殼牌煤氣化兩起事故的經(jīng)驗分享

第第頁殼牌煤氣化兩起事故的經(jīng)驗分享

不當(dāng)隔離造成S1103B發(fā)生嚴峻安全事故SeriousHSSEIncidentatS-1103BasResultof

InadequateSystemIsolation

CustomerCommunicationPackage

Agenda內(nèi)容

1.IncidentDescription

事故描述

2.IncidentClassificationandAnalysis

事故分類和分析

3.KeyLearning

主要教訓(xùn)

4.SystemIsolationStandard

系統(tǒng)隔離標準

IncidentDescription事故描述

1.

2.

3.

4.

5.Timing時間:Dec.2022Venue地點:SCGPLicensee某客戶Whathappened事故:E*plosionoccurredtoS1103B3hafterS/U開車后3小時S1103B發(fā)生爆炸Immediateactions當(dāng)即措施:operatoremergentlyshutdowngasifier緊急手動停車。Consequences事故后果:

①S1103Bfullydamaged布袋除塵器S1103B完全損壞

②Largeamountofcoalpowderpouredontotheground大量煤粉拋向地面

③ifsomebodyhadbeenclosetothebagfiltertheninjuryorworsecouldeasilyhavehappened幸好現(xiàn)場無人，否那么會發(fā)生傷亡。

6.Preliminaryfindings初步查證

①WhenclientswitchedthesyngastotheshiftunitthesyngasflewintotheLPN2systembecausetheLPN2systemwasnotproperlyisolatedfromtheshiftunit.Thenthesyngasflewbacktounit1100thoughLPN2lineandcausedthee*plosionoftheS-1103Bbagfilter.全場低壓氮氣與變換及制粉系統(tǒng)聯(lián)通。由于低壓氮氣與變換系統(tǒng)隔離不當(dāng)，合成氣導(dǎo)入變換系統(tǒng)后，合成氣流入低壓氮氣系統(tǒng)，然后進入磨煤系統(tǒng)而導(dǎo)致布袋除塵器爆炸。

②ClientdidnotaddblindbetweentheLPN2systemandtheshiftunitbutreliedonasinglevalvetoisolatethesystems.在低壓氮氣和變換系統(tǒng)之間未加盲板，僅靠單一閥門隔離。

③Syngasandcoalpowderformedane*plosivemi*turetothee*plosivelimitduetoH2presence.Mostlikelyastaticelectricitysparkbuiltupinthissolidhandlingsystemignitedthemi*ture.合成氣進入布袋除塵器后，合成氣里的氫、一氧化碳與煤粉及系統(tǒng)內(nèi)的氧氣形成爆炸物。氫氣易燃，其混和物的爆炸下限很低，煤粉輸送系統(tǒng)很簡單形成靜電，很可能是靜電火花點燃了可燃粉塵/氣體爆炸物。

IncidentClassificationandAnalysis事故分類和分析1.TypeofIncident事故類別:E*plosionAssetDamage爆炸及資產(chǎn)損壞

2.IncidentRAMRating–HighRiskPotential:P4D,E2D,A3C,R4D;Actual:P0,E1,A3,R4事故分級–高風(fēng)險潛在風(fēng)險：人員4D,環(huán)境2D,資產(chǎn)3C，聲譽4D；實際：無傷亡，無傷亡，環(huán)境1，資產(chǎn)3，聲譽43.ImmediateCauses徑直緣由:

①SyngasingressintoS1103BfromtheshiftunitviaLPN2lineformedane*plosivemi*turewiththecoaldustinsideS1103B變換裝置里的合成氣進入低壓氮氣系統(tǒng)后，又進入S1103B,與煤粉形成爆炸粉塵/氣體混和物。

②Presenceofstaticelectricityduringsolidshandlingignitedthee*plosivemi*tureinsideS1103B固體輸送形成的靜電點燃了S1103B里的爆炸混和物。

4.UnderlyingCauses間接緣由:

①IsolationoftheLPN2systemfromtheshiftunit/syngassystemreliedonasinglevalveinsteadofusingblindsorremovalofspoolpiece

低壓氮氣與變換系統(tǒng)的隔離未采納盲板或斷開的方式，而僅僅依靠單一閥門。

②TheN2firefightingsystemrelyingonO2andCOmonitoringescalatedthefireande*plosionprocessinthisincidentsincemoresyngasinsteadofpureN2waskeptfeedingtoS1103BoncehighCOcontentwasdetected.氮氣消防系統(tǒng)依據(jù)測量到的布袋內(nèi)的氧含量和一氧化碳含量的高低來決斷氮氣消防流量。此次事故中，一氧化碳含量高，氮氣消防流量增加，但此時消防系統(tǒng)送入的恰恰是導(dǎo)致火災(zāi)和爆炸事故的合成氣，而非純氮，導(dǎo)致事故升級。

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KeyLearning主要教訓(xùn)

1.Allvalvesleak.HPmediumwillleaktoLPsystemiftheyareconnectedandisolatedwithvalvesonly.Neverrelyonvalvesforsystemisolation.Airgappingisrecommended.

全部閥門都存在內(nèi)漏。假如高壓系統(tǒng)與低壓系統(tǒng)相連，而僅用閥門隔離，高壓介質(zhì)會流向低壓系統(tǒng)。所以不能依靠閥門擔(dān)當(dāng)系統(tǒng)隔離。建議采納斷開的隔離方式。

2.Proceduresneedbeadoptedtoensurethatwheneveraunitisstarted,thesystemsnotinuseareproperlyisolated,fore*ampletheLPnitrogensystemispositivelyisolatedfromtheshiftunitbydroppingthespoolpiece.需要建立管理程序，當(dāng)裝置開車時，不用的系統(tǒng)需要牢靠隔離，比如對于低壓氮氣系統(tǒng)，應(yīng)拿掉短節(jié)，以確保與變換系統(tǒng)牢靠隔離。

3.Correctratingandinstallationoftherupturediscsarecrucial.ThebagfilterneedbeairtightandO2contenttobekeptbelow8%or6%,dependingonthecoals.ThesystemshallalsohaveaPSV.防爆片的定值和安裝特別重要，布袋除塵器氣密要合格，依據(jù)不同煤種，氧量保持在8%或6%以下。該系統(tǒng)也應(yīng)考慮設(shè)置瀉壓閥。

4.ThebagfilterareaisalsoahighriskareawhenCMDisinoperationandrequiresbarricading.Alongtermsolutionisrequired.

布袋除塵器區(qū)域是高風(fēng)險區(qū)域，需要區(qū)域隔離。需要考慮長期解決放案。

5

SystemIsolationStandard系統(tǒng)隔離標準

No.

1Isolation隔離方式Air

Gapping

斷開

Blinding

盲板E*amples例如①Removalofavalveorspoolpieceandfittingofblankflangestobothopenends拆掉閥門或管段，敞口處加盲法蘭Advantage優(yōu)點Reliable牢靠Disadvantage缺點①Moreworkandtime工作量大，花費時間長②Tightnesstestrequiredbeforeputbackinserviceduetopotentialdamagetoflangesurfaces由于可能損壞法蘭面，投用前需要作氣密試驗③Newgasketsrequired每次需要更換墊片①Moreworkandtime工作量大，花費時間長②Tightnesstestrequiredbeforeputbackinservicedueto

potentialdamagetoflangesurfaces

由于可能損壞法蘭面，投用前需要作氣密試驗

③Newgasketsrequired每次需要更換墊片

①Thismethodwillnotbeusedforliquidhydrocarbon/gas/

nitrogen,to*icmaterialorchemicalsisolationforthe

purposeofisolationformanentry.

假如人員需要進入容器，而需隔離的介質(zhì)是液態(tài)

碳氫化合物/可燃氣體/氮氣/其他窒息性氣體/有毒

材料或腐蝕性化學(xué)品等，不可運用此種隔離方法

②Ifeitheroftheblockvalvesisfoundtobepassing,this

methodwillnotbeused.

假如任一個截止閥存在漏泄，這種隔離方法不得

運用。2①Fittingablindinadditiontovalveisolation在隔離閥后加一塊盲板②Fittingablindorslipplate在法蘭之間加堵板③Turningaspectacleblindtotheclosedposition八字盲板轉(zhuǎn)到關(guān)閉位置①Doubleblockisolation,valveslockedclosed,withaventvalveopenbetweentheisolationvalvesi.e.doubleblockandbleed(DBB)雙截止閥關(guān)閉，中間導(dǎo)淋或排空閥開啟，閥門上鎖。Reliable牢靠3DBB雙隔離閥+排放閥Easye*ecutionNodamagetoflangesandgaskets簡單實施，不會損壞法蘭面和墊片

4Single

valve

單閥Notrecommended不推舉運用

Asgeneralrule,airgappingorblindsaretobeusedasisolationwherethereisriskoffire,e*plosion,poisonandasphy*iate.Donotforgetisolationofmotorradioactiveinstruments!

假如存在火災(zāi)、爆炸、中毒和窒息等風(fēng)險，一般要求運用物理斷開或盲板隔離的系統(tǒng)隔離方式。請勿忘卻隔離馬達和射源！6

連鎖愛護的重要性ImportanceofSafeguarding

CustomerCommunicationPackage

Agenda內(nèi)容

1.IncidentDescription

事故描述

2.IncidentClassificationandAnalysis

事故分類和分析

3.PreliminaryFindings

初步發(fā)覺

4.KeyLearning

主要教訓(xùn)

5.CriticalSafeguardingforSCGP

SCGP關(guān)鍵聯(lián)鎖愛護

IncidentDescription事故描述

1.Timing時間:Jan.2022

2.Venue地點:SCGPLicensee某客戶

3.Whathappened事故:ahugecoalpowderleakagefromV1205AaerationconeandbigfireonthegasifierdeckneartheNo.2coalburner.

V1205A泄漏大量煤粉，2號煤燒嘴平臺處發(fā)生大火。

4.Immediateactions當(dāng)即措施:operatoremergentlyshutdowngasifier90safterwards.90秒后緊急手動停車。

5.Consequences事故后果:

①No.2coalburnerfullydamagedinternally.

2號燒嘴內(nèi)部完全損壞。

②Coalfeedlineburnedoutforroughly1m.

煤粉管線燒毀約1米。

③Someinstruments,cablesandcontrolbo*esalsocaughtfireandwereseriouslydamaged.一些儀表、電纜、掌握盤著火，嚴峻損壞。

④V1205Aaerationconeforline2heavilydamagedleakageobservedintheflangewhereN2wassuppliedtotheaerationcone.

V1205A2號線通氣錐嚴峻損壞，通氣錐氮氣法蘭處發(fā)生泄漏。

⑤ifsomebodyhadbeenclosetothecoalburnertheninjuryorworsecouldeasilyhavehappened

幸好現(xiàn)場無人，否那么會發(fā)生傷亡。

⑥Asignificantamountofcoalpowderspilledintothestructure.Thiscouldeasilyhavebeenignited,resultinginabiggerfireandmuchmoredamage.

大量煤粉在框架內(nèi)飛揚，很簡單被點燃，造成大火或更大損壞。

PreliminaryFindings初步發(fā)覺

①SyngasbackflowtoburnerNo.2andcoalfeedline,resultinginleakageandcreatingafire.合成氣倒流進入2號燒嘴和煤粉管線,造成合成氣泄露和大火.

②SCGPcoalfeedlineshavethreesafeguardsagainstbackflow:the2ndvelocitymeternearthecoalburner,the2nddensitymeternearthecoalburnerandtheo*ygen/coalratiobasedonthe2ndvelocitymeteranddensitymeternearthecoalburner.Fore*ample,ifthevelocitymeasuredbythe2ndvelocitymeterdropsbelow3m/sec,itautomaticallytripstheburner.SCGP煤管線設(shè)有三種防倒流愛護：靠近煤燒嘴的第二個速度計和和第二個密度計，以及建立在第二個速度計和密度計基礎(chǔ)上的氧煤比。假如第二個速度計流速降到3米/秒以下，自動停燒嘴。

③The2ndvelocitysafeguardwasinoverrideandmorethanlikelywasthe2nddensitymetersafeguardingalsooverridden.第二個速度計連鎖被解除，第二個密度計連鎖極可能也被解除。

IncidentClassificationandAnalysis事故分類和分析1.

2.

3.TypeofIncident事故類別:FireAssetdamage火災(zāi)及資產(chǎn)損壞IncidentClassification/RAMRating–HighRiskPotential:P4D,A4D,R4D;Actual:P0,A3,R4事故分級–高風(fēng)險潛在風(fēng)險：潛在風(fēng)險：人員4D，資產(chǎn)4D，聲譽4D；實際：實際：無傷亡，無傷亡，資產(chǎn)3，聲譽4ImmediateCauses徑直緣由:

①

②FailureofthegasketoftheflangeforHPN2totheaerationconeofV-1205Aresultedinsuddendecreaseofthepressureinthecoalfeedline,(leadingtobackflowtothecoalburnerandthecoalfeedlineduetooverrideofmajorityofthesafeguardingfunctions)V1205A通氣錐高壓氮氣法蘭墊片失效，造成煤粉管線內(nèi)壓力突然下降(由于絕大部分聯(lián)鎖愛護功能被解除,造成煤燒嘴和煤管線回流).Thesafeguardsofthecoalflowvelocitywasinoverride.ThedensitywasmostlikelyinoverrideandthoughO2/Cratiowasinoperation煤粉速度聯(lián)鎖愛護被解除，密度聯(lián)鎖愛護可能被解除，盡管氧煤比聯(lián)鎖愛護處于投入狀態(tài)。

Wronggasketmaterial.墊片材料錯誤

Majorityofsafeguardinginoverride.絕大部分連鎖被解除

Noproperinstructions/proceduresforoverridingsafeguardingandriskassessment.解除連鎖無適當(dāng)?shù)墓芾沓绦颍催M行風(fēng)險分析

Incorrectmanualinterventiontoavoidtrippingoftheline.為避開煤線跳車，不當(dāng)運用手動調(diào)整方式PoorHSSEmanagementandphilosophy.Donotlearnfrompreviouslessons

安全管理和理念不到位，未接受以往教訓(xùn)。

Poorequipmentmaintenance設(shè)備檢修不到位。

Underpressuretokeeptheunitrunningcontinuously保持裝置連續(xù)運行的壓力。

114.UnderlyingCauses間接緣由:①②③④⑤⑥⑦

KeyLearning主要教訓(xùn)

1.

2.

3.Safeguardingiscrucialfortheprocesssafety.Ifthe2ndvelocity,densitymetersafeguardswouldhavebeeninoperationandnomanualinterventionwouldhavebeendonetopreventthelinetripsasresultofO2/Cratio,mostlikelythiswouldhavebeenadequatetopreventthisincidentfromhappening聯(lián)鎖愛護對于工藝安全至關(guān)重要。假如第二個速度計、密度計聯(lián)鎖愛護處于投入狀態(tài),且未對氧煤比進行手動干預(yù)，本領(lǐng)故很可能就可以避開。TwokindsofsafeguardingforSCGP有兩種聯(lián)鎖愛護:①ForplantprotectionlocatedinESD(UZfunction)whichisverycritical用于裝置愛護，帶有UZ，分布在ESD中，特別重要。②ForequipmentprotectionlocatedinDCS(USfunction)whichislesscritical.用于愛護設(shè)備，帶有US，分布在DCS中，重要性次之。AlltheUZfunctionslocatedinESDareverycriticalandshallnotbeoverridden.ESD中的全部UZ聯(lián)鎖愛護功能特別關(guān)鍵，不應(yīng)當(dāng)解除。Allsafeguardingforflow,pressure,differentialpressure,levelandflamedetectionarefollowedinseriesbyatimer.Thetimerpreventsnuisancetripsresultingfromamomentarilylossofsignal.Thetimersettingsaretobedeterminedduringdetaileddesignand/orcommissioning.

全部流量、壓力、差壓、液位和火焰檢測都串接一個定時器。這個定時器可以防止因信號瞬間消逝而導(dǎo)致誤跳車。定時器的定值由具體設(shè)計和試車來決斷。

12

CriticalSafeguarding關(guān)鍵聯(lián)鎖愛護

1.Thegasifieremergencyshutdownsystem(13UZ-0001)–majorincidents

氣化爐緊急停車(13UZ-0001)–重大事故

2.Thegasifiero*ygensupplyshutdownsystems(13UZ-0002/0003)-backflashofburnerflame氣化爐氧氣供應(yīng)停車系統(tǒng)(13UZ-0002/0003)-回火危急

3.Theslagbathsafeguardingsystem(13UZ-0004)-syngasenteringsprayringandsupplylines.渣池連鎖愛護(13UZ-0004)–合成氣進入噴淋環(huán)和供水管線

4.Thefuelando*ygensystemofthestart-upburner(13UZ-0005),-SUburnerbackflash/damage開工燒嘴燃料氧氣連鎖愛護(13UZ-0005),-開工燒嘴回火損壞危急

5.Thefuelsystemoftheignitionburner(13UZ-0006)-LPG/airmi*tureinthegasifier

點火燒嘴燃料系統(tǒng)連鎖(13UZ-0006)-在氣化爐內(nèi)形成LPG/空氣混和物

6.Thegasifierpurgelogicmonitoringsystem(13UZ-0010)–equipment/e*plosionincidents氣化爐吹掃規(guī)律監(jiān)督系統(tǒng)–設(shè)備/爆炸事故

7.Thecoalburnero*ygenandcoalsupplysystems(13UZ-0011through13UZ-0014).Overheatingofburnersandgasifier

燒嘴氧煤供應(yīng)連鎖愛護(13UZ-0011~13UZ-0014).燒嘴/氣化爐過燒

13

CoalBurnerEmergencyShutdownSyste

ms(13UZ0011/12/13/14)1.13SZL-0103:toolowacoalflowvelocitytoburner煤粉流速過低–burnerfrontoverheatingandbackflow2.13DZL-0102:toolowacoalflowdensitytoburner煤粉密度過低-overheatingofburnerfrontandbackflow3.13PDZL-0127:toolowadifferentialpressureoverO2controlvalve氧氣掌握閥差壓過低-backflow4.13FZLL-0103:toolowano*ygenflowtotheburner燒嘴氧氣流量太低-backflowprotection5.13FZHH-0103:toohighano*ygenflowtoburner燒嘴氧氣流量太高-toohighthermalloadofburner6.13FZHH-0109:toohigho*ygen/coalratio氧煤比太高-seriousover-firing7.13PDZL-0133:toolowapositivedifferentialpressurebetweenpulverisedcoalfeedvesselandsteam/o*ygenlinetoburner高壓粉倉與氧氣/蒸氣管線正壓差太低-backflowprotection

8.13PDZLL-0007:toolowapositivedifferentialpressurebetweeno*ygensupplyandgasifier氧管線與氣化爐之間正壓差太低-unstableburneroperationorbackflowofgasifiercontent

9.12LZLL-0104(via12UZ-0102):toolowlevelinfeedvessel(UNIT1200)withoperationaloverride高壓粉倉料位太低-unstableflowtotheburnerandbackflowprotection

10.13*V-0110:11.13*V-0120:12.13*V-0108:protection

“Notopen’(13GSH-0110notpresent)“Notopen”(13GSH-0120notpresent)“Notopen”(13GSH-0108notpresent)Isolationoffeedlinetopreventbackflow.erosionofshutdownvalve(leakingafterwards)orunstableoperation.閥門磨損(閥門磨損(以后漏粉)以后漏粉)或運行不穩(wěn)定

13.13PdZLL-0122:lowdifferentialpressureovervalve13*V-0116閥門差壓低present-bac