Showing papers in "Journal of Loss Prevention in The Process Industries in 2007"

Safety management system: Development and validation of a multidimensional scale

Abstract: The literature has recognised that implementing a safety management system is the most efficient way of allocating resources for safety, since it not only improves working conditions, but also positively influences employees’ attitudes and behaviours with regards safety, consequently improving the safety climate. The safety climate and the safety management system are considered basic components of the firm's safety culture in various models. However, the literature has focused more on measuring the safety climate, while few studies have correctly tested the psychometric properties of the instruments used to measure how advanced the firm's safety management system is. This paper reviews the most important works on safety management, with the aim of developing a measurement scale operationalising the safety management system concept, and subsequently calculating its reliability and validity. For this purpose, exploratory factor analyses and confirmatory factor analyses are conducted, using structural equation models, on a sample of 455 Spanish companies. This scale provides organisations with a tool for evaluating their situation with regards safety management, as well as guidance about which areas they must improve if they wish to reduce occupational accidents.

The hazards and risks of hydrogen

Abstract: An analysis was completed of the hazards and risks of hydrogen, compared to the traditional fuel sources of gasoline and natural gas (methane). The study was based entirely on the physical properties of these fuels, and not on any process used to store and extract the energy. The study was motivated by the increased interest in hydrogen as a fuel source for automobiles. The results show that, for flammability hazards, hydrogen has an increased flammability range, a lower ignition energy and a higher deflagration index. For both gasoline and natural gas (methane) the heat of combustion is higher (on a mole basis). Thus, hydrogen has a somewhat higher flammability hazard. The risk is based on probability and consequence. The probability of a fire or explosion is based on the flammability range, the auto-ignition temperature and the minimum ignition energy. In this case, hydrogen has a larger flammability zone and a lower minimum ignition energy—thus the probability of a fire or explosion is higher. The consequence of a fire or explosion is based on the heat of combustion, the maximum pressure during combustion, and the deflagration index. Hydrogen has an increased consequence due to the large value of the deflagration index while gasoline and natural gas (methane) have a higher heat of combustion. Thus, based on physical properties alone, hydrogen poses an increase risk, primarily due to the increased probability of ignition. This study was unable to assess the effects of the increased buoyancy of hydrogen—which might change the probability depending on the actual physical situation. A complete hazard and risk analysis must be completed once the actual equipment for hydrogen storage and energy extraction is specified. This paper discusses the required procedure.

Influence of ignition position and obstacles on explosion development in methane–air mixture in closed vessels

Abstract: The paper outlines an experimental study of influence of the ignition position and obstacles on explosion development in premixed methane–air mixtures in an elongated explosion vessel. As the explosion vessel, 1325 mm length tube with 128.5 mm diameter was used. Location of the ignition was changeable, i.e., fitted in the centre or at one of ends of the tube, when the tube was in a horizontal position. When it was in a vertical position, three locations of the ignition (bottom, centre and top) were used. In the performed study, the influence of obstacles on the course of pressure was investigated. Two identical steel grids were used as the obstacles. They were placed 405 mm from either end of the tube. Their blockage ratio (grid area to tube cross-section area) was determined as 0.33 for most of experiments. A few additional experiments (with smaller blockage ratio—0.16) were also conducted in order to compare the influence of the blockage ratio on the explosion development. Also some experiments were conducted in a semi-cylindrical vessel with volume close to 40 l. All the experiments were performed under stabilized conditions, with the temperature and pressure inside the vessel settled to room values and controlled by means of electronic devices. The pressure–time profiles from two transducers placed in the centreline of the inner wall of the explosion vessel were obtained for stoichiometric (9.5%), lean (7%) and rich (12%) methane–air mixture. The results obtained in the study, including maximum pressures and pressure–time profiles, illustrate a quite distinct influence of the above listed factors upon the explosion characteristics. The effect of ignition position, obstacles location and their BR parameters is discussed. The additional aim of the performed experiments was to find the data necessary to validate a new computer code, developed to calculate an explosion hazard in industrial installations.

Operational risk assessment of chemical industries by exploiting accident databases

Abstract: Accident databases (NRC, RMP, and others) contain records of incidents (e.g., releases and spills) that have occurred in the USA chemical plants during recent years. For various chemical industries, [Kleindorfer, P. R., Belke, J. C., Elliott, M. R., Lee, K., Lowe, R. A., & Feldman, H. I. (2003). Accident epidemiology and the US chemical industry: Accident history and worst-case data from RMP*Info . Risk Analysis , 23 (5), 865–881.] summarize the accident frequencies and severities in the RMP*Info database. Also, [Anand, S., Keren, N., Tretter, M. J., Wang, Y., O’Connor, T. M., & Mannan, M. S. (2006). Harnessing data mining to explore incident databases . Journal of Hazardous Material , 130 , 33–41.] use data mining to analyze the NRC database for Harris County, Texas. Classical statistical approaches are ineffective for low frequency, high consequence events because of their rarity. Given this information limitation, this paper uses Bayesian theory to forecast incident frequencies, their relevant causes, equipment involved, and their consequences, in specific chemical plants. Systematic analyses of the databases also help to avoid future accidents, thereby reducing the risk. More specifically, this paper presents dynamic analyses of incidents in the NRC database. The NRC database is exploited to model the rate of occurrence of incidents in various chemical and petrochemical companies using Bayesian theory. Probability density distributions are formulated for their causes (e.g., equipment failures, operator errors, etc.), and associated equipment items utilized within a particular industry. Bayesian techniques provide posterior estimates of the cause and equipment-failure probabilities. Cross-validation techniques are used for checking the modeling, validation, and prediction accuracies. Differences in the plant- and chemical-specific predictions with the overall predictions are demonstrated. Furthermore, extreme value theory is used for consequence modeling of rare events by formulating distributions for events over a threshold value. Finally, the fast-Fourier transform is used to estimate the capital at risk within an industry utilizing the frequency and loss-severity distributions.

Explosion temperatures and pressures of metals and other elemental dust clouds

Abstract: The Pittsburgh Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) conducted a study of the explosibility of various metals and other elemental dusts, with a focus on the experimental explosion temperatures. The data are useful for understanding the basics of dust cloud combustion, as well as for evaluating explosion hazards in the minerals and metals processing industries. The dusts studied included boron, carbon, magnesium, aluminum, silicon, sulfur, titanium, chromium, iron, nickel, copper, zinc, niobium, molybdenum, tin, hafnium, tantalum, tungsten, and lead. The dusts were chosen to cover a wide range of physical properties—from the more volatile materials such as magnesium, aluminum, sulfur, and zinc to the highly “refractory” elements such as carbon, niobium, molybdenum, tantalum, and tungsten. These flammability studies were conducted in a 20-L chamber, using strong pyrotechnic ignitors. A unique multiwavelength infrared pyrometer was used to measure the temperatures. For the elemental dusts studied, all ignited and burned as air-dispersed dust clouds except for nickel, copper, molybdenum, and lead. The measured maximum explosion temperatures ranged from ∼1550 K for tin and tungsten powders to ∼2800 K for aluminum, magnesium, and titanium powders. The measured temperatures are compared to the calculated, adiabatic flame temperatures.

Thermo-kinetic modelling of dust explosions

Abstract: The guidelines for protection and mitigation against hazard coming from dust explosion require the knowledge and then the evaluation either experimentally or theoretically of the thermo-kinetic parameters (i.e. KSt, Pmax). We developed a numerical tool for the evaluation of the thermo-kinetic parameters of dust explosion. This model is based on the simulations of the combustion reaction by means of a detailed reaction mechanism assuming that the pyrolysis/devolatilization step is very fast and then gas combustion is controlling dust explosion. The model allows then the determination of the most conservative values of KSt, Sl, Pmax. In the present paper we calculated the deflagration index and the laminar burning velocity for dusts utilized in various process industries (i.e. cornstarch, polyethylene, cellulose) as function of dust concentration. The obtained data were successfully compared with the available experimental results.

Blast overpressures from medium scale BLEVE tests

Abstract: The measured blast overpressures from recent tests involving boiling liquid expanding vapour explosions (BLEVE) has been studied The blast data came from tests where 04 and 2 m 3 ASME code propane tanks were exposed to torch and pool fires In total almost 60 tanks were tested, and of these nearly 20 resulted in catastrophic failures and BLEVEs Both single and two-step BLEVEs were observed in these tests This paper presents an analysis of the blast overpressures created by these BLEVEs In addition, the blast overpressures from a recent full scale fire test of a rail tank car is included in the analysis The results suggest that the liquid energy content did not contribute to the shock overpressures in the near or far field The liquid flashing and expansion does produce a local overpressure by dynamic pressure effects but it does not appear to produce a shock wave The shock overpressures could be estimated from the vapour energy alone for all the tests considered This was true for liquid temperatures at failure that were below, at and above the atmospheric superheat limit for propane Data suggests that the two step type BLEVE produces the strongest overpressure The authors give their ideas for this observation The results shown here add some limited evidence to support previous researchers claims that the liquid flashing process is too slow to generate a shock It suggests that liquid temperatures at or above the Tsl do not change this The expansion of the flashing liquid contributes to other hazards such as projectiles, and close in dynamic pressure effects Of course BLEVE releases in enclosed spaces such as tunnels or buildings have different hazards

Moderation of dust explosions

Abstract: Inherent safety is a proactive approach to process safety in which hazards are removed or minimized so as to reduce risk without engineered (add-on) or procedural intervention. Four basic principles are available to attain an inherently safer design—minimization, substitution, moderation, and simplification. The subject of the current paper is the principle of moderation as it applies to the prevention and mitigation of dust explosions. Moderation can be achieved by processing a material under less severe operating conditions or by processing the material in a less hazardous form. With respect to the latter approach, it may be possible to alter the composition of a dust by admixture of solid inertants, or to increase the dust particle size so as to decrease its reactivity. Additionally, avoidance of the formation of hybrid mixtures of explosible dusts and flammable gases is an application of moderation of the material hazard. Several examples are given for each of the above three forms of moderation. The discussion on admixture of solid inertants includes examples from the following industrial applications: (i) refractory materials manufacturing, (ii) food processing, (iii) power generation, (iv) industrial recycling, and (v) foundry shell mold fabrication. The importance of particle size consideration is explained first from the perspective of engineering tools such as the Dow Fire & Explosion Index, and professional guidance on the definition of a dust and suitable particle sizes for explosibility testing. Industrial examples are then drawn from the following areas: (i) rubber recycling and textile manufacturing, (ii) industrial recycling, (iii) wood processing, (iv) dry additive handling (polyethylene facility), (v) polyethylene production, (vi) carbon block recycling, and (vii) coal mining. The concluding discussion on hybrid mixtures includes brief cases from the process safety literature.

The integration of Dow's fire and explosion index (F&EI) into process design and optimization to achieve inherently safer design

Abstract: For the processing industries, it is critically to have an economically optimum and inherently safer design and operation. The basic concept is to achieve the best design based on technical and business performance criteria while performing within acceptable safety levels. Commonly, safety is examined and incorporated typically as an after-thought to design. Therefore, systematic and structured procedure for integrating safety into process design and optimization that is compatible with currently available optimization and safety analysis methodology must be available. The objective of this paper is to develop a systematic procedure for the incorporation of safety into the conceptual design and optimization stage. We propose the inclusion of the Dow fire and explosion index (F&EI) as the safety metric in the design and optimization framework by incorporating F&EI within the design and optimization framework. We first develop the F&EI computer program to calculate the F&EI value and to generate the mathematical expression of F&EI as a function of material inventory and operating pressure. The proposed procedure is applied to a case study involving reaction and separation. Then, the design and optimization of the system are compared for the cases with and without safety as the optimization constraint. The final result is the optimum economic and inherently safer design for the reactor and distillation column system.

Flame propagation in hybrid mixture of coal dust and methane

Abstract: To investigate the flame propagation through hybrid mixture of coal dust and methane in a combustion chamber, a high-speed video camera with a microscopic lens and a Schlieren optical system were used to record the flame propagation process and to obtain the direct light emission photographs. Flame temperature was detected by a fine thermocouple. The suspended coal dust in the mixture of methane and air was ignited by an electric spark. The flame propagation speeds and maximum flame temperatures of the mixture were analyzed. The results show that the co-presence of coal dust and methane improves the flame propagation speed and maximum flame temperature notably, which become much higher than that of the single-coal dust flame. The flame front temperature varies with the coal dust concentration.

Ignitability characteristics of aluminium and magnesium dusts that are generated during the shredding of post-consumer wastes

Abstract: The authors investigated the ignitability of aluminium and magnesium dusts that are generated during the shredding of post-consumer waste. The relations between particle size and the minimum explosive concentration, the minimum ignition energy, the ignition temperature of the dust clouds, etc. the relation between of oxygen concentration and dust explosion, the effect of inert substances on dust explosion, etc. were studied experimentally. The minimum explosive concentration increased exponentially with particle size. The minimum explosive concentrations of the sample dusts were about 170 g/m 3 (aluminium: 0–8 μm) and 90 g/m 3 (magnesium: 0–20 μm). The minimum ignition energy tended to increase with particle size. It was about 6 mJ for the aluminium samples and 4 mJ for the magnesium samples. The ignition temperature of dust clouds was about 750 °C for aluminium and about 520 °C for magnesium. The lowest concentrations of oxygen to produce a dust explosion were about 10% for aluminium and about 8% for magnesium. A large mixing ratio (more than about 50%) of calcium oxide or calcium carbonate was necessary to decrease the explosibility of magnesium dust. The experimental data obtained in the present investigation will be useful for evaluating the explosibility of aluminium and magnesium dusts generated in metal recycling operations and thus for enhancing the safety of recycling plants.

Shock-induced ignition of hydrogen gas during accidental or technical opening of high-pressure tanks

Abstract: This paper is devoted to the numerical and experimental investigation of hydrogen self-ignition as a result of the formation of a primary shock wave in front of a cold expanding hydrogen gas jet. Temperature increase, as a result of this shock wave, leads to the ignition of the hydrogen–air mixture formed on the contact surface. The required condition for hydrogen self-ignition is to maintain the high temperature in the area for a time long enough for hydrogen and air to mix and inflammation to take place. Calculations of the self-ignition of a hydrogen jet are based on a physicochemical model involving the gas-dynamic transport of a viscous gas, the kinetics of hydrogen oxidation, the multi-component diffusion, and the heat exchange. We found that the reservoir pressure range, when a shock wave formed in the air during depressurization, has sufficient intensity to produce self-ignition of the hydrogen–air mixture formed at the front of a jet of compressed hydrogen. We present an analysis of the initial conditions (the hydrogen pressure inside the vessel, the temperature of the compressed hydrogen and the surrounding air, and the diameter of the hole through which the jet was emitted), which leads to combustion.

Measuring the violence of dust explosions with the “20 l sphere” and with the standard “ISO 1 m3 vessel”: Systematic comparison and analysis of the discrepancies

Abstract: On the basis of a systematic testwork with a number of different dusts, the explosion indices as determined within the 20 l sphere and with the ISO-VDI 1 m 3 vessel have been compared. The repeatability has been assessed and since some systematic deviations appear a refined physical analysis of the explosion processes is developed. It appears in particular that the cube root law supposed to link both vessels is not verified. A striking illustration of this appears when a dust with a significant explosion severity inside the 20 l sphere is not even explosible in the larger vessel. It is strongly suggested that the ignition energy is forcing very significantly the explosion in the smaller vessel inducing several tens of Celsius degrees of preheating. It is shown also that the inner level of turbulence is decreasing very fast in the 20 l sphere during the flame development so that difficult-to-ignite mixtures would tend to burn at a lower combustion rate. It is further demonstrated that the major bias between the chambers can be explained and quantified with these elements. A correlation with the standard 1 m 3 vessel and a grid of interpretation of the data is proposed.

Common cause failures in safety instrumented systems on oil and gas installations: Implementing defense measures through function testing

Abstract: This paper presents a common cause failure (CCF) defense approach for safety instrumented systems (SIS) in the oil and gas industry. The SIS normally operates in the low demand mode, which means that regular testing and inspection are required to reveal SIS failures. The CCF defense approach comprises checklists and analytical tools which may be integrated with current approaches for function testing, inspection and follow-up. The paper focuses on how defense measures may be implemented to increase awareness of CCFs, to improve the ability to detect CCFs, and to avoid introducing new CCFs. The CCF defense approach may also be applicable for other industry sectors.

Review of the DESC project

Abstract: Dust Explosion Simulation Code (DESC) was a project supported by the European Commission under the Fifth Framework Programme. The main purpose of the project was to develop a simulation tool based on computational fluid dynamics (CFD) that could predict the potential consequences of industrial dust explosions in complex geometries. Partners in the DESC consortium performed experimental work on a wide range of topics related to dust explosions, including dust lifting by flow or shock waves, flame propagation in vertical pipes, dispersion-induced turbulence and flame propagation in closed vessels, dust explosions in closed and vented interconnected vessel systems, and measurements in real process plants. The new CFD code DESC is based on the existing CFD code FLame ACceleration Simulator (FLACS) for gas explosions. The modelling approach adopted in the first version entails the extraction of combustion parameters from pressure–time histories measured in standardized 20-l explosion vessels. The present paper summarizes the main experimental results obtained during the DESC project, with a view to their relevance regarding dust explosion modelling, and describes the modelling of flow and combustion in the first version of the DESC code. Capabilities and limitations of the code are discussed, both in light of its ability to reproduce experimental results, and as a practical tool in the field of dust explosion safety.

Accidental risk of superheated liquids and a framework for predicting the superheat limit

Abstract: The phenomenon of superheating of liquids has fostered the development of several beneficial technologies and has the potential of revolutionizing the design and application of thermal micro-machines. But liquid superheat is also behind some of the most common and destructive accidents in the process industry. These include boiling liquid expanding vapor explosion (BLEVE), which occurs when a vessel storing pressure liquefied gas such as propane, chlorine, or ammonia is accidentally depressurized. Superheating was also responsible for the catastrophic release of methyl isocyanate in Bhopal. Besides great losses of life and inanimate assets, such accidents often cause severe environmental contamination. In nuclear industry superheated liquids pose an ever-present threat of thermo-hydraulic explosion if a leak or a break occurs in a pipeline carrying a superheated coolant. In metallurgical industries accidental contact of molten metal with another substance of much lower boiling point—such as water—can superheat the latter, causing explosion of great severity and destructive potential. Accidental dropping of water in hot oil and the resulting explosive vaporization of superheated water has been identified as the cause the largest number of household kitchen accidents. Even as knowledge of superheat limit temperature (SLT)—which is the temperature above which a liquid cannot exist at a given pressure—is central to the safe design and control of several industrial operations, reliable experimental or theoretical methods do not exist with which SLT can be determined accurately or quickly. In this paper we describe an attempt to develop a framework with which SLT of new substances can be theoretically determined with fair degree of confidence. Seven cubic equation of state (EOS) have been transformed by the application of the Maxwell's and the SLT criteria to eliminate those parameters of which correct values cannot be determined with certainty. The transformed equations have then been solved to generate SLT values. A comparison between the calculated and the observed values has been done for 75 industrial chemicals. It reveals that for a large number of chemicals the transformed Redlich–Kwong (RK) EOS is able to predict the SLT within less then 1% deviation from its experimental value. In case of the SLT of noble gases the transformed van der Waals (vdW) EOS has the best predictive ability. Only in a very few cases other EOS give a closer fit than the RK-EOS and the vdW-EOS. The ‘second best fit’ is almost always achieved with either the RK-EOS or the Twu–Redlich–Kwong (TRK) EOS.

Coal dust particle size survey of US mines

Abstract: The National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted a joint survey to determine the range of coal particle sizes found in dust samples collected from intake airways of US coal mines. The last comprehensive survey of this type was performed in the 1920s. The size of the coal dust is relevant to the amount of rock dust required to inert the coal dust, with more rock dust needed to inert finer sizes of coal dust. Dust samples were collected by MSHA inspectors from several mines in each of MSHA's 10 bituminous Coal Mine Safety and Health Districts. Samples were normally collected in several intakes at each mine. The laboratory analysis procedures included acid leaching of the sample to remove the limestone rock dust, sonic sieving to determine the dust size, and low-temperature ashing of the sieved fractions to correct for any remaining incombustible matter. The results indicate that particle sizes of mine coal dust in intake airways are finer than those measured in the 1920s. This finer size coal dust in intake airways would require more incombustible matter to be effectively inerted than the 65% incombustible specified in current regulations.

Explosibility of hydrogen–graphite dust hybrid mixtures

Abstract: To evaluate the hazard of combined hydrogen/dust explosions under severe accident conditions in International Thermonuclear Experimental Reactor (ITER), standard method of 20-L-sphere was used to measure the explosion indices of 4-μm fine graphite dust in lean hydrogen/air mixtures The mixtures were ignited by a weak electric spark The tested fuel concentrations were 8–18 vol% H2 and 25–250 g/m3 dust If the hydrogen content is higher than 10 vol%, the dust constituent can be induced to explode by the hydrogen explosion initiated by a weak electric spark Depending on the fuel component concentrations, the explosions proceed in either one or two stages In two-stage explosions occurring at low hydrogen and dust concentrations, the mixture ignition initiates first a fast hydrogen explosion followed by a slower phase of the dust explosion With increasing dust concentration, the dust explodes faster and can overlap the hydrogen-explosion stage At higher hydrogen concentrations, the hybrid mixtures explode in one stage, with hydrogen and dust reacting at the same time scale Maximum overpressures of hybrid explosions are higher than those observed with hydrogen alone; maximum rates of pressure rise are lower in two-phase explosions and, generally, higher in one-stage explosions, than those characteristic of the corresponding H2/air mixtures

Flammability envelopes for methanol, ethanol, acetonitrile and toluene

Abstract: The flammability envelope was experimentally determined up to the point of vapor saturation for four flammable liquids: methanol, ethanol, acetonitrile, and toluene. The experimental apparatus consisted of a 20-L spherical chamber with a centrally located 10 J fuse wire igniter. The liquid was injected and vaporized into the chamber via a septum and a precision syringe. Nitrogen and oxygen were mixed from pure components using a precision pressure gauge. Pressure versus time data were measured for each ignition test. Flammability was defined as any ignition resulting in an increase in pressure of 7% over the initial pressure, as per ASTM E 918–83. All data were obtained at an initial temperature of 298 K and 1 atm. The experimental values of the LFL agreed well with published values. Limiting oxygen concentrations (LOC) were also determined—although these were somewhat lower than published values. The calculated adiabatic flame temperature (CAFT) method was used to model the data using a threshold temperature of 1200 K. A reasonable fit of the flammability envelope was obtained, although this could be improved with a higher threshold temperature.

Model-based HAZOP study of a real MTBE plant

Abstract: Integration of a mathematical model approach with hazard and operability (HAZOP) analysis is presented in this contribution. The presented analysis is based on the mathematical modelling of a process unit, where both the steady-state analysis (including continuation and bifurcation analyses), and the dynamic simulation are used. The main benefit of this integration is the ability to perform a detail safety analysis for a relatively complicated process. Such an approach may dramatically decrease the possibility that several sources of hazard will be overlooked. Of course, the presented methodology may also seriously reduce the time necessary for the hazard identification process. In this paper, a methyl tertiary-butyl ether (MTBE) production unit was chosen to identify potential hazard and operational problems of a real process. This simplified case-study unit consists of two investigated types of equipment: a tubular fixed bed reactor and a reactive distillation column.

A quantitative risk assessment tool for the external safety of industrial plants with a dust explosion hazard

Abstract: A quantitative risk assessment (QRA) tool has been developed by TNO for the external safety of industrial plants with a dust explosion hazard. As a first step an industrial plant is divided into groups of modules, defined by their size, shape, and constructional properties. Then the relevant explosion scenarios are determined, together with their frequency of occurrence. These include scenarios in which one module participates, as well as domino scenarios. The frequency is partly based on casuistry. A typical burning velocity is determined depending on the ignition type, the dust properties and the local conditions for flame acceleration. The resulting pressure development is predicted with the 'thin flame model'. Module failure occurs when the explosion load exceeds thresholds, which are derived from single degree of freedom (SDOF) calculations for various types of modules. A model has been developed to predict the process of pressure venting after module failure and the related motion of launched module parts. The blast effects of the primary explosion are based on results from calculations with BLAST3D. The blast and flame effects of the secondary external explosion due to venting are calculated using existing models. The throw of fragments and debris is quantified with a recently developed model. This model is based on trajectory calculations and gives the impact densities, velocities, and angles as output. Furthermore the outflow of bulk material is taken into account. The consequences for external objects and human beings are calculated using existing models. Finally the risk contours and the Societal risk (FN curve) are calculated, which can be compared to regulations. © 2007 Elsevier Ltd. All rights reserved.

Modeling of BP Texas City refinery incident

Abstract: This paper presents detailed modeling results of the BP Texas City refinery incident. Three different approaches and explosion modeling tools were used to study the event. The results predicted by all three approaches are similar and all approaches identified a hazard potential comparable to what was witnessed on March 23, 2005. This confirms that quantitative risk assessment (QRA) has the ability to model a realistic scenario, and is therefore useful in safety measure design and emergency preparedness decision making to improve overall safety performance. Had QRA been conducted during a management of change (MOC) decision-making process, personnel trailers likely would not have been sited in such close proximity to the process units. The resulting severe consequences would then not have occurred. This work also aims to emphasize the importance of QRA in process safety management. The paper presents the authors’ perception of the sequence of events involved in the incident based on the published literature available at the time of writing. It also assesses potential consequences for the perceived sequence of events using a variety of consequence assessment tools. In doing so, the analysis illustrates how this incident could have been prevented in spite of many operational difficulties. The observations and commentary presented in this paper are intended solely for the purpose of process safety enhancement on the basis of the lessons learned. BP has published its own detailed report; the incident is also the subject of a recent investigation by the US Chemical Safety and Hazard Investigation Board, with the CSB's final report being available at http://www.csb.gov/index.cfm?folder=completed_investigations&page=info&INV_ID=52 (as of April 2007).

Dust explosion incidents and regulations in the United States

Abstract: The US Chemical Safety and Hazard Investigation Board (CSB) investigated three fatal dust explosions that all occurred in 2003 These explosions caused the deaths of 14 people and injured hundreds more Two of the facilities were damaged beyond repair, and several hundred employees lost their jobs CSB's investigations revealed that the explosions had common causes, despite their geographic and industrial diversity Consequently, CSB commissioned a study of combustible dust fire and explosion hazards This paper presents a summary of CSB's findings and recommendations developed during that study

Influence of the oxide content on the ignition energies of aluminium powders

Abstract: Some results of determination of ignition energies for an aluminium powder with various oxide contents are presented. Common use of processes like high-speed cutting produce explosive dust clouds, so that we focused this study on hazard of metallic powders. An industrial aluminium powder has been used for this work. An original process, based on the principle of electrochemical anodisation, has been developed to increase, under control, the oxide coating of particles. The sensitivity study to spark ignition was performed in an Hartmann explosion tube of 1.3 L . The Langlie test method was applied to evaluate the energies leading to a probability of ignition of 50% ( E 50 ) of the selected samples. The results confirm that the ignition energies increase with the oxide content of the powder.

Minimum propagation diameter and thickness of high explosives

Abstract: The critical diameter and critical thickness of two heterogeneous explosives were measured experimentally. By comparing these experimentally determined values of critical diameter and critical thickness, the role of front curvature in the failure of the detonation can be investigated. Current theories of detonation based on front curvature would predict the critical diameter should be twice the critical thickness. Experimentally, the expected two-to-one ratio was only validated for the case of a heterogeneous explosive with very fine scale heterogeneities. The ratios of critical diameter to critical thickness (for the two selected explosives) are also compared to previously measured values for homogeneous (liquid) explosives in order to contrast the dominant failure mechanism in these different explosives.

Improved qualitative fault propagation analysis

Abstract: Fault propagation analysis is the cornerstone to assure safe operation, optimized maintenance, as well as for the management of abnormal situations in chemical and petrochemical plants. Due to plant complexity and dynamic changes in plant conditions, current approaches have major limitations in identifying all possible fault propagation scenarios. This is due to the lack of realistic equipment and fault models. In this paper, practical framework is proposed to synthesize and assess all possible fault propagation scenarios based on robust modeling methodology. Fault models are constructed where deviations are identified and associated with symptoms, faults, causes, and consequences. Fault models are tuned using real time process data, simulation data, and human experience. The proposed system is developed and applied on case study experimental plant.

Reactive shock and detonation propagation in U-bend tubes

Abstract: The objective of the research outlined in this paper was to provide new experimental and computational data on initiation, propagation, and stability of gaseous stoichiometric propane–air detonations in tubes with U-bends. Extensive experimental and computational studies with the tube 51 mm in diameter with U-bends of two curvatures and two different shock-wave generators were performed. Numerical simulations of the process were used to reveal the salient features of the accompanying phenomena.

Modelling of dust lifting process behind propagating shock wave

Abstract: Dust dispersion from a layer is a complicated problem, which has not been completely solved yet, especially if an Eulerian–Eulerian approach has to be used to model the two-phase dusty flow. In previous investigation, a phenomenological model of the dust dispersion process from a layer was developed, but the evaluation of the model revealed some weaknesses. In the current paper, the model of the dust dispersion process was presented and three improvements of the model were studied: Saffman force, Magnus force and particles collisions. The implementation of Magnus and Saffman forces into the code did not improve the numerical results and it was shown that it had very little influence on the dust lifting process, in case the phenomenological model of the layer is used. Some explanations were proposed in the paper. Besides, an empirical model of particles collisions was also added to the code and its influence on the results was studied. It was shown that the particles collisions model improved the obtained results, but further modifications are to be studied in the future.

Deflagration suppression using expanded metal mesh and polymer foams

Abstract: Expanded metal mesh and polymer foams of appropriate pore or cell size and sufficient surface area per unit volume can suppress deflagrations of gas/vapor–air mixtures. This paper reviews the requirements that have been established for use of these materials in military aircraft fuel tanks. Extensions and generalizations of these requirements for other applications have been developed and incorporated into the 2008 edition of the NFPA 69 Standard for Explosion Prevention. The new NFPA 69 requirements for testing, evaluating, and installing these materials are summarized here along with an explanation of the basis and rationale for these requirements.

Post-explosion observations of experimental mine and laboratory coal dust explosions

Abstract: The Pittsburgh Research Laboratory (PRL) of the National Institute for Occupational Safety and Health (NIOSH) and the Mine Safety and Health Administration (MSHA) conducted joint research on dust explosions by studying post-explosion dust samples. The samples were collected after full-scale explosions at the PRL Lake Lynn Experimental Mine (LLEM), and after laboratory explosions in the PRL 20-L chamber and the Fike 1 m 3 chamber. The dusts studied included both high- and low-volatile bituminous coals. Low temperature ashing for 24 h at 515 °C was used to measure the incombustible content of the dust before and after the explosions. The data showed that the post-explosion incombustible content was always as high as, or higher than the initial incombustible content. The MSHA alcohol coking test was used to determine the amount of coked dust in the post-explosion samples. The results showed that almost all coal dust that was suspended within the explosion flame produced significant amounts of coke. Measurements of floor dust concentrations after LLEM explosions were compared with the initial dust loadings to determine the transport distance of dust during an explosion. All these data will be useful in future forensic investigations of accidental dust explosions in coal mines, or elsewhere.