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Risks
A recent study of 58 known distillation plant fires by Koch-Glitch, Inc., a leading
supplier of distillation products and technology indicates the following:
It appears that the frequency of these incidents is increasing from less than 1/year in
the 1970-1989 time frame to more than 3/year since 1990. In the last two years, there
have been 11 known incidents. This appears to coincide with the increased use sheet
metal structured packing in the chemical and petrochemical industry.
38 of the 58 incidents were in columns with sheet metal structured packing. 11 were
in columns with wire gauze packing.
32 of the incidents were attributed to spontaneous ignition of materials in the column
after opening with 18 due to ignition of pyrophoric materials
7 incidents were due to ignition from hot work
36 of the incidents were in refinery units
Design
Clearly, the time to address the risks of fires in distillation columns is at the design
stage.
For new columns and retrofits of existing columns, the increased risk of fire in
structured packing should be a factor in the decision on choice of packing. Other
types of packing, though less efficient, could be inherently safer. If corrosion is an
issue, periodic replacement of the packing needs to be factored into the decision
as well.
Shutdown Planning
Investigations indicate that the shutdown planning process is critical in preventing
fires in packed columns.
The planning needs to address all of the risks discussed above. The Job Safety
Analysis (JSA) is an excellent tool for addressing these risks.
The process should include all of the key players – operations, process
engineering, design engineering, maintenance, contractor(s) and plant
protection/hole watch personnel.
It is very important to use knowledgeable, experienced and trained contractors for the
work
The first option should be to look for ways to avoid doing hot work over packed
beds.
If hot work is required, the packing should be removed from the column.
Use cold cutting techniques where cutting is required over packed beds
When hot work over a packed bed is the only feasible means to achieve the
turnaround objectives, the precautions discussed below must be in place.
Shutdown/Opening Procedures
Shutdown and opening procedures need to address the potential for pyrophoric material
in the column. The following procedures assume the presence of pyrophorics:
There should be multiple washes to remove any residue
There needs to be a chemical cleaning process tochemically neutralized the
pyrophorics. Contact the chemical cleaning experts to develop a procedure for
the wash. Operations review of this procedure is critical.
It must be assumed that, even with the best of cleaning procedures, there will
remain some fuel on the packing.
The column should be steam or inert purged prior to opening to reduce and control air
entry.
Warning: the use of inert gas entails risk of asphyxiation to personnel who enter
the column or who may be near openings to the columns.
If pyrophorics are suspected, the column should be cooled to 150F before opening.
An effective way to do this is by water washing or water flooding the packing.
Warning: the use of inert gas entails risk of asphyxiation to personnel who enter
the column or who may be near openings to the columns.
If a fire occurs, monitor the external surface temperatures of the column with a
remote temperature scanning device such as an IR camera to follow the progress in
extinguishing the fire and to give indication where to apply cooling water.
There needs to be a communication plan and evacuation procedure in place which has
been reviewed with all Company and contractor employees.
Consider a need for an evacuation drill at the onset of the shutdown to practice the
above contingency plans.