IMPROVING INDUSTRIAL SAFETY AT DELAYED COKING UNITS

Abstract

A significant part of the installations of oil refineries are hazardous production facilities and are characterized by the presence of a large amount of flammable substances that can form explosive mixtures with air. One of such units is a delayed coking unit (DCO). The ultrasonic treatment plant plays an important role as part of a refinery, increasing the depth of oil refining (up to 98%) and contributing to the production (along with coke) of large volumes of light oil products and gas. The action of a number of dangerous factors can lead to depressurization/destruction of equipment, as well as to the failure of flange connections of devices and pipelines, seals of pumps and fittings, and to the release of hazardous substances. The article provides information about a number of registered accidents that occurred at ultrasonic testing facilities in Russia, as well as their causes. In the analyzed cases, there were human errors. Particular attention should be paid to the training of ultrasonic testing operators, on whose actions the stable functioning of the technological process depends. The plant operator must be actively involved in the management of the production cycle, which requires a thorough understanding of not only how the plant operates, but also the ability to anticipate potential problems and respond in a timely manner to problems that arise. Often, classical methods of training personnel for emergency situations show insufficient effectiveness, so the solution to the problem is seen in strengthening the rules of industrial safety when working at ultrasonic testing facilities, and practicing skills through training on specialized computer simulators. To date, there is no information in open sources on simulators specifically for delayed coking units. The authors considered aspects of the formation of the technical specifications and architecture of the simulator for ultrasonic testing operators with an emphasis on industrial safety and response during an emergency. A block diagram of a virtual training complex for ultrasonic testing has been proposed.