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Hazards of Delayed Coker Unit (DCU) SHIB 03-08-29 August 2003 Operations

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Hazards of Delayed Coker Unit (DCU) SHIB 03-08-29 August 2003 Operations Chemical Emergency Preparedness Occupational Safety and Health Administration and Prevention Office Directorate of Science, Technology and Medicine (5104A) Office of Science and Technology Assessment United States United States Environmental Protection Department of Labor Agency CEPPO EPA 550-F-03-001 Hazards of Delayed Coker Unit (DCU) SHIB 03-08-29 August 2003 www.osha.gov www.epa.gov/ceppo Operations The Environmental Protection Agency (EPA) and the Occupational Safety and Health Administration (OSHA) are jointly issuing this Chemical Safety Alert/Safety and Health Information Bulletin (CSA/SHIB) as part of ongoing efforts to protect human health and the environment by preventing chemical accidents. We are striving to better understand the causes and contributing factors associated with chemical Information Bulletin Safety and Health accidents, to prevent their recurrence, and to provide information about occupational hazards and noteworthy, innovative, or specialized procedures, practices, and research that relate to occupational safety and health and environmental protection. Major chemical accidents cannot be prevented solely through regulatory requirements. Rather, understanding the fundamental root causes, widely disseminating the lessons learned, and integrating these lessons into safe operations are also required. EPA and OSHA jointly publish this CSA/SHIB to increase awareness of possible hazards. This joint document supplements active industry efforts to exchange fire and safety technology and to increase awareness of environmental and occupational hazards associated with DCU operations. It is important that facilities, State Emergency Response Commissions (SERCs), Local Emergency Planning Committees (LEPCs), emergency responders, and others review this information and take appropriate steps to minimize risk. This document does not substitute for EPA or OSHA regulations, nor is it a regulation itself. It cannot and does not impose legally binding requirements on EPA, OSHA, states, or the regulated community, and the measures it describes may not apply to a particular situation based upon the circumstances. This guidance does not represent final agency action and may change in the future, as appropriate. This process yields higher value liquid Problem products and creates a solid carbonaceous T residue called “coke.” As the supply of The batch portion of DCU lighter crude oils has diminished, refiners operations (drum switching and have relied increasingly on DCUs. coke cutting) creates unique hazards, resulting in relatively Unlike other petroleum refinery operations, the DCU is a semi-batch frequent and serious accidents. operation, involving both batch and The increasingly limited supply of continuous stages. The batch stage of the higher quality crude oils has resulted in operation (drum switching and coke greater reliance on more intensive cutting) presents unique hazards and is refining techniques. Current crude oils responsible for most of the serious tend to have more long chain accidents attributed to DCUs. The molecules, known as “heavy ends” or continuous stage (drum charge, heating, “bottom of the barrel” than the lighter and fractionation) is generally similar to crude oils that were more readily other refinery operations and is not further available in the past. These heavy ends discussed in this document. About 53 can be extracted and sold as a relatively DCUs were in operation in the United low value industrial fuel or as a States in 2003, in about one third of the feedstock for asphalt-based products, refineries. such as roofing tile, or they may be In recent years, DCU operations have further processed to yield higher value resulted in a number of serious accidents products. One of the most popular despite efforts among many refiners to processes for upgrading heavy ends is share information regarding best practices the DCU, a severe form of thermal for DCU safety and reliability. EPA and cracking requiring high temperatures OSHA believe that addressing the hazards for an extended period of time. Chemical Safety ALERT ……… Chemical Emergency Preparedness and Prevention Office Page 1 HAZARDS OF DELAYED COKER UNIT (DCU) OPERATIONS August 2003 of DCU operations is necessary given the increasing This document focuses on the coke drums, which are importance of DCUs in meeting energy demands, the large cylindrical metal vessels that can be up to 120 array of hazards associated with DCU operations, and feet tall and 29 feet in diameter. the frequency and severity of serious incidents involving DCUs. In delayed coking, the feed material is typically the residuum from vacuum distillation towers and frequently includes other heavy oils. The feed is Understanding the Hazards heated by a fired heater (furnace) as it is sent to one of the coke drums. The feed arrives at the coke drum Safe DCU operations require an understanding with a temperature ranging from 870 to 910°F. of the situations and conditions that are most Typical drum overhead pressure ranges from 15 to 35 prone to frequent or serious accidents. psig. Under these conditions, cracking proceeds and lighter fractions produced are sent to a fractionation tower where they are separated into gas, gasoline, Process Description and other higher value liquid products. A solid Each DCU module contains a fired heater, two (in residuum of coke is also produced and remains some cases three) coking drums, and a fractionation within the drum. tower. After the coke has reached a Flange and predetermined level within the Top Head “on oil” drum, the feed is diverted to the second coke drum. This use of multiple coke drums enables the Borehole cut Vapors, refinery to operate the fired completed. Enroute To heater and fractionation tower r Rotating cutting um g Fractionator e n i Dr head shown w continuously. Once the feed y Tower o g reset for side T n i has been diverted, the original l nve l i cutting operation. o tor F C a Water jets drum is isolated from the n e om v discharge at l process flow and is referred to r oo a about 5 degrees as the “off oil” drum. Steam is acti Foam rs F y V r off horizontal. po F introduced to strip out any a o wa 3 V T remaining oil, and the drum is cooled (quenched) with water, Open Fluid drained, and opened Material (unheaded) in preparation for Channels decoking. Decoking involves using high pressure water jets Plugged from a rotating cutter to Channel fracture the coke bed and Solid allow it to fall into the Coke receiving area below. Once it is decoked, the “off oil” drum is closed (re-headed), purged of air, leak tested, warmed-up, and placed on stand-by, ready Bottom Head a g to repeat the cycle. Drum e r and Flange lin A l switching frequency ranges a g F n i from 10 to 24 hours. DCU e Charge Entering Drum iv k e o From Fired Heater c filling and decoking operations e C t R u are illustrated in Figure 1. C To Equipment used in coke cutting (hydroblasting) Figure 1 - Delayed Coker Unit operations is illustrated in Cutaway to Depict Drum In Filling and Migration Mode (Left) Figure 2. and Drum In Cutting Mode (Right) Chemical Emergency Preparedness and Prevention Office Page 2 HAZARDS OF DELAYED COKER UNIT (DCU) OPERATIONS August 2003 Drilling Gantry Structure Rotation Motor Hydroblast Water Supply Hose Rotating Drill Stem Drill Stem Guide Cutting Head 3 Way Valve --Isolating Open Drum and Winch Conveying Vapors To Fractionator Tower For ng y d ei a g B e - in R t d - um Cut r D ke harge Drum C am Co e ned str e n p O O Bottom Unheading Deck - Section Removed For Coke Discharge Stripping Steam Inlet Valve Quench Water Inlet Valve Drum Feed From Fired Heater Sent To Filling Drum Via 3 Way Valve Figure 2 - Delayed Coker Unit Coke Drums and Hydroblast Systems Chemical Emergency Preparedness and Prevention Office Page 3 HAZARDS OF DELAYED COKER UNIT (DCU) OPERATIONS August 2003 Once removed from the coke drums, the coke is hazards during removal of the top and bottom drum transported away from the receiving area. From here, heads. The most frequent and/or severe hazards the coke is either exported from the refinery or associated with this operation are described below: crushed, washed, and stored prior to export. f Geysers/eruptions - Under abnormal situations, The following specific operations and more general such as feed interruption or anomalous short- situations and conditions contribute most circuiting during steaming or quenching, hot significantly to the hazards associated with DCU spots can persist in the drum. Steam, followed by operations: water, introduced to the coke drum in preparation for head removal can follow Specific operation hazards established channels rather than permeate • Coke drum switching throughout the coke mass. Because coke is an excellent insulator, this can leave isolated hot • Coke drum head removal areas within the coke. Although infrequent, if the • Coke cutting (hydroblasting operation) coke within the drum is improperly drained and Emergency and general operational hazards the coke bed shifts or partially collapses, residual • Coke transfer, processing, and storage water can contact the isolated pockets of hot coke, resulting in a geyser of steam, hot water, • Emergency evacuation coke particles, and hydrocarbon from either or • Toxic exposures, dust irritants, and burn both drum openings after the heads have been trauma removed. The hazards associated with these specific operations f Hot tar ball ejection - Feed interruption and and DCU operations, in general, are explained below steam or quenching water short-circuiting can to share lessons learned and increase awareness of also cause “hot tar balls,” a mass of hot (over the situations and conditions that are most prone to 800°F) tar-like material, to form in the drum. serious accidents. Following this section, the joint Under certain circumstances, these tar balls can CSA/SHIB describes actions that can be taken to help be rapidly ejected from the bottom head opening.
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