Sections concerned with two-stage natural-gas conversion are amongst the commonest sources of emergencies in the manufacture of ammonia. The system contains hazardous substances in large volumes in combination with specific technology associated with the state of the working material and the high temperatures and pressures, so the plant in such a division belongs to the potentially hazardous class. Existing Russian legislation lays down that the design of such a section must necessarily involve considering quantitative hazard evaluations, i.e., accident risk estimation. There is only a very restricted volume of actual statistics on failu res in such equipment, while it is necessary to obtain quantitative estimates of hazards on the basis of accident prevention measures, so we chose the barrier diagram method. The results serve to compare various organizational and engineering measures to reduce accident risks. In such a section, natural gas purified from sulfur is used at 350‐370°C and 4.15‐4.20 MPa in a tubular oven, where it is mixed with steam in a steam‐gas ratio of 3.7:4.0. The mixture passes to a heater in the convection zone in the tubular ov en, where heat from stack gases is used to heat it to 510‐525°C. The mixture is uniformly distributed in the radiation zone over the vertically placed reaction tubes, where the reactions occurring are: CH 4 + H 2 O = CO + 3H 2 and CO + H 2 O = CO 2 + H 2 . The temperature of the converted gas at the outlet from the reaction tubes is 790‐800°C. The residual methane content in the dry converted gas after the oven is 9‐11%. The converted gas passes to tubes where it is additionally heated by 25‐30°C and passes to the other collector, which is lined with heat-insulating concrete and placed in a water jacket. Then the gas passes to the annular space in a mixer in the upper part of the methane convector in the second stage (shaft convector) at 465‐480°C. The free volume of that convector is located above a layer of catalyst, and part of the gas is burnt with atmospheric oxygen. The conversion is performed on a nickel catalyst at 990‐1002°C. The residual methane content in the converted gas is 0.35‐0.55%. The stack gases, after their heat has been utilized at 200°C, are discharged into the atmosphere [1, 2]. The barrier diagram method uses the definition of equipment failure combinations, various deficiencies in adjustment, and errors made by the staff (subsequently causes) that can lead to accidents. The graphical representation of the entire chains of initiating causes and the measures to eliminate them may be called the barrier diagram. The connections between the causes and their combinations are indicated by OR and & logic functions. Measures to prevent the causes are specified by the &‐NOR logic function. One of the main tasks in the method is to estimate the probabilities of various events arising. The frequencies of the initiating causes and the failure probabilities for protective measures are often very low, so one uses a special point system for representing the event frequencies. The points are specified from the formula p = ‐2 logh, where p is the number of points on the expert evaluation and h is the frequency with which failure causes arise. The probabilities (frequencies) of causes (events) for which one lacks reliable statistics are derived by expert estimation.
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