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."