Chen-5006 (Group 1)

CHEN-5006
(GROUP 1)
Farhan Ahmed
(18686184)
M. Saqib Soherwerdy (18178131)

Zaid Nedhal
(17614825)
Ashiq Saleem
(18693061)
Marwa Daoud
(18035003)
GOALS OF THE SYSTEM

1. CRUDE TEMPERATURE:
To heat the crude to a desired temperature (say 900 degree Celsius)
2. FUEL CONSUMPTION:
To use the minimum fuel in reaching the desired temperature.
FUNCTIONS
To heat up the crude
Complete combustion of fuels
Function of Steam: to atomize and purge
Function of air stream: To provide combustion air
Function of soot blowing steam: to remove carbon from tubes
Function of instruments: to monitor parameters and control them
Function of fuel and fuel gas: to supply heat energy by combustion
STRUCTURE
Described from the P&ID in detail on document camera.
Plant (material and information streams considered)
Procedure (operating, control and safety procedures)

Three major loops:
Steam loops: 1. Atomizing steam to burners for efficient combustion,
2. Snuffing steam for purging,

3. Steam for soot blowing .
Fuel loops: Carry the fuel and fuel gas to the burners, also fuel return lines.
Crude loop: Carry crude oil to be heated and after heating.
BOUNDARY AND LIFE CYCLE

Furnace and its associated piping and instrumentation
Fuel inlet pipes, Raw Crude inlet and outlet, Steam inlet and outlets
Life Cycle:
Operations and Maintenance
Shutdown and startup
It is existing and operating facility

Furnace used for pre heating of crude (processing)
HAZARDOUS SUBSTANCES
Fuel
Used in heating the crude.

Crude
Main product which has to be heated

Hot water
Condensed water from steam may leak and burn people
HAZARDOUS SUBSTANCES
Soot
Unburnt carbon
Hydrocarbon fumes
Cleaning chemicals
Used during maintenance
IDENTIFIED HAZARDS
Fire: can happen due to flammable service,
Toxicity: hydrocarbon fumes and chemicals if released.
Explosion: can happen due to pressure buildup.
Steam leakage can cause high degree burns to nearby operators
IDENTIFIED HAZARDS
(CONT.)
Loss of containment
1. Fuel
2. Crude
Blast of furnace due to high pressure
High Temperature
POTENTIAL RECEPTORS
Inside boundary limit:
Furnace operators
Water
Assets (furnace, equipment)
Outside boundary limit:

Employees
Production
nearby residents
Ecosystem
Company image
PROBABILITY CRITERIA
RANKING
FREQUENCY
1 time in 1000 years
1 time in 100 to 500 years
May occur 1 time in system life cycle
May occur 1 time in 10 years
May occur every year
Highly subjective as it depends on the gut feeling
CONSEQUENCE CRITERIA
RANKING
EFFECT ON
PEOPLE
ENVIRONMENT
PROPERTY
PRODUCTION
Minor injury
Not lasting
effects
Minor damage
No loss of
production
Injury requiring
medical
practitioner
Minimum effects
(lasting for max.
6 months)
Loss of <5% of
assets
Minimum delays
in production
Moderate effects
but not affecting
ecosystem
Damage to <25%
assets
Significant loss of
production
Single Death
Some impairment
of ecosystem
Loss of <50%
assets
Serious loss of
production and
quality
Multiple Deaths
Long term effects
Total loss of
>50% assets
Production totally
stopped
Hospitalization
Tube leak
inside furnace
Tube rupture,
BLEVE
2
Leak
through hole
Incomplete
burning of
fuel
Consequence
Explosion
in furnace
3
Probability
Causes
Events
Consequences
Consequ
ence
Severity
Risk
Furnace tube rupture
Choking, high pressure, high

temperature
Fuel leak
insulation, blinds,
valves
leak through hole
corrosion
Fuel leak
maintenance
explosion in furnace
insufficient purging
blast, fire
snuffing steam
tube leak inside furnace
overfiring/ overheating
fuel leak inside furnace, fire
flow element
incomplete burning of fuel
inadequate air/fuel ratio
emission of greenhouse gases,

economic loss
flow element
fire
temperature guages
BLEVE (boiling liquid expanding vapor

explosion)
heat
Existing Control Likelihoo

Measures
d
ACCEPTANCE AND
TOLERABILITY
Risk considered to be:
acceptable if risk 4. (green region)
{mostly very low probability events here}
tolerable if 5 risk 7. (yellow region) {risk tolerable for benefits i.e. production}
unacceptable if risk 7. (red region) {immediate reduction to ALARP required}

(risk + consequence).
COMBINATION OF RISKS
Hydrocarbon leak may lead to fire and spread in other areas.
tube rupture: may contribute to large fire in other areas.

not considered for small leak as the amount released will be low.
REFERENCES
American Petroleum Institute. 2002. API Recommended practice 580 "Risk
Based Inspection". Washington.
2009. Guidelines for Developing Quantitative Safety Risk Criteria. New
York: Wiley.
Safe Work Australia. 2013. "Guide To Managing Risks Associated With
Foundry Work."
Cameron, Ian, and Raghu Raman. 2005. Process Systems Risk
Management. Elsevier.
Health and Safety Executive. 2001. "Reducing risks, protecting people."

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CHEN-5006

M. Saqib Soherwerdy (18178131)

GOALS OF THE SYSTEM

Complete combustion of fuels

Function of Steam: to atomize and purge

Function of air stream: To provide combustion air

Function of soot blowing steam: to remove carbon from tubes

Function of instruments: to monitor parameters and control them

Function of fuel and fuel gas: to supply heat energy by combustion

Procedure (operating, control and safety procedures)

2. Snuffing steam for purging,

Crude loop: Carry crude oil to be heated and after heating.

BOUNDARY AND LIFE CYCLE

It is existing and operating facility

Used in heating the crude.

Main product which has to be heated

Condensed water from steam may leak and burn people

Used during maintenance

Toxicity: hydrocarbon fumes and chemicals if released.

Explosion: can happen due to pressure buildup.

Steam leakage can cause high degree burns to nearby operators

Outside boundary limit:

1 time in 1000 years

1 time in 100 to 500 years

May occur 1 time in system life cycle

May occur 1 time in 10 years

May occur every year

Highly subjective as it depends on the gut feeling

Long term effects

Furnace tube rupture

Choking, high pressure, high

leak through hole

tube leak inside furnace

fuel leak inside furnace, fire

incomplete burning of fuel

inadequate air/fuel ratio

emission of greenhouse gases,

BLEVE (boiling liquid expanding vapor

Existing Control Likelihoo

{mostly very low probability events here}

unacceptable if risk 7. (red region) {immediate reduction to ALARP required}

tube rupture: may contribute to large fire in other areas.

Based Inspection". Washington.

2009. Guidelines for Developing Quantitative Safety Risk Criteria. New

Safe Work Australia. 2013. "Guide To Managing Risks Associated With

Cameron, Ian, and Raghu Raman. 2005. Process Systems Risk

Health and Safety Executive. 2001. "Reducing risks, protecting people."

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