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Achieving Safe &

Efficient Designs

with SimSci

SoftwareMarina Velazquez

Product Manager

SimSci by Schneider Electric

SimSci Simulation for Business Excellence. Schneider Electric confidential.

Agenda

●Safety: Nobody wants property damages

●Emergency Relief Design

●After Steady State Design – Reduce the relief needed

●Human error – Preventive measures

●Case examples: Preventable accidents

●Case examples: Success Stories

●A real life example

SAFETY: Nobody

Wants Property

Damages


Property Damage – Root Causes

“Industry studies of the 170 largest property-damage

losses over the last 30 years in the hydrocarbon processing industry have shown that 28% are due to operational error or process upsets”

“...about 40% of abnormal operations were caused by human errors”


Not a Pretty Sight

Image from KTLA5 February 18, 2015

Emergency

Relief Design


• Source: PetroWiki 2015 Flare and vent disposal

systems (accessed September 15, 2015)

• Image from KTLA5.com, February 18, 2015

Emergency Relief Design28% are Due to Operational Error or Process Upsets

• A flare or vent disposal system

collects and discharges gas from

atmospheric or pressurized process

components to the atmosphere to

safe locations for final release during

normal operations and abnormal

conditions (emergency relief)

• In vent systems, the gas exiting the

system is dispersed in the

atmosphere


VISUAL FLARE

• Major incidents causing human loss

and irreparable damage to the

environment, have focused

worldwide attention on the suitable

design, maintenance and operation

of pressure relief systems

• VISUAL FLARE includes Visual

Flare™ and Visual Network™ • Visual Flare is designed for modeling relief

system hydraulic calculations

• Visual Network performs hydraulic calculations on systems such as cooling water or steam distribution networks


Relief System Connected to Flare

KnockOutDrum

P2 = 0 psig

Dptip = 3 psig

DPsello= 2 psig

P1= ? psig

(Set pressure)

(Backpressure)

Relief Valve

Flare

Criteria to define

the relief valve type:

Conventional: BP/SP<10%

Balanced: 10%<BP/SP<30%

Pilot: 30%<BP/SP<75%

(%) =BP Backpressure (psig)

SP Set Pressure (psig)

Other units


Design and Rate Flare Networks


VISUAL FLARE

●VISUAL FLARE Incorporates˃ API Standard 521: Pressure-relieving and Depressuring Systems

˃ API Standard 520: Sizing, Selection, and Installation of Pressure-relieving Devices (Rev 2008 latest edition available in VISUAL FLARE 5.7)

˃ DIERS Benchmark. Particular interest for the prediction of two-phase flow venting and the applicability of various sizing methods for two-phase and vapor-liquid flashing flow

˃ Rigorous thermodynamic methods: SIM4ME Thermo

After Steady

State DESIGN –

Reduce the Relief

Needed


Dynamic Simulation

●SimSci’s DYNSIM and other Dynamic Simulation Suite (DSS) software provide the full power of rigorous dynamic simulation and high-fidelity control system emulation for process engineers, control engineers, plant operators, and plant managers to optimize plant design and operation

●Safety Design Simulation Applications ˃ Relief analysis to accurately set flare capacity

˃ Compressor surge studies to reduce the possibility of damage to rotating equipment

˃ Cryogenic depressuring to determine low temperature metallurgy requirements

˃ Boiler draft studies to assess the risk of furnace implosion

˃ Refinery cooling and steam system analysis to improve reliability


●Objectives˃ Identify peak relief load for different

scenarios—total power failure and partial power failure

●Results● Working with EPC and Tesoro, applied

API 521 Procedures to establish peak relief

● Analysis– Peak Relief Load lower than Static Calc’s

– Showed 56% reduction in peak relief load versus static loads

– Analyzed Crude Unit and DIB

●Benefit˃ Millions of dollars of capital expenditure avoided for flare expansion

Tesoro Kenai Refinery, AlaskaHydrocracker Fractionator Flare Relief Analysis


Case Study – Alkylation Unit

●Objectives˃ Estimate relief loads from the de-

isobutanizer and the de-butanizer towers for CW failure and Power failure

˃ Verify the impact of safety instrumented systems (SIS)

●Results˃ Estimated lower relief loads of 20-70%

compared to static loads

˃ Verified that the designed PSVs are able to handle the peak relief loads

˃ Verified that SIS would lead to significant additional reduction in relief loads


●Objectives˃ Establish control strategy around 4 stage

compressor with 3 control valves

˃ Verify equipment size and operation during swinging gas composition

●Benefits˃ Study demonstrated that as-designed anti-

surge circuit was inadequate and needed a hot recycle loop for compressor trip

˃ Discovery in the design stage saved need to modify the equipment during commissioning potentially saving millions of dollars. Design correction also saved potential damage to expensive compressor.

˃ Verified compressor performance and operating philosophy over variety of operating conditions and confirmed valve sizes, trim and actuator times

PetroCanadaHydroprocessing Unit (HPU) Tail Gas Compressor

Human Error –

Preventive

Measures


About 40% of Abnormal Operations

Were Caused by Human Errors●Operators have a significant impact on plant safety

●Operators will make mistakes sometimes...

... but how can we prevent them?

●Operators can save the plant from an accident...

...so what’s making those successful?


...So What’s Making Those Successful?

●Operator education˃ Fundamentals of the process & operation

˃ Understanding why accidents happen

˃ Prevent accidents in the future

●Validating and improving rules and procedures˃ Identify and train best-practice

˃ Violated rules: “Change or adopt”

˃ Analyze new procedures on plant safety impact

● Improving communication skills

● Improve critical situation readiness

●Sustain improvements!


Why Operator Training Simulators?

� Understanding the process fundamentals

� Understanding why accidents happen

� Preventing accidents

� Identify best practice & roll-out

� Adoption of rules and procedures

� Analyze lack of information vs. information overkill

� Test changes using the simulator on safety impact

� Improving communication skills

� Critical situation readiness

� Avoiding routine by re-training

� Don’t forget the lessons-learnt


The Competency Pyramid & OTS

Pyramid Copyright: John M Campbell and Company

Examples of applying OTS in the different training levels


New Regulations and Technologies

●OTS is mandatory for nuclear power plants

● Introduction of new (voluntary) standards, e.g. ANSI Z490.1 for best HSE

practices

● Industry leaders including OTS as a standard in their training concepts. A key

driver is process safety

●New technologies enable new concepts for operator-centric safety training

3D virtual reality environments

integrated with OTS for field and

control room operator training

Preventable

Accidents


Bayer Crop Science Institute WV Plant

●The accident – August 28th 2008˃ Runaway reaction caused an explosion of a tank and a fire killing 2 people

˃ 40000 people were asked to shelter in place for three hours

●Some Chemical Safety Board investigation results˃ Deviation from written start-up procedures

˃ Inadequate training of operators after a installing a new DCS

˃ Insufficient technical expertise in the control room during restart

˃ Operators bypassed safety devices during start-up (“it’s necessary”)

˃ The plant (equipment + DCS) was simply not ready for start-up

●Lessons to learn˃ Enforce procedures – understand why they aren’t followed

˃ If operators aren’t aware of the safety impact of actions, they will take risk

˃ New DCSs can impact the operators’ emergency response skills


Chevron Richmond Refinery 2012

Handling of Emergency Situations

●The accident˃ Pipe failure due to corrosion

˃ Release of vapor which eventually ignited

˃ Root cause: Corrosion and lack of maintenance

●Some investigation results (Cal/OSHA and CSB)˃ “Chevron failed to implement its own emergency procedures to shut down the No. 4

Crude Unit ...”

˃ “...strong indicator that workers aren’t properly trained for emergency situation”

●Lessons to learn˃ Procedures might not be followed

˃ Team readiness for emergency situations?

˃ Identify gaps in the operator’s competency!

Success Stories


Brunner Mond Chemical Plant, UK

●Situation in 2001˃ Higher than average accident rate˃ Statistics: 1 LTI per employee during working life

●Safe and Unsafe Acts (Susa) Training Initiative˃ Training of Trainers˃ Training of Observers (25% of the workforce)˃ Training of all employees and of contractors

●Result˃ 0 LTI in 1 million hours (1st in 10 years)˃ Top safety records in the UK chemical industries

● Lessons to learn˃ Accidents aren’t fate˃ Training needs to be safety-centric˃ Active participation increases adoption


Engro Fertilizer Plant, Pakistan 2007

●Sequence of events August 2007˃ Shift found issue with the synthesis gas compressor˃ Operators tripped the compressor after analysis˃ Compressor repaired & restarted˃ Compressor still showed abnormal behavior˃ Full shut-down, inspection and rotor replacement˃ Re-start after 10 days

●Analysis by the plant engineers and management˃ Well-trained shift identified the problems correctly˃ Operators took the right decision˃ Prevention of an accident or long shut-down

●Lessons to learn˃ Trained & empowered operators take right decisions˃ If you train them, you’ll trust them

A Real Life

Example…


…this is a Canada Goose – beautiful bird!

A Real Life Example…


US Airways flight 1549 from La Guardia Airport

January 15, 2009


0:00 Take-off of US Airways flight 1549 from La Guardia at 3:25 pm

1:40 A large flock of Canada Geese hit the airplane…

Immediate loss of both (all) engines.

Plane descending at 2 floors/second from ca. 975 m.

Time to hit ground: 208 seconds.

Decisions and options:

– Re-start engines - failed.

– Return to La Guardia – already too far away.

– Teterboro airport (NJ) – still to far away.

155 lives at risk.

248 sec – This is not an Exercise!


2:40 Captain Sullenberger decided to land on the Hudson

3:40 Sullenberger announces “brace for impact”.

Cabin crew completing preparation of the passengers.

4:08 Plane landing on the Hudson river

Cabin crew started evacuation immediately.

All people were saved.

Captain Sullenberger the last to leave the plane after making sure

that nobody was left behind in the plane.

248 sec – This is not an Exercise!


“One way of looking at this might be that for 42 years, I've been making small,

regular deposits in this bank of experience, education and training. And on

January 15 the balance was sufficient so that I could make a very large withdrawal.”

- Captain Sullenberger, CBS News February 10, 2009

January 15, 2009


…really? Could your operators be the next Captain Sully Sullenberger?

Satety does not happen

by accident

This Doesn’t Apply to Me!


PRO/IIVISUAL FLARE

DYNSIM

OTS

EYESIM

Let us keep you safe!

SimSci Simulation for Business Excellence. Schneider Electric confidential.©2015 Schneider Electric. All Rights Reserved.All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective owners.

Thank you!


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Achieving Safe & Efficient Designs with SimSci - Velazquezglobal.wonderware.com/EN/SimulationBizExcellence2015PPTs/Achievin… · Achieving Safe & Efficient Designs with SimSci