Safety

Bulletin

U.S. Chemical Safety and Hazard Investigation Board

AFTER KATRINA: PRECAUTIONS NEEDED DURING

OIL AND CHEMICAL FACILITY STARTUP

Introduction

The startup of major processes is a hazardous phase in the

operation of oil refineries and chemical plants. Hurricane Katrina

has now disrupted production at numerous petrochemical facilities in

the Gulf Coast region and caused extensive water and wind damage

to facilities in hard-hit areas.

Over the coming weeks and months, these facilities will be restarting.

This is a time to make sure no more lives are claimed by this tragedy

and no further delays occur in the production of essential

transportation fuels and chemicals. Facilities should pay particular

attention to process safety requirements during this critical period to

assure a safe and expeditious return to operation.

No. 2005-01-S

September 2005

As the industry recognizes, starting

up a complex petrochemical

process requires establishing stable

flows, levels, temperatures, and

pressures within large-scale

equipment. Startup requires and

receives a higher level of attention

and care than normal processing,

because numerous activities are

occurring simultaneously and

many automatic systems are run

under manual control.

Of 38 significant process incidents

investigated by the U.S. Chemical

Safety and Hazard Investigation

Board (CSB) since 1998, three

catastrophic incidents occurred

during the startup of continuous

process equipment, causing 22

deaths and more than 170 injuries.

Other tragic incidents investigated

by CSB occurred during the startup

of batch processes and during

maintenance operations that

followed a power outage.

While these incidents had a variety

of causes, their occurrence

underscores the hazards of startup

even under “normal” conditions.

In the wake of the hurricane,

adhering to appropriate safety

management systems can spell the

difference between a safe and

uneventful startup and a serious

incident.

Rely on

Established

Safety Systems

As facilities resume operations, it

is important to follow established

startup procedures and checklists

and carefully perform pre-startup

safety reviews. In addition,

facilities should remember to:

z Use appropriate management-ofchange (MOC) processes before

modifying any startup

procedures, equipment, or

staffing arrangements due to the

impact of the hurricane.

z Make sure that adequate staffing

and expertise are available before

starting up, recognizing that

human performance may be

compromised due to crisis

conditions.

z Use up-to-date startup

procedures and ensure that the

available staff are trained in how

to execute them.

z Evacuate nonessential personnel

(including personnel in trailers)

from the vicinity of process units

that are starting up.

Photo Courtesy of National Oceanic &

Atmospheric Administration
2

Check Process

Equipment

Thoroughly

Equipment, tanks, and

instrumentation should be

thoroughly evaluated for damage

prior to startup. In particular,

facilities should remember to:

Examine large bulk storage tanks

for evidence of floating

displacement or damage

✔ Foundation, chime ring, undertank voids

✔ Overturning, shell shifting

✔ Floodwater leakage into tanks

✔ Piping connections distortion

or damage

✔ Piping and component support

displacement or damage

✔ Ladder support displacement

or damage

✔ Floating roof submersion or

damage

✔ Fixed roof distortion from

support damage

✔ Debris impact damage

✔ Test grounding integrity

Examine pressure vessels and small

storage tanks for evidence of

floating displacement or damage

✔ Support structure or foundation

damage

✔ Floodwater leakage into vessels

or tanks

✔ Piping connections distortion or

damage

✔ Debris impact damage

Examine insulation systems for

piping, vessels, and tanks

✔ Floodwater trapped in

insulation

✔ Damaged or missing insulation

Examine sewers and drains

✔ Debris and silt obstruction

Examine furnace systems

✔ Damaged or missing refractory

✔ Damaged or missing insulation

✔ Floodwater trapped in refractory

or insulation

✔ Debris impact damage

✔ Fuel system and control damage

✔ Debris in firebox

Examine electric motors and drives

✔ Floodwater leakage into housing

✔ Drive component damage

✔ Debris impact damage

✔ Test motors for ground faults

(megohmmeter testing)

✔ Verify lubrication systems are

functional on associated

equipment

Examine switchgear, conduit,

electrical boxes, electronic and

pneumatic instrumentation,

emergency warning systems,

emergency equipment (e.g.

eyewash stations, fire detection and

suppression systems)

✔ Floodwater leakage into devices

and conduit

✔ Debris impact damage

✔ Conduct infrared scans to detect

hot-spots in equipment upon

energizing.

This list is not exhaustive and is

not intended to substitute for any

other procedures or checklists

regularly used or developed in

response to Hurricane Katrina. For

further information on CSB

investigations and safety

recommendations, visit

www.csb.gov.

CSB Safety Bulletins offer advisory information on good practices for managing

chemical process hazards.

The U.S. Chemical Safety and Hazard Investigation Board (CSB) is an independent

Federal agency whose mission is to ensure the safety of workers, the public, and

the environment by investigating and preventing chemical incidents. CSB is a

scientific investigative organization; it is not an enforcement or regulatory body.

Established by the Clean Air Act Amendments of 1990, CSB is responsible for

determining the root and contributing causes of accidents, issuing safety

recommendations, studying chemical safety issues, and evaluating the

effectiveness of other government agencies involved in chemical safety.

No part of the conclusions, findings, or recommendations of CSB relating to any

chemical incident may be admitted as evidence or used in any action or suit for

damages arising out of any matter mentioned in an investigation report

(see 42 U.S.C. § 7412(r)(6)(G)).

U.S. Chemical Safety and Hazard Investigation Board

Office of Investigations

2175 K Street NW, Suite 400

Washington, DC 20037-1848

202-261-7600 http://www.csb.gov