pressure of tank – 1.2 atm Mass of gas – 0.016tons (2000lbs)

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Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride (GRDJE/ Volume 5 / Issue 8 / 002)

Fig. 5: Storage Tank specifications

Fig. 6: Mass and pressure of gas

4) ALOHA Analysis After getting all the values right from the industry and their norms let’s assume a leak happens in the tank with a hole diameter of 5� (5 inches).

Fig. 7: Tank leakage specifications

There may be various causes (not discussing here) for the leakage to occur. If the leak is to be continuing for one minute continuously then, according to the ALOHA analysis: All rights reserved by www.grdjournals.com

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Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride (GRDJE/ Volume 5 / Issue 8 / 002)

Warning: HYDROGEN FLUORIDE can react with water and/or water vapor. This can affect the evaporation rate and downwind dispersion. ALOHA cannot accurately predict the air hazard if this substance comes in contact with water.

Table 1: Input data in ALOHA software HYDROGEN FLUORIDE Molecular Weight 20.01 g/mol AEGL-1 (60 min) 1 ppm AEGL-2 (60 min) 24 ppm AEGL-3 (60 min) 44 ppm IDLH 30 ppm Ambient Boiling Point 67.1° F ATMOSPHERIC DATA Wind Speed 4.5 meters/second DIRECTION NE Ground Roughness open country Air Temperature 28° C Inversion Height 5 meters Stability Class D Relative Humidity 50% SOURCE STRENGTH Leak from hole in spherical tank Non-flammable chemical is escaping from tank Tank Diameter Tank Volume Tank contains Internal Temperature Chemical Mass in Tank Internal Press Circular Opening Diameter Release Duration Max Average Sustained Release Rate Total Amount Released

10 feet 14827 ltrs. gas only 28° C 0.016 tons 1.2 atmospheres 5” 1 minute 0.0829 pounds/sec 4.97 pounds

5) Results

Model Run Red Orange Yellow

Table 2: Results RESULTS THREAT ZONE Gaussian 237 m (44 ppm = AEGL-3 [60 min]) 438 m (24 ppm = AEGL-2 [60 min]) 3.2 km (1 ppm = AEGL-1 [60 min])

According to the given conditions we can conclude that if there is a release in gas tank there will be at least three threat zones, we can define as- Red (most affected) i.e. 0 to 237 meters Orange (moderately affected) i.e. 238 to 438 meters and Yellow 439 to 3.2 km (least affected)

Fig. 8: Results (threat zones)

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Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride (GRDJE/ Volume 5 / Issue 8 / 002)

II. HEALTH HAZARDS HF is found to be an irritant to the mucosa of the upper and lower portions of the respiratory tract. As in ocular tissues, present in eyes also, the concentrations as low as 5 mg/L (5 ppm) may produce irritation to the nasal mucosa. If it is present in higher concentrations i.e. greater than 48%, the fumes occur in the solution, and add uo in air in volatile fraction. Due to which bronchospasm, mucosal edema, wheezing, bronchorrhea, atelectasis, and airways obstruction may result. Symptoms may sustain in survivors for a year or on-site symptoms may occur immediately and may cause death in as little time as 30 minutes.

A. First Aid EXPOSURE

Inhalation

Dermal/Eye

Ingestion

FIRST AID Move victims to fresh air Evaluate vital signs including pulse and respiratory rate If no pulse is detected, provide CPR. If not breathing, provide artificial respiration.

If breathing is labored, administer oxygen or other respiratory support.

Transport to a health care facility Remove victims from exposure.

Evaluate vital signs including pulse and respiratory rate If no pulse is detected, provide CPR Remove contaminated clothing as soon as possible If eye exposure has occurred, eyes must be flushed with lukewarm water for at least 15 minutes.

Wash exposed skin areas three times with soap and water.

Transport to a health care facility.

Evaluate vital signs including pulse and respiratory rate If no pulse is detected, provide CPR Immediately give the victims milk or water to dilute the hydrofluoric acid DO NOT induce vomiting Milk of Magnesia should be administered if victims are conscious and alert.

Obtain authorization and/or further instructions from the local hospital

III. COMPETENCY FOR EMERGENCY HANDLING Emergency response team members should be thoroughly trained for these kinds of crises and physically capable of completing their duties. Team members got to realize toxic hazards within the workplace and be ready to judge when to evacuate personnel or when to ask for outside help. One or more teams must be trained in: – Use of various types of fire extinguishers.

– First aid, including CPR and (SCBA).

– Requirements of the OSHA bloodborne Pathogens standard.

– Shutdown procedures.

– Chemical spill control procedures.

– Search and emergency rescue procedures.

– Hazardous materials emergency response.

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Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride (GRDJE/ Volume 5 / Issue 8 / 002)

IV. SAFE HANDLING OF HYDROCARBONS To handle hydrocarbons is a big challenge to the oil refineries. Probability of a drag, like refrige safety are often managed alright, as long as service technicians follow their training and therefore the rules for handling hydrocarbons. Safety can also be ensured by conducting regular risk assessments, creating safe zones free of ignition sources, ensuring the presence of fire extinguishers and monitoring the area with hydrocarbon detectors.

Flammable Liquids Storage, Chemical Safety. Hazardous chemicals can affect our health, may cause severe injury also may harm the environment and badly damage the property. Training on the safe handling of chemicals is vital for any teams who work with, supply, or store hazardous materials.

Chart 1: Hazardous Chemical Accident Analysis

Advanced featured floating roof tanks for storage of volatile hydrocarbons to avoid fire & explosion due to formation of vapor space.

Fig. 9: Safety Features for Floating Roof Petroleum Storage Tank

A. Containment of Hazardous Chemicals Develop procedures for working with hydrocarbons and follow them on every job, keeping in mind the flammable nature of these refrigerants. Because hydrocarbon refrigerants do not have an odorant, a quality combustible gas leak detector is mandatory for service work.

Pass the combustible gas detector tool, through every work place you go or every worksite you enter. Ensure there is a fire protection as per the inventory of hydrocarbons.

V. DISASTER MANAGEMENT PLAN Emergency planning is very essential tool during catastrophic failure, which needs to localize any accidents that may occur and, Its main objective is to reduce the probability of serious loss or damage to people, machinery, equipment and important documents, etc. The loss can be measured in terms of both human and monetary. If the effective action is taken in time, the full potential loss can be avoided. The action can be effective only when there is an existence of preplanned and practiced procedure for handling major emergencies utilizing the combined resources of the industry and outside services like Government Agencies, Fire Brigade, Medical, Police, international logistic support members, etc.

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Safety Management & Emergency Response for Oil and Gas Manufacturing Industries using Hydrogen Fluoride (GRDJE/ Volume 5 / Issue 8 / 002)

Thus “Emergency Response and Disaster Management Plan” (ERDP) is ready with the target of defining the functions and responsibilities of all concerned – Operations, Maintenance and Support Services Department Personnel with respect to detection of possible emergencies and effective implementation of the action plan.

Chart 2: Oil Refineries Incident: Disaster Incident Chart

VI. EMERGENCY STRATEGY PLANNING An emergency management plan may be a course of action developed to mitigate the damage of potential events that would endanger an organization's ability to function. Such an idea should include measures that provide for the security of personnel and, if possible, property and facilities.

Fig. 10: Emergency Response Strategy

VII.

CONCLUSIONS

In case of HF leakage from the tank for 1 minute, following conclusions can be made: 1) Red zone (237m) most affected area, evacuate the area in radii and provide them with first aid as described above according to respective exposure type.

2) Orange zone (438m) moderately affected area evacuate the area immediately and provide first aid as described 3) Yellow zone (3.2km) least affected, provide first aid immediately and check for any initial symptoms for exposure and treat accordingly.

Safe design and operation of installations with advanced technological up gradation are basic obligations. I have emphasized more on technological up gradation of emergency resources for specifically full surface tank fire of oil refineries & strategic approach during emergency. Management and staff must have expertise to deal oil refinery emergencies to protect human life and health, and the environment. The oil industry processes, stores and distributes large quantities of flammable materials, including gasoline which is classified as highly flammable, and liquefied petroleum gases are very hazardous & proper strategy with technical expertise based on the international standard like NFPA11, API2021 essential.

REFERENCES [1] [2] [3]

Refinery Manual OISD Data PNGRB 201

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