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Joseph Isimite
Outline
Introduction & background
Previous studies
Simulation approach
Simulation results
Quantitative HAZOP
Conclusion
Questions
Plant background
Rated capacity of
460,000 bpd of
gasoline
29 oil refining
units and 4
chemical units
covering 1200
acre site
Incident Introduction
15 deaths, many injuries
financial losses exceeded
US$1.5b
Catastrophic failure of
isomerisation units raffinate
splitter
Explosion occurred at 1:20pm on
23 March 2005, with subsequent
fires
Previous studies
Woodward & Moosemiller (2005): Baker Risk Report,
evaluation of possible event scenarios
Palacin-Linan (2005): PSE, gPROMS model
Manca & Brambilla (2012): Aspen HYSYS simulation
Khan and Amyotte (2007): consequence modelling
Kalantarnia et al. (2010): predictive consequence model
Process simulation
Suitability of Aspen Hysys
Replicate column filling dynamics
2-phase flow of sub-cooled liquid in the blowdown pipe
Dynamic HAZOP
Process Flowsheet
Simulation approach
Initial conditions
Transient process variables evolution from 0200am
0120pm
Isothermal temperature regime before 1000am
Model validation with published accident data
Results show
Column filling dynamics
Feed vapourisation dynamics
Feed temperature profile
Dynamic simulation of Texas City Refinery explosion for safety studies
Simulation results
60
50
40
30
20
10
0
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
Time [Hrs]
Feed vapourisation
dynamics
0.8
0.6
0.4
0.2
0
10
11
12
13
14
Feed temperature
Time [Hrs]
140
120
Feed temperature
dynamics
100
80
60
40
20
0
10
10.5
11
11.5
12
12.5
13
13.5
Time [Hrs]
Dynamic HAZOP
Extrapolation of model for use in dynamic HAZOP studies
Provide a visual representation of quantified level of risks
All four burners lit instead of two
1.2
0.8
0.6
Actual incident
DynHAZOP
0.4
0.2
0
10
-0.2
10.5
11
11.5
12
12.5
13
13.5
14
Time [Hrs]
Conclusions
Additional temperature increase of 43% occurred, leading to
a mixed phase feed flow with a vapour fraction of 0.4
Complete vaporisation of the feed takes place at 1230pm
Help secure management buy-in by demonstrating the likely
consequences