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HAZARDS OF TRAPPED PRESSURE AND VACUUM

through the formation of hydrate. Hydrate formation is experienced during

periods of low ambient temperature more commonly in gas lines; this was the
first experience of it with liquid butane lines. Hortonspheres are drained on a
weekly basis and only trace amounts of water are normally found. In this instance
some additional water may have accumulated in the bottom of the sphere due to
steaming out to remove air in preparation for commissioning following a recent
inspection or from exceptionally wet butane (steam condensate is sometimes
used to relieve fouling in the LPG splitter feed preheaters).

ACCIDENT Jet fuel tank spill!

A spill of about 8,200 barrels of Jet-A fuel from a broken sight glass on a
storage tank’s water drainage piping occurred when the sight glass was
broken due to expansive forces exerted as water in the piping froze.

ACCIDENT Explosion and fire due to freeze-up in deadleg!

An explosion and fire occurred in the pipe alley of a Vacuum Distillation Unit. The
incident was caused by the freeze-up and subsequent failure of a 2 inch (50
mm) carbon steel pipe which released a high pressure spray of light hydrotreated
naphtha towards the vacuum furnace and transfer line, where it ignited. Total
cost of the incident is estimated at $14 million–$10.5 million in production losses,
the remainder in maintenance and associated costs. The failed line had been
taken out of service approximately 20 years before, but had never been fully
isolated or decommissioned. The piping acted as a large pocket or ‘dead leg’,
allowing water to accumulate. As the result of an extreme cold front, the trapped
water froze, expanded, and cracked the pipe. During a subsequent warm up of
the weather the next day, the ice plug melted, releasing hydrocarbon.

ACCIDENT Water froze in deadleg!

A section of utility piping failed in a distillate desulfurization unit. The failure
was the result of internal overpressure generated from water freezing in a
dead leg section of piping. There was a release of hot product from the
stripper section of the hydrotreater. The resulting vapour cloud ignited, and
fire damage to nearby equipment released additional hydrocarbon. Although
the unit was quickly isolated, there was extensive damage to pumps, several
air coolers, analysers, instrumentation, electrical conduits, and process piping.
Direct damage to the unit was $5.9 million, and the unit was down for 52 days.

• Out of service pipelines and ‘dead-legs’ must be identified by operators and

during the PHA revalidation and MOC processes. They should be removed if
reasonably practicable to do so and, in the interim, the mechanical integrity
should be assured through the inspection and freeze protection programme, or
the lines positively isolated.
• ‘Dead-legs’ should be carefully monitored in the piping inspection programme
since the stagnant end may also corrode at a much higher rate in addition to
accumulating more water.
• It is good practice to check for leaks immediately when freezing stops (i.e.
when temperatures allow possible ice plugs to thaw).

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HAZARDS OF TRAPPED PRESSURE AND VACUUM

2.8 Leak and pressure testing

Compressed gas is dangerous and must be employed with caution. Numerous
accidents have occurred and a few examples are given below. They
demonstrate that leak tests using air or nitrogen at low pressure can kill…

ACCIDENT Ejected bundle!

A leak test on a heat exchanger was being conducted using low pressure
gas (4.5 barg or 65 psig) when the tube bundle was ejected with great force
striking two employees. One of them died from massive internal injuries as a
result of the bundle striking him directly in the chest. The other was seriously
injured. It was found that a test ring was not used to secure the tube bundle in
case it propelled outwards, and spot welds that temporarily secured the
bundle sheet to the shell failed.

Location of personnel at the time of incident

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