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OPERATION PROCEDURE IN A CHEMICAL PLANTS

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radhakrishnan unni
radhakrishnan unni

OPERATION PROCEDURE

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OPERATION PROCEDURE DURING EMERGENCY CONDITIONS (OPEC) FOR SGTF 1
OPEC In Operating Procedure for Emergency Conditions (OPEC) the emergency conditions and incidents of SGTF and operation procedure to be followed under these conditions are explained. 2
OPEC This part deals with emergency operations that are to be carried out by the operator in the event of sodium leak/fire and sodium water reaction SODIUM FIRE In the event of a sodium leak/fire outside fire heater, wire type leak detectors, spark plug leak detectors or SID type leak detector will detect and give alarm in control room. acknowledge the alarm and observe the leak location with the help of CRT Physically verify the sodium leak On confirmation of leak, dump sodium by using push button or manually in absence of air supply . 3
OPEC EM pump, NaX blower, CT blower and fired heater, boiler feed pump etc will be tripped automatically Maintain a cover gas pressure in the system Confirm dumping of sodium by monitoring the level rise in storage tank Inform fire service and proceed as per fire order Use recommended safety dresses and fight sodium fire Ensure exhaust fans are working Inform Head, SGTF-OS and Head-RIOD. LARGE SODIUM WATER REACTION In case of large sodium water reaction hydrogen pressure in the sodium side will build up within milliseconds and rupture disc provided at inlet or outlet side of SG will be ruptured. The spark plug type detectors provided at the down streamside of rupture disc in the reaction products discharge line will give signal that rupture disc is ruptured 4
OPEC On receiving this signal the water side and sodium side of SG will be automatically isolated, water/steam in tubes will be de-pressurised and the SG tube filled with nitrogen. Dump sodium in the loop manually Inform Head, SGTF-OS and Plant Superintendent, SGTF TSUNAMI AND CYCLONE On issuance of Tsunami/Cylone warning 1) Shutdown the plant and dump the loop sodium. If compressed air or Class- 1 power supply is not available, manually open the dump valves 2) Confirm the dumping by monitoring level rise in storage tank 3) De-energise all control panels including Emergency Control Panel (ECP) and allow the sodium system to cool to room temperature. 4) Maintain argon pressure of system at 50-100mbar 5) Isolate the individual LPG cylinders 5
OPEC 7) Close down all the doors and rolling shutters of the building to minimize water entry into the building 8) Stay at a height elevation and wait for the Tsunami/cyclone warning to be withdrawn. 9) Inform Head, SGTF-OS and Head,RIOD & Director, RDTG FLOOD IN SGTF BUILDING Follow steps 1 to 6 Stay at higher elevation and wait for water to recede After water inside the hall recedes off, switch on the diesel operated dewatering pump provided above the dump pit and pump out water inside the dump pit. Continue salvaging operation with the support of concerned staff of IGCAR Inform Head, SGTF-OS and Division Head, RIOD, & Director, RDTG
OPEC Earth quake On receiving earth quake warning Follow steps 1 to 4 All the staff shall go outside the building and stay in open area. Inform Head, SGTF-OS and Head RIOD, Director, RDTG Extended black out scenario Manually open the dump valves and dump sodium in the loop to dump tank Wait for resumption of Class-III and Class-IV power supplies All the surface heaters will go off and the temperature in the system will start reducing Maintain argon pressure of 50-100mbar. Emergency DC lights will be available in loop area for visibility during the night times. Inform Head, SGTF-OS, Head RIOD, Director, RDTG 7
OPEC INCIDENTS SMALL WATER LEAK HSD/HAD Normal background value will be equal to 70ppb if the level raises to 140ppb(HSD) and 1000vppm (HAD) an alarm (Level-1) is generated. For alerting the operator. when the hydrogen level increases to 170ppb(HSD) and 1500vppm(HAD) or if the rate of rise is above threshold Second alarm (Level-2)is initiated. After confirmation operator manually puts SG in safe configuration Third alarm (Level-3)is initiated when hydrogen level increases to 200ppb(HSD) and 2000vppm(HAD) or if the rate of rise is above threshold. Under this condition SG will go to safe configuration automatically. This results in tripping of main sodium pump(ALIP), Em pump, NaX blower, Cold trap blower, fired heater and boiler feed pump. After SG safe configuration operator has to manually dump the loop. Inform Head, SGTF-OS , Head RIOD & Director, RDTG 8
OPEC INTERMEDIATE WATER LEAK In case of water leak into sodium is in between 10g to 0.1kg/s, it is predicted that the cover gas pressure in buffer tank can build up faster compared to detection level of HSD. In such case , pressure rise in buffer tank is measured and when the pressure exceeds 0.16MPa, alarm and safety actions are initiated automatically. SG will go safe configuration automatically. This results in tripping of main sodium pump(ALIP), Em pump, NaX blower, Cold trap blower, fired heater and boiler feed pump. After SG safe configuration operator has to manually dump the loop. Inform Head, SGTF-OS ,Head RIOD, SGTF, Director, RD&TG 9
OPEC Genaral fire, Oil fire, Electrical fire Proceed as per fire order Class IV power failure On Class IV failure some of the surface heaters, immersion heaters, blowers, main air compressor and ALIP will not work. Similarly all SWS loads and FH loads will not be available. DG should come on. All instrumentation and control will be available. Using mobile compressor maintain required instrument air to dump valves. Dump line heaters are on Class-III. Monitor dump line temperature. If it goes below 150属C dump loop sodium Class II power failure In case of 20kVA UPS failure, all PLC panels of Sodium system, FH and SWS will fail. This will result in tripping of all main loads such as ALIP, FH, BFP and EM pump. PC based timer will not be available.SWS pumps and FO pumps trips automatically. 10
OPEC If required heaters can be switched on by changing the toggle switch manual mode from control panel. All PCs will not be available. Only annunciation windows, indication lamps in control room safety panel will be available. Important sodium loop temperature readings such as hot leg, cold leg dump line temperatures and FH coil temperature can be known from class-1 fed scanner available in sodium auxiliary room. Leak detection system will not be available OPERATOR ACTION REQUIRED DURING THE INCIDENT Ensure ALIP, BFP, EMP, CEP, CWP, Boiler, raw water pump are tripped if not trip manually. Since mobile compressor is available it will provide air supply to dump valves and FH (Class 2 only failed) If UPS or leak detection system is not resumed within 15 minutes dump the loop 11
OPEC Dumping should be done as explained below: Open dump valves either by operating dump key from control room or by pressing dump push button provided in field. Open NaX bypass valve and SG drain vlalve by pressing open push buttons on safety panels. After dumping watch cover gas pressure and maintain 30mbar SG tube side: Close vent valve (VS-ni-5153 and open nitrogen supply valves (VS-ni-5152, 5154) at 27m elevation For putting SG into safe configuration, close QC valves(VS-fw-5105 and Vs-st- 5159) and sodium side valves (Vpna2001 and 2002) manually. Open small depressuring valve (vs-fw-5109) and isolation valve on depressurising manually and let out steam. Watch SG tube pressure in PG and when it reaches 15bar, inject nitrogen into tubes and purge for 5minutes. Then close small depresssurising valve and maintain Sg tubes at a pressure of 10bar. 12
OPEC Class I failure Dump valves open automatically on Class-1 failure. Maintain loop cover gas pressure. DCS failure In case of DCS failure, DAS, leak detection system and PIDICON controllers also fails. Due to PIDICON failure ALIP and EM pump trips automatically. Try to resume DCS or dump the loop. DUMP TANK leak This will be detected by wire type leak detector and will give an alarm in control room Find the leak location and physically verify the leak Switch off the dump tank surface heater Depressurise the dump tank to atmospheric pressure Use recommended safety dress and fight fire. 13
OPEC Inform fire service and proceed as per fire order. Ensure exhaust fans are running. Otherwise open the shutter to reduce oxide fumes in the area. Allow sodium to freeze by removing more insulation. Inform Head, SGTF-OS and Plant Superintendent, SGTF, Director, FRTG Low dump line temperature, low temperature in fired heater coil, low air pressure, low nitrogen pressure, low LPG pressure, failure of flame photometer, failure of leak detectors, non availability of hydrogen in sodium meter, non availability of hydrogen in argon meter are discussed already FIRST AID First aid for sodium burns Skin damage Remove visible pieces of liquid metal. Take care to avoid their entry into eyes, ears, nose and mouth. 14
OPEC Paraffin oil can be used for flushing to remove sticky sodium particles Thoroghly water wash the affected area after all chunks of metal have been removed. Burnt area may be neutralised with 2% acetic acid or 2% boric acid. Eyes Should be cleaned with water for at least fifteen minutes. There is no exception to this rule. Use eye sprinkler for this purpose. Digestive track Give copious quantity of water or milk to drink 15

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OPERATION PROCEDURE IN A CHEMICAL PLANTS

  • 2. OPEC In Operating Procedure for Emergency Conditions (OPEC) the emergency conditions and incidents of SGTF and operation procedure to be followed under these conditions are explained. 2
  • 3. OPEC This part deals with emergency operations that are to be carried out by the operator in the event of sodium leak/fire and sodium water reaction SODIUM FIRE In the event of a sodium leak/fire outside fire heater, wire type leak detectors, spark plug leak detectors or SID type leak detector will detect and give alarm in control room. acknowledge the alarm and observe the leak location with the help of CRT Physically verify the sodium leak On confirmation of leak, dump sodium by using push button or manually in absence of air supply . 3
  • 4. OPEC EM pump, NaX blower, CT blower and fired heater, boiler feed pump etc will be tripped automatically Maintain a cover gas pressure in the system Confirm dumping of sodium by monitoring the level rise in storage tank Inform fire service and proceed as per fire order Use recommended safety dresses and fight sodium fire Ensure exhaust fans are working Inform Head, SGTF-OS and Head-RIOD. LARGE SODIUM WATER REACTION In case of large sodium water reaction hydrogen pressure in the sodium side will build up within milliseconds and rupture disc provided at inlet or outlet side of SG will be ruptured. The spark plug type detectors provided at the down streamside of rupture disc in the reaction products discharge line will give signal that rupture disc is ruptured 4
  • 5. OPEC On receiving this signal the water side and sodium side of SG will be automatically isolated, water/steam in tubes will be de-pressurised and the SG tube filled with nitrogen. Dump sodium in the loop manually Inform Head, SGTF-OS and Plant Superintendent, SGTF TSUNAMI AND CYCLONE On issuance of Tsunami/Cylone warning 1) Shutdown the plant and dump the loop sodium. If compressed air or Class- 1 power supply is not available, manually open the dump valves 2) Confirm the dumping by monitoring level rise in storage tank 3) De-energise all control panels including Emergency Control Panel (ECP) and allow the sodium system to cool to room temperature. 4) Maintain argon pressure of system at 50-100mbar 5) Isolate the individual LPG cylinders 5
  • 6. OPEC 7) Close down all the doors and rolling shutters of the building to minimize water entry into the building 8) Stay at a height elevation and wait for the Tsunami/cyclone warning to be withdrawn. 9) Inform Head, SGTF-OS and Head,RIOD & Director, RDTG FLOOD IN SGTF BUILDING Follow steps 1 to 6 Stay at higher elevation and wait for water to recede After water inside the hall recedes off, switch on the diesel operated dewatering pump provided above the dump pit and pump out water inside the dump pit. Continue salvaging operation with the support of concerned staff of IGCAR Inform Head, SGTF-OS and Division Head, RIOD, & Director, RDTG
  • 7. OPEC Earth quake On receiving earth quake warning Follow steps 1 to 4 All the staff shall go outside the building and stay in open area. Inform Head, SGTF-OS and Head RIOD, Director, RDTG Extended black out scenario Manually open the dump valves and dump sodium in the loop to dump tank Wait for resumption of Class-III and Class-IV power supplies All the surface heaters will go off and the temperature in the system will start reducing Maintain argon pressure of 50-100mbar. Emergency DC lights will be available in loop area for visibility during the night times. Inform Head, SGTF-OS, Head RIOD, Director, RDTG 7
  • 8. OPEC INCIDENTS SMALL WATER LEAK HSD/HAD Normal background value will be equal to 70ppb if the level raises to 140ppb(HSD) and 1000vppm (HAD) an alarm (Level-1) is generated. For alerting the operator. when the hydrogen level increases to 170ppb(HSD) and 1500vppm(HAD) or if the rate of rise is above threshold Second alarm (Level-2)is initiated. After confirmation operator manually puts SG in safe configuration Third alarm (Level-3)is initiated when hydrogen level increases to 200ppb(HSD) and 2000vppm(HAD) or if the rate of rise is above threshold. Under this condition SG will go to safe configuration automatically. This results in tripping of main sodium pump(ALIP), Em pump, NaX blower, Cold trap blower, fired heater and boiler feed pump. After SG safe configuration operator has to manually dump the loop. Inform Head, SGTF-OS , Head RIOD & Director, RDTG 8
  • 9. OPEC INTERMEDIATE WATER LEAK In case of water leak into sodium is in between 10g to 0.1kg/s, it is predicted that the cover gas pressure in buffer tank can build up faster compared to detection level of HSD. In such case , pressure rise in buffer tank is measured and when the pressure exceeds 0.16MPa, alarm and safety actions are initiated automatically. SG will go safe configuration automatically. This results in tripping of main sodium pump(ALIP), Em pump, NaX blower, Cold trap blower, fired heater and boiler feed pump. After SG safe configuration operator has to manually dump the loop. Inform Head, SGTF-OS ,Head RIOD, SGTF, Director, RD&TG 9
  • 10. OPEC Genaral fire, Oil fire, Electrical fire Proceed as per fire order Class IV power failure On Class IV failure some of the surface heaters, immersion heaters, blowers, main air compressor and ALIP will not work. Similarly all SWS loads and FH loads will not be available. DG should come on. All instrumentation and control will be available. Using mobile compressor maintain required instrument air to dump valves. Dump line heaters are on Class-III. Monitor dump line temperature. If it goes below 150属C dump loop sodium Class II power failure In case of 20kVA UPS failure, all PLC panels of Sodium system, FH and SWS will fail. This will result in tripping of all main loads such as ALIP, FH, BFP and EM pump. PC based timer will not be available.SWS pumps and FO pumps trips automatically. 10
  • 11. OPEC If required heaters can be switched on by changing the toggle switch manual mode from control panel. All PCs will not be available. Only annunciation windows, indication lamps in control room safety panel will be available. Important sodium loop temperature readings such as hot leg, cold leg dump line temperatures and FH coil temperature can be known from class-1 fed scanner available in sodium auxiliary room. Leak detection system will not be available OPERATOR ACTION REQUIRED DURING THE INCIDENT Ensure ALIP, BFP, EMP, CEP, CWP, Boiler, raw water pump are tripped if not trip manually. Since mobile compressor is available it will provide air supply to dump valves and FH (Class 2 only failed) If UPS or leak detection system is not resumed within 15 minutes dump the loop 11
  • 12. OPEC Dumping should be done as explained below: Open dump valves either by operating dump key from control room or by pressing dump push button provided in field. Open NaX bypass valve and SG drain vlalve by pressing open push buttons on safety panels. After dumping watch cover gas pressure and maintain 30mbar SG tube side: Close vent valve (VS-ni-5153 and open nitrogen supply valves (VS-ni-5152, 5154) at 27m elevation For putting SG into safe configuration, close QC valves(VS-fw-5105 and Vs-st- 5159) and sodium side valves (Vpna2001 and 2002) manually. Open small depressuring valve (vs-fw-5109) and isolation valve on depressurising manually and let out steam. Watch SG tube pressure in PG and when it reaches 15bar, inject nitrogen into tubes and purge for 5minutes. Then close small depresssurising valve and maintain Sg tubes at a pressure of 10bar. 12
  • 13. OPEC Class I failure Dump valves open automatically on Class-1 failure. Maintain loop cover gas pressure. DCS failure In case of DCS failure, DAS, leak detection system and PIDICON controllers also fails. Due to PIDICON failure ALIP and EM pump trips automatically. Try to resume DCS or dump the loop. DUMP TANK leak This will be detected by wire type leak detector and will give an alarm in control room Find the leak location and physically verify the leak Switch off the dump tank surface heater Depressurise the dump tank to atmospheric pressure Use recommended safety dress and fight fire. 13
  • 14. OPEC Inform fire service and proceed as per fire order. Ensure exhaust fans are running. Otherwise open the shutter to reduce oxide fumes in the area. Allow sodium to freeze by removing more insulation. Inform Head, SGTF-OS and Plant Superintendent, SGTF, Director, FRTG Low dump line temperature, low temperature in fired heater coil, low air pressure, low nitrogen pressure, low LPG pressure, failure of flame photometer, failure of leak detectors, non availability of hydrogen in sodium meter, non availability of hydrogen in argon meter are discussed already FIRST AID First aid for sodium burns Skin damage Remove visible pieces of liquid metal. Take care to avoid their entry into eyes, ears, nose and mouth. 14
  • 15. OPEC Paraffin oil can be used for flushing to remove sticky sodium particles Thoroghly water wash the affected area after all chunks of metal have been removed. Burnt area may be neutralised with 2% acetic acid or 2% boric acid. Eyes Should be cleaned with water for at least fifteen minutes. There is no exception to this rule. Use eye sprinkler for this purpose. Digestive track Give copious quantity of water or milk to drink 15