1、Safe Operation of Hydrofluoric Acid Alkylation UnitsAPI RECOMMENDED PRACTICE 751 FOURTH EDITION, MAY 2013Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither
2、 API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any
3、 use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API publications may be used by
4、anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or respo
5、nsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are no
6、t intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or
7、 materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.Classified areas ma
8、y vary depending on the location, conditions, equipment, and substances involved in any given situation. Users of this Recommended Practice should consult with the appropriate authorities having jurisdiction.Users of this Recommended Practice should not rely exclusively on the information contained
9、in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, co
10、ncerning health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction.Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manuf
11、acturer or supplier of that material, or the material safety data sheet.Where applicable, authorities having jurisdiction should be consulted.Work sites and equipment operations may differ. Users are solely responsible for assessing their specific equipment and premises in determining the appropriat
12、eness of applying the Recommended Practice. At all times users should employ sound business, scientific, engineering, and judgment safety when using this Recommended Practice.API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip thei
13、r employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, el
14、ectronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2013 American Petroleum InstituteForewordNothing contained in any API publication is to
15、be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent
16、.Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the specification.Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in order to conform to the specification.This document was produced under API stand
17、ardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication
18、was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.Generally, API
19、standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications a
20、nd materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage0 Scope . . . . . . . . . . . . . . . . . . . . . . .
21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hazards Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Process Hazards M
22、anagement Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 API 751 Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
23、1.3 Environmental Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.4 Incident Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24、. . . . . . . . . . . . . . . . 51.5 Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Operating Procedures and Worker Protection. . . . . . . . . . . . . . . . . . . . . . . .
25、. . . . . . . . . . . . . . . . . . . . . . . . . 62.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Health Hazard Information . . . . . . . . . . . . . . . . . . . . . .
26、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.3 Plant Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.4 Laboratory Safety . . . . . . . . . . . .
27、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.5 Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.6
28、Personal Protective Equipment and Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.7 Safety Showers and Eyewash Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.8 Control
29、led Access to the HF Alkylation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.9 Medical Response to HF Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Materials
30、, New Construction, Inspection, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.2
31、Materials Performance in HF Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.3 Construction and Equipment Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173.4
32、Inspection of Commissioned HF Unit Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.5 Equipment Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Tr
33、ansportation and Inventory Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.1 Refiner/Shipper Cooperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34、. 304.2 HF Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314.3 Inventory Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35、. . . . . . . . . . . . . . . . . . . 315 Relief and Utility Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325.1 Relief and Neutralization Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36、. . . . . . . . . . . . . . . . . . . . . . . . . . 325.2 Utility Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Risk MitigationOptions and Techniques . . . . . . . . . . . . . . . . . . .
37、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.2 Mitigation Systems . . . . . . . . . . . . . . . . . . . . .
38、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.3 Assessment Approach and Scenario and Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356.4 Detection Systems . . . . . . . . . . . . . . . . . . . .
39、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366.5 Active Mitigation Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.6 Passive Mitigation Systems . . .
40、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376.7 Event Duration Management Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Annex A (informative) Elements
41、 of a Comprehensive Audit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Annex B (informative) HF Exposure Limitations and Guidance Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Annex C (informative) Procedures for Unloading HF Acid Ta
42、nk Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Annex D (informative) Corrosion and Materials Considerations Specific to HF Alkylation . . . . . . . . . . . . . . . . 47Annex E Reference Documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43、 . . . . . . . . . . . . . . . . . . . . . . . . . 53vContentsPageAnnex F (informative) Examples of Tasks for Each Clothing Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Annex G (informative) Design Features of an HF Acid-truck Unloading Station . . . . . . . . . . .
44、. . . . . . . . . . . . . . 57Annex H (informative) Design Considerations for Assessment and Mitigation Options . . . . . . . . . . . . . . . . . . 59Tables1 Minimum Requirements of the Four Classes of PPE for Planned Work Activity. . . . . . . . . . . . . . . . . . . . 12B-1 Occupational Exposure L
45、imitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41B-2 AIHAEmergency Response Planning Guidelines (ERPGTM) in ppm . . . . . . . . . . . . . . . . . . . . . . . . . . . 41B-3 Acute Exposure Guideline Levels for HF, in ppm . .
46、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411Safe Operation of Hydrofluoric Acid Alkylation Units0 ScopeThe refining industry has long demonstrated that HF acid alkylation units can be operated safely and responsibly. Like many industrial processes, the HF
47、 acid alkylation process presents operational risk and must be properly designed, well-maintained and operated to assure safe operation. RP 751 is an industry document that communicates proven industry practices to support the safe operation of an HF acid alkylation unit. The philosophy of this four
48、th edition is to build on the previous editions base of recommendations for HF acid leak prevention, detection and mitigation with the document section topics of hazard management, operating procedures and worker protection, material inspection and maintenance, transportation and inventory control,
49、relief and utility systems, and risk mitigation. This edition changes some previous provisions from recommendations (should) to requirements (shall) based on regulatory requirements, broad industry acceptance and proven effective industry practices along with the addition of some new recommendations and requirements. The recommendations presented in the document are those that have been found effective or those which are advised for safe operations. 1 Hazards Management 1.1 Process Hazards Management Plan1.1.1 GeneralProcess hazards management applies to hydrofluoric acid (HF) alkylati
