저밀도 폴리에틸렌 고압분리 공정사고에 관한 법공학적 접근
Forensic Engineering Approach on Accidents of High Pressure Separator in Low-density Polyethylene Process
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초록
산업현장에서 발생하는 화재 및 폭발사고의 조사는 기계공학 및 화학공학을 기본으로 하는 법공학적 관점에서 실시하여야 한다. 본 연구에서는 저밀도 폴리에틸렌 고압분리 공정에서 발생한 2건의사고원인을 규명하기 위해 공정설계 분석과 관련 장치 분해조사를 실시하였으며 모두 고압분리기 내부압력 상승에 의한 고압분출로 인하여 사고가 발생하였다는 공통점이 있다. 그러나 사고의 근원적 원인은 고압분리기 후단 고압회수가스 냉각기의 막힘에 의한 경우와 분자량조절제 투입량 조절 실패에따른 고압분리기 내부에서의 열분해 반응에 의한 것으로 확인되었다. 사례 1 건에서는 과압에 의해 고압분리기가 파손되지 않도록 보호하기 위해 설치되어 있는 파열판의 기능이 정상적으로 작동하지 않은 기계적 결함도 확인할 수 있었다. 이 처럼 화학공장에서 공정사고가 발생한 경우, 공정설계 검토, 표준안전 절차검토, 교육?훈련 및 관리감독 등 여러 분야에 대한 조사가 필수적으로 이루어져야 한다. 또한 저밀도폴리에틸렌 제조공정의 안전에 있어서 고압분리기 전 후단 온도관리, 녹아웃 포트의 적정설계, 고압분리기 압력방출장치 유지관리, 냉각기 막힘 관리가 매우 중요한 요소임을 확인하고 그에 대한 안전대책을 제시할 수 있었다.
Abstract
Investigations of fire and explosion incidents occurring at industrial sites should be conducted from the viewpoint of legal engineering based on mechanical engineering and chemical engineering. In this study, the process design analysis and facilities inspection by overhauling were carried out to identify the causes of two accidents in the LDPE (low density polyethylene)’s high pressure separation process. In both cases, there is a common point that an accident occurred due to the high pressure ejection due to the pressure increase inside the high pressure separator. However, one was caused by the plugging of the high pressure recycle gas cooler after the high pressure separator and the other was caused by the decomposion reaction inside the high pressure separator due to failure to control the amount of telomer. In one case, it was also confirmed that the rupture disk installed in order to prevent breakage by overpressure of the high pressure separator did not operate properly. In addition to the characteristics of the processing method, it is necessary to investigate whether the process inspection, standard operating procedure (SOP), training, and supervision conformity are appropriate for the accident investigation. The importance of the temperature management before and after the high pressure separator, optimal design of knock-out port, maintenance of the pressure relief device on the high pressure separator, and management of the plugging of the cooler were confirmed and the policy for safety measures could be suggested in this study.
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