Identification of Process Hazards in the Hot Stripping Tower of Common Crude Oil Sweetening Projects Using HAZOP Study

Nowadays, oil and gas resources play a vital role in supplying energy and raw materials so that any disruption in the operation of refineries leads to compensatory damages. Therefore, the continuous, safe, and accurate operation of refineries is essential. The presence of impurities in oil and gas has a negative effect on equipment and reduces the quality of the final product. Hence, a hot stripping unit was used for the separation of Hydrogen sulfide gas from crude oil. And identifies deviations in this desalination unit that will cause harm to humans, equipment, and the environment.

To prevent human, economic, and environmental damages, we need a systematic approach to study hazards and risk analysis. The Hazard and Operability Study (HAZOP) techniques were applied to identify hazards in the sweetening of the crude oil project. Initially, the HAZOP team divided the sweetening unit into 11 nodes and evaluated 94 deviations in these nodes. The faults and their causes, consequences, and safeguards were traced and reported.

Based on operational deviations, risk factors, consequences, and barriers were reviewed and weaknesses in protection layers were identified. Outcomes of risk and operational management sessions, deviations, causes, consequences, safeguards, and possible solutions are identified. The most vital faults were traced in the desalination unit, overfilling of the tank surface, high pressure and incorrect function of the flare, which occurred in nodes 6, 7, and 9, respectively, for various reasons.

After summarizing the findings, for preventing the occurrence of consequences and accidents, recommendations were presented in the form of a general suggestion. The results of this study could create a safer surroundings with higher reliability and environmental-friendly product.