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Oil and Gas Industry Process Hazards Guidebook - Icarus-ORM Academy 2021
1.1 The Icarus-ORM Academy Team ................................................................................................................................................... 1
1.2 Overpressure ............................................................................................................................................................................................. 2
1.3 Level ............................................................................................................................................................................................................... 22
1.4 Control Valves .......................................................................................................................................................................................... 27
1.5 Temperature ............................................................................................................................................................................................. 31
1.6 Safeguards ................................................................................................................................................................................................. 34
1. Introduction & Basic Concepts
2. Upstream Processes
Important Process Parameters ............................................................................................................................................. 42
Common Hazardous Scenarios ............................................................................................................................................ 44
References .......................................................................................................................................................................................... 47
Important Process Parameters ............................................................................................................................................. 49
Reciprocating compressors .................................................................................................................................................... 51
Reciprocating compressors .................................................................................................................................................... 52
Common Hazardous Scenarios ............................................................................................................................................ 53
Other Hazardous Scenarios .................................................................................................................................................... 55
References ......................................................................................................................................................................................... 56
Important Process Parameters ............................................................................................................................................. 58
Tank features .................................................................................................................................................................................... 60
Tank location ..................................................................................................................................................................................... 61
Common Hazardous Scenarios ............................................................................................................................................ 62
Other Hazardous Scenarios ..................................................................................................................................................... 64
References .......................................................................................................................................................................................... 65
Important Process Parameters ............................................................................................................................................. 68
Common Hazardous Scenarios ............................................................................................................................................ 70
Other Hazardous Scenarios ..................................................................................................................................................... 71
References .......................................................................................................................................................................................... 73
2.1 Production ................................................................................................................................................................................................... 41
2.2 Gas Compression ................................................................................................................................................................................... 48
2.3 Tank Farms ................................................................................................................................................................................................ 57
2.4 Rail Loading .............................................................................................................................................................................................. 66
3. Midstream Processes
Important Process Parameters ............................................................................................................................................. 75
Common Hazardous Scenario ............................................................................................................................................... 77
Other Hazardous Scenarios ..................................................................................................................................................... 79
References ......................................................................................................................................................................................... 80
Important Process Parameters ............................................................................................................................................. 82
Common Hazardous Scenarios ............................................................................................................................................ 84
Other Hazardous Scenarios .................................................................................................................................................... 86
References ......................................................................................................................................................................................... 87
Important Process Parameters ............................................................................................................................................ 89
Common Hazardous Scenarios ............................................................................................................................................ 91
Other Hazardous Scenarios .................................................................................................................................................... 93
References ......................................................................................................................................................................................... 94
Important Process Parameters ............................................................................................................................................ 96
Common Hazardous Scenarios ............................................................................................................................................ 98
Other Hazardous Scenarios .................................................................................................................................................. 100
Turbo Expander ............................................................................................................................................................................ 101
References ....................................................................................................................................................................................... 102
3.1 Sour Gas Treating..................................................................................................................................................................................... 74
3.2 Gas Dehydration ..................................................................................................................................................................................... 81
3.3 Condensate Stabilization ................................................................................................................................................................. 88
3.4 NGL Recovery .......................................................................................................................................................................................... 95
Important Process Parameters............................................................................................................................................. 122
Common Hazardous Scenarios ........................................................................................................................................... 124
Other Hazardous Scenarios.................................................................................................................................................... 128
Previous Incidents........................................................................................................................................................................ 129
References ....................................................................................................................................................................................... 131
Important Process Parameters............................................................................................................................................ 135
Common Hazardous Scenarios .......................................................................................................................................... 137
Other Hazardous Scenarios.................................................................................................................................................... 139
Previous Incidents........................................................................................................................................................................ 140
References ....................................................................................................................................................................................... 141
Important Process Parameters............................................................................................................................................. 144
Common Hazardous Scenarios ........................................................................................................................................... 146
Other Hazardous Scenarios.................................................................................................................................................... 149
References ....................................................................................................................................................................................... 150
4.1 Hydrocracking Unit .............................................................................................................................................................................. 118
4.2 Fluidized Catalytic Cracking Unit .............................................................................................................................................. 132
4.3 Cavern Storage ...................................................................................................................................................................................... 142
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