输油管道在投产和运行中可能出现的事故和处理.docx
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输油管道在投产和运行中可能出现的事故和处理.docx
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输油管道在投产和运行中可能出现的事故和处理
输油管道在投产和运行中可能出现的事故和处理
18.1PossibleAccidentTypesoftheMainPumpandTreatment
Mainkindsoffailureswithresponseprocedureswhichmayhappenduringcommissioningarelisted.
18.1.1MechanicalSealLeakageofPump
A.Twogradesofprotectionaredesignedagainstsealleakage,HIGHprotectionandHIGHshutdown.
B.IncasethattheleakagesurpassestheHIGHprotectionvalue,thestandbypumpwillbestarted,andtherunningpumpmustbeshutdownimmediatelyafterthestandbypumpisstarted.
C.IncasethattheleakagesurpassestheHIGHlimit,thepumpshallbeshutdownpromptly,protectthepumpUnits,startthestandbypumpatthesametime.
18.1.2TheLowPressureProtectionReachestheAlarmingValueattheInletValve
Checkthedifferentialpressureatthestrainerandthepressurefromtheupstreamstation.Incasethatthestrainerisblocked,switchthestrainercleantheblockedstrainerimmediately.Incasethatitiscausedbythepressurefromtheupstreamstation,informtheupstreamstationtoraisedischargepressure.Ifthepressurecannotmeettherequirementofthepump,shutdownthepump,andrestartthepumpwhenthepressuremeettherequirementofthepump.
18.1.3UnexpectedPowerFailureofPumpandMotor
Startthestandbypumpunitsimmediately.
18.1.4TheTemperatureoftheMainPumpBearingandCasingSurpassestheAlarmingValue
Incasethatthetemperatureofthepumpbearingorthepumpcasingsurpassestheovertemperaturealarmingvalue,startthestandbypumpunitsimmediately,thenshutdownthemalfunctionedpump.Checkthemalfunctionedpumpandclearthefault.
18.1.5TheTemperatureofPumpBearingandCasingSurpassestheProtectionValue
Shutdownthepumpimmediatelytoprotectthepumpunits,startthestandbypumpunitsatthesametime.
18.1.6ThePumpBearingVibratestooseriously
Therearetwogradesofprotectiontothepumpunit’svibration,overhighprotectionandoverfiniteprotection.Incasethatthemainpumpvibrationisoverhighandlastslong,startthestandbypumpunitsandshutdownthemalfunctionedpump,checkforthecauseandclearthefault.
18.1.7TheOutletOverpressureProtectionoftheMainPump
Incasethattheoutletpressuresurpassestheoverpressureprotectionvalue,theentirepipelineshallbeshutdown.
18.1.8TheBearingofthePumportheConverterMotorOvertemperatureAlarming
Reducetherotatespeedoftherunningpumpandstarttheotherpumpimmediately.Thencheckforthecauseandclearthefault.
18.1.9OvertemperatureofthePumpCasing
Checkthetemperatureofthecomingoil,informCPFtoreducethetemperatureincasethatthetemperatureisoverhigh.Checkthemotor,shutdownthemotorincaseitiscounter-rotating,andstartthestandbypump.
18.2WarbreaksoutorthePersonnelareattackedbyMilitaryForces.
A.OWNERshallappealtheSudangovernmenttoaccreditarmytosafeguardthewholepipelineandthecommissioningpersonnelfromthecompletionthepipetotheendofCommissioning.Thekeypumpstationsandthecrossingsectionrequirestressedprotection
B.CPPEshalltakechargeofthesecurityofthecommissioningpersonnel.TheCONTRACTORpersonnelreservetherighttoevacuatefromthesiteorrefusetocometositewhentheirpersonalsecuritiesaremenaced.
C.Incasethatwarbreaksoutduringcommissioningperiod,itisthecommissioningleadinggroupcomposedbyOWNERandCPPEthatshallrevisethecommissioningplanandmakethedecisionthatthecommissioningpersonnelevacuatefromthesite.
D.Incasethatthepipelineisdestroyedbymilitaryforcesduringcommissioning,theleadinggroupshallmakethedecisionofrushrepair,carryoutrushrepairwithensuringthepersonalsecurity.
18.3CrudeOilLeakageatPumpStations
Closethevalvesatthetwosidesoftheleakagepointimmediately.Taketheoilinoilpitorcontainersincasethattheleakageamountissmall.Thefirefighteratsiteshallcarryoutsafetywardship,andorganizerushrepair.
18.4LeakageattheoutFlangeattheOutletofthePump
ShutdownPS#01immediatelyandclosethedischargevalve.Informrelevantpersonnelrushtorepairatsite,andarrangefirefighterstowardthesite.Theelectricalpersonnelshallswitchoffthepowerofthecontaminatedarea.Dischargethesumpoilinthemainpipelinetothesumptankbythewasteoilpipeatthemainpump,givinganeyetotheliquidlevelofthesumptank.Fastentheflangeorreplacethegasketandcleartheoilontheearth.
18.5StrainerBlockatPS#01
TherearetwocentralstrainersatPS#01duringcommissioning,onerunningandtheotherstandby.Whentherunningstrainerisblocked,andthedifferentialpressureatsurpasses0.05MPa,itshallbeswitchtothestandbyoneimmediately,andcleartheblockedone.
18.6PigReceiverBeingBlockatPS#03,PS#04andKhartoumTerminal(#06)
Inreceivingpig,thereceivingpigpersonnelandthetrackingpigpersonnelatsiteshalljudgethepigreceiverblockingconditionaccordingtothedifferentialpressureandthelocationofthepig.TheoperatoratPS#01shalljudgetheblockingconditionofthepigreceiveraccordingtothepressurevariationandthereportfromthesite.Incasethattheblockageisnotserious,openthevalveofthemainflowprogressslowlytopushthepigfromthepigreceiver,thentakeoutthepig,finalcleanthepigreceiver.Incasethattheblockageisserious,increasetheoutletpressureatPS#01topushthepig(whilewithinthenormalpressurelimit).Ifitstillcannotmakeit,conductthepumpemergencyshutdownatPS#01,andrestartthepipelinetoreceivethepigafterthepigreceiveriscleaned.
18.7SeparationPigBlockingandCrashingDuringPigLaunchingandReceiving
Incasethattheseparationpigisblockedinthepipe,thedischargingpressurewillincrease.Thepigtrackingpersonnelshalljudgeandmakesureofthelocationofthepig.Firstincreasethepressuretopushthepig,ifthepigdoesnotmove,andthentakeoutthepigbyperforatingorplugginginfrontthepig.
Incasethattheseparationpigiscrashedandstaysinthepipeline,andifthepressureisstable,anotherpigshallbelaunchedthepushitoutofthepipeline.
Table18.7-1TheCommonFaultandTreatmentduringPiggingOperation
BreakDown
PossibleCause
Remedies
Theseparationpigcannotbelaunched
1Thedifferentialpressureinfrontofandbehindthepigistoosmall
2Theflowprocessisnotthrough
3Thepigisdamaged
1Increasethepressureinfrontthepig
2Checktheflowprocessandmakeitthrough
3Replacetheseparationpig
Theseparationpigcametoastandstill
1Thepipelinedeformsseriously
2Sundriesinthepipelineistoomuch
3Thepigisdamaged
4Toomanyleakagepointsbeforetheseparationpig
1Replacethepipesection
2Stoppipingblowdown,andcleanthepig
3Re-launchapigtopushitout
4Checkforthecauseandtreattheleakage.
Leakageatthequickopeningclosure
1Thesealingringisnottightordamaged
2Sundriesexistatthesealingring
3Thequickopeningclosuredeformed
1Re-greaseorreplacethesealingring
2Suspendpiglaunchinganddischargetheoilinthepiglauncher
3Replacethequickopeningclosure
18.8PipelineSectionBurstduringWaterInjection
Inthesectionwaterinjection,incasethatbursthappens,stopwaterinjectionimmediately,judgethelocationoftheburstandwaterheadtimely.ThewaterinjectionpersonnelshalldownthenearestESDvalveswiththehelpofpatrolpersonnelattheupstreamanddownstreamoftheburstpoint,thenorganizerushrepair.
18.9CrudeOilLeakageCausedbyPipelineBurst
Intheoilfillingstage,thejeopardycausedbycrudeoilleakageisveryserious.Therefore,certainrushrepairprogramsmustbeadoptedtodealwiththeaccidents:
ØIncasethatthepipelineisjudgedcrudeoilleakagecausedbypipelineburstaccordingtothereportofthepatrolpersonnelorthelocalinhabitantsortheoperationparametersofthepipeline,shutdownthewholepipelineimmediately.
ØAfterthewholepipelineisshutdown,closelineblockvalvesattheupstreamanddownstreamoftheleakagepointimmediately.
ØDefinetherushrepairmeasures
Protecttheaccidentalsitefrombeingintrudedbyirrespectivepersonnel.Defineandmarkthecontaminatedarea,andcarryoutemergencytreatmenttostoptheoilflow.
Studythecauseoftheaccident,theambienceandtopography.Testthepossibleexplosivescopewiththecombustiblegasdetectortodeterminethedemandoftechnicalequipmentandmanpower.
Therushrepairgroupshallrushtotheaccidentalsitetocarryoutmendingwork.Theprocedureofrushrepair:
A.Theoilclearanceandfirefightingmeasuresatsite
Dischargetheoilfromtheexplodedpipeline,andtestthepossibleexplosivescopewiththecombustiblegasdetector.Incasethattherush-repairpointisintheexplosionarea,collecttheoilatthesiteorremovetheoiltoanotherplace.Protectthesitewithfirefightingdevicestilltherushrepairfinishes.
B.Groundwork
Thegroundworktoclearpipelineaccidentsincludes:
ØDigearthstorageandbuildembankment(tocollecttheoverflowoil),anddigditch(todischargethecrudeoil)
ØPreparetheworksite,auxiliaryworksiteandpassagefortherushrepair.
ØDiggeosynclinesandbackfillit.
Beforedigginggeosynclines,locatethepipelinewithpipelinedetectororothermethods,andmarktheborderofthepipeline.
Digoutthedamagedpipesectionswiththedredgingmachineanddiggeosynclines.Strikingthepipewithmechanicaltoolsisstrictlyforbiddenatthistime.
Thesizeofthegeosynclinesshallensuretheexecutionoftherushrepairwork(pipeliningup,weldingofirrotationaljointsandth
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