Tag: Safety

Undegassed molten sulphur can contain several hundred ppmw H2 S. If the headspace in the storage tank is stagnant, the H2 S can accumulate in the vapour space above undegassed liquid sulphur to dangerous levels. Sweeping and blanketing systems are commonly applied to manage the explosion risk in the headspace of molten sulphur storage tanks. D. J. Sachde , C. M. Beitler , K. E. McIntush , and K. S. Fisher of Trimeric Corporation review these approaches, outlining the benefits and limitations, design considerations, and industry experience/guidance for each approach. Calculation methods for natural draft flow of sweep air are also presented.

Chris Heaton has joined Baker Engineering and Risk Consultants, Inc. as Chief Executive Officer. Chris replaces Quentin Baker as part of BakerRisk’s ownership and management succession plan. Baker will remain with BakerRisk, serving as chairman of the board, and will continue to support clients with incident investigations, engineering studies and research programs. Heaton has executive experience with risk engineering and consulting, fire protection engineering, life safety and incident investigation companies, and holds degrees in civil engineering and architecture.

For the protection of nozzles in sulphur forming plants it is important to prevent larger particles from entering the forming machinery and possibly blocking the nozzles. In normal operation, pipeline strainers are used. Sulphurnet has designed a new system which is suitable for continuous or batch operations and has lower maintenance costs. J. Hermans of Sulphurnet introduces the self-cleaning sulphur strainer.

Fluor’s case study of recently constructed ultra-sour gas treating facilities provides new information about the operation of DGA-based AGRUs. B. Lynch and C. Graham of Fluor Corporation discuss how using this knowledge and leveraging the recent improvements to process simulators in the gas sweetening space, Fluor has developed an efficient, flexible, and cost effective solution in the two-stage absorption process to maximise mercaptan removal from ultra-sour gases with minimal equipment.

It’ s not a very worthy thought, I’m afraid, but I must admit it was my first reaction on seeing the terrible pictures from Beirut on August 4th. The explosion that ripped through the centre of the historic and much troubled Mediterranean city was captured from many different smartphone cameras, and watching the expanding vapour cloud from the supersonic shockwave, and witnessing the sheer size of the explosion, it seemed immediately evident to me that it had to be a high explosive responsible, not the fireworks that could be glimpsed sparkling beforehand in the smoke from the burning warehouse. The rising cloud of orange-brown nitrogen dioxide that followed the blast was the clincher – it looked like it was ammonium nitrate yet again.

Troubleshooting and root cause analysis help to identify and solve problems in the operation of nitric acid plants and to prevent future reoccurrences. Johnson Matthey, Casale and Sabin Metal Corporation discuss their approach to solving problems in nitric acid plants to improve plant reliability and efficiency and to avoid unplanned shutdowns, costly replacement of equipment and loss of production.

In spite of continuing safety concerns due to the Beirut explosion, and the rise of the use of urea as a nitrogen fertilizer, ammonium nitrate demand continues to increase in several key markets.

The following case study reports on a serious incident in a urea plant where a leak in the weld overlay in the urea reactor bottom resulted in a costly plant shutdown and near miss of rupture of the high pressure vessel. It is known that carbon steel can corrode with rates of 1000 mm/year not taking into account erosion due to flashing. The impact of the NH3/CO2 ratio on the corrosion rate is questionable.

High pressure urea equipment often has lined nozzles. A lined nozzle is a full strength carbon steel nozzle that is protected against carbamate corrosion by a 5 or 6 mm thick stainless steel liner plate, which is welded to the carbon steel nozzle on either end. This design is however very vulnerable to fatigue cracking due to the difference in thermal expansion between the austenite liner and the carbon steel nozzle. History shows that such a design will lead to cracking in the long term. The following case study reports on a serious incident in a urea plant where a leak in a urea reactor nozzle caused a plant shutdown but could have resulted in rupture of the high pressure vessel.

Nitrogen+Syngas asked some of the industry’s leading EPC companies what they are doing to make construction sites safer around the world in pursuit of the goal for zero incident safety performance. Read on to find out what approaches have been taken by Maire Tecnimont Group, thyssenkrupp, Toyo Engineering Corporation and Saipem.