Request credible Coker emergencies?

[kennycramp9]

I am looking suggestions for three or more credible emergencies or casualties in our coker industry. I intend to use these scenarios for training. So far I have:  1) Tarry Drum Scenario (3 hrs after switch, furnace trip leading to plugged drum inlet)2) Foam Over (Bad Drum Switch, dropping inlet temperatures to 800F with antifoam aligned to the wrong drum).   Any suggestions, gang? I am looking for at least one more. Perhaps water into the bottom of the main frac (it just seems to plain)?

[Claus Graf]

How about:
3) Coke bed collapse trapping drill stem assy. inside the drum.(and/or cutting system malfunction causing a delay in coke removal operation)
4) Hot Spot during cutting ( due to bad quenching of the drum.)

[Anonymous]

Hot spot in drum

[Anonymous]

Some not mentioned above: 
 
Recent fatalities (2008-2009):
– 2 fatalities due to scalding after failed coke drum pressure tests. Operators were replacing bottom gasket when hot condensate came out of drum bottom
– 1 fatality from manual bottom unheading when operator opened drum full of hot quench water
– 2 fatalities when heater inlet line ruptured
 
Other
– piping failures due to high temperature, high sulfur corrosion (increases in operating temperature and sulfur content from original design)
– closed block valve on coke drum inlet, causing heater tube rupture/fire
– fires due to coke drum valving misalignment (HCGO quench oil flowing to open drum, coke drum overhead valves opened to open drum, coke drum inlet line opened to drain)

[Tim Sawyer]

Thanks guys!
 
     Tarry Drum Scenario (3 hrs after switch, furnace trip leading to plugged drum inlet)
     Foam Over (Bad Drum Switch, dropping inlet temperatures to 800F with antifoam aligned to the wrong drum).  
     Stuck Drill Stem (or cutting system malfunction causing a delay in coke removal operation)
     Hot Spot during cutting ( due to bad quenching of the drum.)
     Dead-Head Scenario (closed block valve on coke drum inlet, causing heater tube rupture/fire)
     Fires due to coke drum valving misalignment (HCGO quench oil flowing to open drum, coke drum overhead valves opened to open drum, coke drum inlet line opened to drain)
     Cool down scenarios
o       furnace tripping, long recovery coupled by failing to introduce enough cutterstock to the bottom of the main frac, leading to high viscosities or even partial solidification, and the inability to start the charge pumps
o       Low rates, leading to a cold blowdown system, leading to HGO transfer pump issues.

[ted pivo]

Tim I;d like to add these emergencies;;;

Operator pulling a fully charged drill stem out of a coke drum (by passing interlocks)
Operator/maintenance person on drill deck when HP water hose breaks
Operator/ maintenance personnel not secured when checking fluids in drill stem motor;;replacing drill stem motors;high pressure hoses, anytime when in the upper derrick
escape routes with deluge systems;or stairways that have fire restant walls
BYPASSING interlocks to get the job done
locking out decoking equipment to replace/repair equipment( remember the hydraulic pump produces between 1100 to 3000# of pressure)
Have a emergency rescue plan in place to remove injured personnel of the drilling deck/structure

[zachariah wilbur]

Good to know these kinda info..!! Thanks for sharing..!!

Will..!!

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