Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.
The expectation at Chevron is ZERO leaks:
Zero Leaks regardless of the number of startups and shutdowns
Zero Leaks during plant upsetsBefore and After
Top 10% with the lowest leak rates.
The Leak Response Protocol guides decisions:
Anyone can use Stop Work Authority in response to a leak, including upon discovery and at any point during mitigation or response efforts.
Protocol Guides Dialog
Mitigation or Emergency Shutdown and Response
ERT deploys for leak response or standby coverage.
Site cleared of non-essential employees.
Gather available resources (Op’s, ERT, Management, Inspection, Engineering, Materials, Maintenance, Safety, etc. as needed and if available) and establish a safelocation to meet.
Notifications of internal and external parties as appropriate.
Limit site access around the leak to essential personnel only.
Identify the leaking material. . . . - Steam, Water, Hydrocarbon, Toxic or Hazardous Chemical - Size / Location / Accessibility - TemperatureStep 3:
(1) Does it pose an immediate danger to safety, health or the environment?
Consider acute toxicity, vapor cloud forming, potential exits, above auto Ignition temperature and personnel exposure.(2) Can the leak be safely isolated or safely mitigated? Remote isolation valves/equipment is available to secure leak without exposing personnel to unacceptable risk, even if the leak gets worse.(3) Can unit continue to operate with leak/system isolated? Consider if bypasses or alternative routings/mitigations are available.(4) Is the worst case failure mechanism understood (pin hole vs. generalized thinning)?(5) Are you in doubt that we can safely continue to operate the unit or safely secure the leak?
WARNING: Do not remove insulation if source of leak and failure mechanism are not well understood.
Use the below checklist to organize emergency responses to leaks.
(Double click this link while in the “Normal View” mode to access just the checklist.)
For any plan put in place, evaluate the most likely worst-case outcomes, the possibility of them happening, and then make sure there is a Plan B in place to deal with them. If there is no workable Plan B to stop the incident from escalating, and there is a very real possibility the initial plan could fail, shut the plant down.
For instance, Plan B might be using proper PPE and having charged hose lines to protect people and equipment while studs are tightened, or while someone is standing by to operate manual isolation valves. However if an operation is likely to cause a sudden uncontrollable release, it should not be attempted and the plant should be shutdown.
(Double click this link while in the “Normal View” mode to access a single page that contains both the checklist and protocol. If you print it “double sided”, it will also contain slides 28 and 29.)
March 21, 2013
Many refineries in Manufacturing and throughout industry have defined policies for how to mechanically repair leaks. These policies focus more on clamps and injections, rather than on the decision-making process as to whether a given plan of action is the best and safest course to follow. These existing written instructions do not contain specific criteria to be considered for deciding whether or not the unit should be shut down, or whether the repair can safely be made with the unit in operation.
This Leak Response Protocol attempts to mitigate risk in responding to leaks by providing additional guidance to Operations and bringing standardization to leak response decision-making.
If there is any doubt about what to do, shut down the plant or move it to a safe condition.
If there is no time to review options, shut down the plant or move it to a safe condition.
In some cases it may not be immediately clear what action should be taken to best protect people, the plant and the environment. If there is time to review options, get all available parties together in a meeting so all issues and concerns can be considered. After all the inputs have been gathered, develop an action plan, make sure it is clearly communicated to everyone involved, and then move forward to implement it. Utilize the Leak Response Protocol and Emergency Response checklist to guide the decision-making.
To assist with decision-making when responding to a leak, we have created a single page checklist. Operations can initiate its use for any leak, or it can be brought to the incident by the ERT and filled out jointly with Operations.
When Responding To Leaks –Ask “What is The Right Thing To Do?”
To implement this Leak Response Protocol, each facility must:
Practice using the tools by reading through the Emergency Response Checklist and Protocol, and then consider how you might respond to the following leak examples. If they would require the use of the checklist, try filling one out.
Equipment in rapid vaporization / auto-ignition service can have much higher consequence than most other services
LPG Explosion in Japanese Refinery
1. FCC, Crude and Coker Distillation bottoms
Overhead Liquid Recovery
Side Cuts to first exchanger
Vacuum Bottoms/ Reflux Pumps
Vac Bottoms Exchangers and Filters
TKC and Isomax Reactors
Isomax Distillation/Gas Recovery
LPG Spheres/ Loading
Crude and Gasoline Tanks
Fire/Foam/ Deluge Systems
2. Hydrotreaters, Crackers, Reformers from Heater to Low Pressure Separator
Finfan Coolers and Exchangers
High and Low Pressure Separators
3. Crude, FCC, Coker, Alky and Treater Gas Recovery Units