Showing papers in "Journal of Loss Prevention in The Process Industries in 2015"

Modelling of pitting corrosion in marine and offshore steel structures – A technical review

Abstract: Corrosion is a major cause of structural deterioration in marine and offshore structures. It affects the life of process equipment and pipelines, and can result in structural failure, leakage, product loss, environmental pollution and the loss of life. Pitting corrosion is regarded as one of the most hazardous forms of corrosion for marine and offshore structures. The total loss of the structure might be very small, but local rate of attack can be very large and can lead to early catastrophic failure. Pitting corrosion is a localized accelerated dissolution of metal that occurs as a result of a breakdown in the protective passive film on the metal surface. It has been studied for many years; however, the structural failure due to pit characteristics is still not fully understood. Accurate pit depth measurements, precise strength assessment techniques, risk analysis due to pitting, and the mathematical relationship of the environmental factors that causes pitting failure are also factors, which need further understanding. Hence this paper focuses on these issues. It reviews and analyses the current understanding of the pitting corrosion mechanism and investigates all possible factors that can cause pitting corrosion. Furthermore, different techniques employed by scientists and researchers to identify and model the pitting corrosion are also reviewed and analysed. Future work should involve an in-depth scientific study of the corrosion mechanism and an engineering predictive model is recommended in order to assess failure, and thereby attempt to increase the remaining life of offshore assets.

Risk analysis of deepwater drilling operations using Bayesian network

Abstract: Deepwater drilling is one of the high-risk operations in the oil and gas sector due to large uncertainties and extreme operating conditions. In the last few decades Managed Pressure Drilling Operations (MPD) and Underbalanced Drilling (UBD) have become increasingly used as alternatives to conventional drilling operations such as Overbalanced Drilling (OVD) technology. These newer techniques provide several advantages however the blowout risk during these operations is still not fully understood. Blowout is regarded as one of the most catastrophic events in offshore drilling operations; therefore implementation and maintenance of safety measures is essential to maintain risk below the acceptance criteria. This study is aimed at applying the Bayesian Network (BN) to conduct a dynamic safety analysis of deepwater MPD and UBD operations. It investigates different risk factors associated with MPD and UBD technologies, which could lead to a blowout accident. Blowout accident scenarios are investigated and the BNs are developed for MPD and UBD technologies in order to predict the probability of blowout occurrence. The main objective of this paper is to understand MPD and UBD technologies, to identify hazardous events during MPD and UBD operations, to perform failure analysis (modelling) of blowout events and to evaluate plus compare risk. Importance factor analysis in drilling operations is performed to assess contribution of each root cause to the potential accident; the results show that UBD has a higher occurrence probability of kick and blowout compared to MPD technology. The Rotating Control Devices (RCD) failure in MPD technology and increase in flow-through annulus in UBD technology are the most critical situations for kick and blowout.

A fuzzy DEMATEL method to evaluate critical operational hazards during gas freeing process in crude oil tankers

Abstract: Gas freeing process in crude oil tanker ships is widely recognized one of the most hazardous aspects of shipboard operations. Although the process provides practical benefits to ship by removing the explosive or poisonous gases from the cargo tanks and raising the oxygen level up to 21 percent, the consequences of failure may cause serious damage to human health, marine environment and cargo. Therefore, the crew exercise utmost care and become aware of the potential hazards in gas freeing process. In this context, this paper provides a fuzzy DEMATEL (Decision Making Trial and Evaluation Laboratory) method to evaluate critical operational hazards in gas freeing process. While the DEMATEL method enables to identify and analyse the potential hazards of gas freeing process with respect to causal–effect relation diagram, fuzzy sets deal with the uncertainty in decision-making and human judgements through the DEMATEL. Thus, the hybrid approach provides smart solution for safety practitioners to prevent critical hazards in gas freeing process. The results of the research will contribute to maritime safety at sea and prevention of environment pollution as well as loss of life on-board crude oil tankers ships.

Analysis and assessment of the Qingdao crude oil vapor explosion accident: Lessons learnt

Abstract: A devastating crude oil vapor explosion accident, which killed 62 people and injured 136, occurred on November 22, 2013. It was one of the most disastrous vapor cloud explosion accidents that happened in Qingdao's storm drains in China. It was noted that blast overpressure and flying debris were the main causes of human deaths, personal injuries and structure damages. Two months after the accident, it was reported that there were three contentious issues in the investigation report. First issue was the discrepancy between the temperature of the crude oil vapor explosive limits which were measured by the investigation panel and the temperature reported by the local fire department. Second issue was the contradiction between the upper explosive limit and vapor pressure of the crude oil vapor. The last issue was the location of the ignition source which led to the explosion. In the present study some specific features of this accident and various causes led to the explosion, high casualties and severe damages were analyzed. Three contentious issues in the official investigation report were investigated and tested in detail. The first element tested was the explosive limits and limiting oxygen concentration of the crude oil vapor at different temperatures. Based on theoretical analysis and field investigations, the last two elements in the report were analyzed from multiple perspectives. Based on the TNO Multi-Energy model and PROBIT equations, damage probability of affected people at the leaking site was also estimated. The investigation concluded with a result that precautions need to be taken to prevent flammable gas explosions in the drainage systems. Key steps were explicitly discussed for improving the hazard identification and risk assessment of similar accidents in the future.

Applications of fuzzy faulty tree analysis and expert elicitation for evaluation of risks in LPG refuelling station

Abstract: A method is presented for analysis of reliability of complex engineering systems using information from fault tree analysis and uncertainty/imprecision of data. Fuzzy logic is a mathematical tool to model inaccuracy and uncertainty of the real world and human thinking. The method can address subjective, qualitative, and quantitative uncertainties involving risk analysis. Risk analysis with all the inherent uncertainties is a prime candidate for Fuzzy Logic application. Fuzzy logic combined with expert elicitation is employed in order to deal with vagueness of the data, to effectively generate basic event failure probabilities without reliance on quantitative historical failure data through qualitative data processing. The proposed model is able to quantify the fault tree of LPG refuelling facility in the absence or existence of data. This paper also illustrates the use of importance measures in sensitivity analysis. The result demonstrates that the approach is an apposite for the probabilistic reliability approach when quantitative historical failure data are unavailable. The research results can help professionals to decide whether and where to take preventive or corrective actions and help informed decision-making in the risk management process.

Application of CREAM human reliability model to cargo loading process of LPG tankers

Abstract: The storage and handling processes of liquefied petroleum gas (LPG) constitutes a complex operational environment in the maritime mode of transportation. The LPG cargo is carried by specially designed ships called LPG tankers. The LPG cargo loading and discharging operations have always potential hazards. Thus, the crew on-board LPG tankers should be fully aware of operational risks during the cargo handling process, which includes various critical tasks such as drying, inerting, gassing-up, cooling, and reliquefaction. During these stages, human reliability (operation without failure) plays a crucial role in sustainable transportation of cargo. Human reliability analysis (HRA), related to various parameters such as the human factor, technology, and ergonomics, is always a critical consideration as regards maritime safety and environment. The main focus of the research is to systematically predict human error potentials for designated tasks and to determine the required safety control levels on-board LPG ships. The paper adopted CREAM (Cognitive reliability and error analysis method) basic and extended versions in order to assess human reliability along with the cargo loading process on-board LPG tanker ships. Specifically, the model is demonstrated with an operational case study. Consequently, the research provides should contribute to maritime safety at sea and prevention of human injury and loss of life on-board LPG ship.

Kinetics characteristics of coal low-temperature oxidation in oxygen-depleted air

Abstract: The longwall gob (mined-out) area is one of the main places that are prone to coal spontaneous combustion and most of the residual coal in it is in oxygen-depleted air as it is a semi-enclosed space. A DSC (Differential scanning calorimetry) test system was designed to accurately test the heat generation of coal oxidation in different oxygen concentration atmosphere, based on which the kinetics parameters (activation energy and pre-exponential factor) of coal low-temperature oxidation in oxygen-depleted air were solved out. The results show that the kinetics parameters present obvious stage features and the lower the oxygen concentration is, the smaller is the difference of the kinetics parameters that in different oxidation stages. When the oxygen concentration is lower than 5% and 3% for jet coal and meagre coal respectively, the kinetics parameters of slow oxidation start to be greater than that of rapid oxidation. Both in the slow oxidation and rapid oxidation stage, with the decrease of oxygen concentration, kinetics parameters present significant decline on the whole while in different oxygen concentration range, the decline rate is different. It's concluded that when assessing the residual coal's self-heating risk, we need to use the corresponding kinetics parameters of coal oxidation in the oxygen concentration of the location where the residual coal is and the safety factor will be greater to only use the kinetics parameters of coal oxidation in slow oxidation stage. This study is of great significance for the assessment and control of the self-heating risk of coal that in different oxygen concentration atmospheres of the longwall gob areas.

The effect of vent size and congestion in large-scale vented natural gas/air explosions

Abstract: A typical building consists of a number of rooms; often with windows of different size and failure pressure and obstructions in the form of furniture and decor, separated by partition walls with interconnecting doorways. Consequently, the maximum pressure developed in a gas explosion would be dependent upon the individual characteristics of the building. In this research, a large-scale experimental programme has been undertaken at the DNV GL Spadeadam Test Site to determine the effects of vent size and congestion on vented gas explosions. Thirty-eight stoichiometric natural gas/air explosions were carried out in a 182 m 3 explosion chamber of L/D = 2 and K A = 1, 2, 4 and 9. Congestion was varied by placing a number of 180 mm diameter polyethylene pipes within the explosion chamber, providing a volume congestion between 0 and 5% and cross-sectional area blockages ranging between 0 and 40%. The series of tests produced peak explosion overpressures of between 70 mbar and 3.7 bar with corresponding maximum flame speeds in the range 35–395 m/s at a distance of 7 m from the ignition point. The experiments demonstrated that it is possible to generate overpressures greater than 200 mbar with volume blockages of as little as 0.57%, if there is not sufficient outflow through the inadvertent venting process. The size and failure pressure of potential vent openings, and the degree of congestion within a building, are key factors in whether or not a building will sustain structural damage following a gas explosion. Given that the average volume blockage in a room in a UK inhabited building is in the order of 17%, it is clear that without the use of large windows of low failure pressure, buildings will continue to be susceptible to significant structural damage during an accidental gas explosion.

A critique of the Hazard and Operability (HAZOP) study

Abstract: Conventional wisdom holds that the Hazard and Operability (HAZOP) study is the most thorough and complete process hazard analysis (PHA) method. Arguably, it is the most commonly-used PHA method in the world today. However, the HAZOP study is not without its weaknesses, many of which are not generally recognized. This article provides a critique of the method to assist study teams in compensating for them to the extent possible and to help guide the development of improved methods.

A new leak location method based on leakage acoustic waves for oil and gas pipelines

Abstract: In order to study a new leak detection and location method for oil and natural gas pipelines based on acoustic waves, the propagation model is established and modified. Firstly, the propagation law in theory is obtained by analyzing the damping impact factors which cause the attenuation. Then, the dominant-energy frequency bands of leakage acoustic waves are obtained through experiments by wavelet transform analysis. Thirdly, the actual propagation model is modified by the correction factor based on the dominant-energy frequency bands. Then a new leak detection and location method is proposed based on the propagation law which is validated by the experiments for oil pipelines. Finally, the conclusions and the method are applied to the gas pipelines in experiments. The results indicate: the modified propagation model can be established by the experimental method; the new leak location method is effective and can be applied to both oil and gas pipelines and it has advantages over the traditional location method based on the velocity and the time difference. Conclusions can be drawn that the new leak detection and location method can effectively and accurately detect and locate the leakages in oil and natural gas pipelines.

Numerical study on dust movement and dust distribution for hybrid ventilation system in a laneway of coal mine

Abstract: Coal dust disaster is the most serious problem in a laneway of coal mine. Dust movement regularity for comprehensive mechanized heading face is the key scientific issues for the principle and technology of dust prevention. The special topic on systematic study of the variation regularity of dust movement and dust distribution is presented with hybrid ventilation for the comprehensive mechanized heading face: Euler–Euler method was firstly established on the numerical platform for gas–solid two phase flow in a laneway. And the forces and the dynamic model of dust particles were performed in three-dimensional flow field. Then based on the visible simulations, the movement characteristics of diffusion, sedimentation and accumulation of dust particles were investigated under the action of the complex air flow, and the spatiotemporal variation of dust distribution was studied with hybrid ventilation system. Meanwhile, the obtained dust distribution regularities were compared with the obtainable experimental results. Finally, selected method on different ventilation patterns for dust control was brought out for the heading face according to the gained regularity. The research results is helpful for further understanding of the essence of dust movement with air flow, which could provide more suitable guidance for the principle of dust control and technology of ventilation.

A novel hybrid technique for leak detection and location in straight pipelines

Abstract: Underground gas pipeline leaks can lead to tremendous economic loss and human injury. Therefore, it is vital to detect and locate the pipeline leaks in time to maintain the normal operation. However, continuous leak-detection methods of require a lot of manpower, marterial resources and financial supports, while other detecting activities break the normal operation of the pipeline. Hybrid techniques consisting of two or more different technologies appear to be the most probable future trend in pipeline leak detection and location field. In this paper, a novel hybrid technique based on real-time transient modeling method and negative pressure wave method is proposed. An experimental bench for straight pipelines is set up to evaluate the performance of the proposed hybrid technique, and corresponding experimental test programs for gas leak detection and location are designed and conducted. A mathematical model for the transient flow in pipelines has been established and solved under different boundary conditions. The occurrence of a leak can be preliminarily judged by the difference between the measured data and the predicted value from the model; and the changing patterns of parameters under the leak condition, the valve-opening adjusting condition and the compressor-speed regulating condition are investigated to identify the leak condition out of the operational changes. Finally, the leak point is located using the stimulus-response method. Results show that the hybrid technique is successful in detecting and locating gas pipeline leaks. It is expected that the research outcomes can serve as a technical base for the safe operation of gas supply networks.

Performance assessment system of health, safety and environment based on experts' weights and fuzzy comprehensive evaluation

Abstract: Performance evaluation of Health, Safety and Environment (HSE) is the measurement of a company's achievement in HSE management. In order to receive a comprehensive and objective evaluation result, it is necessary to consider all evaluation factors and experts at different levels when HSE performance assessment is conducted. To improve conventional HSE performance evaluation, where weighted average method was used, a Fuzzy Comprehensive Evaluation (FCE) method is used in this study by taking experts' weights into account. Further, an HSE operating performance assessment system is designed to simplify manual and complex assessment process and generate charts and analysis reports automatically. Finally, a case of petrochemical enterprise is used to illustrate the effectiveness of the method and system.

Flame propagation mechanisms in dust explosions

Abstract: To reveal the effects of particle characteristics, including particle thermal characteristics and size distributions, on flame propagation mechanisms during dust explosions clearly, the flame structures of dust clouds formed by different materials and particle size distributions were recorded using an approach combining high-speed photography and a band-pass filter. Two obviously different flame propagation mechanisms were observed in the experiments: kinetics-controlled regime and devolatilization-controlled regime. Kinetics-controlled regime was characterized by a regular shape and spatially continuous combustion zone structure, which was similar to the premixed gas explosions. On the contrary, devolatilization-controlled regime was characterized by a complicated structure that exhibited heterogeneous combustion characteristics, discrete blue luminous spots appeared surrounding the yellow luminous zone. It was also demonstrated experimentally that the flame propagation mechanisms transited from kinetics-controlled to devolatilization-controlled while decreasing the volatility of the materials or increasing the size of the particles. Damkohler number was defined as the ratio of the heating and devolatilization characteristic time to the combustion reaction characteristic time, to reflect the transition of flame propagation mechanisms in dust explosions. It was found that the kinetics-controlled regime and devolatilization-controlled regime can be categorized by whether Damkohler number was less than 1 or larger than 1.

Risk assessment of offshore crude oil pipeline failure

Abstract: Failure of Leak Detection System (LDS) to detect pipeline leakages or ruptures may result in drastic consequences that could lead to excessive financial losses. To minimize the occurrence of such failure, the functionality of the LDS and the integrity of the pipeline should be assessed on a priority basis. This paper presents an integrated risk-based assessment scheme to predict the failure and the failure consequences of offshore crude oil pipelines. To estimate risk, two important quantities have to be determined, the joint probability of failure of the pipeline and its LDS and the consequences of failure. Consequences incorporate the financial losses associated with environmental damage, oil spill cleanup and lost production. The assessment provides an estimate of the risk in monetary value and determines whether the estimated risk exceeds a predefined target risk. Moreover, the critical year for the asset can be determined. In essence, the outcome of the assessment facilitates an informed decision-making about the future of the asset.

Vent burst pressure effects on vented gas explosion reduced pressure

Abstract: The overpressure generated in a 10 L cylindrical vented vessel with an L/D of 2.8 was investigated, with end ignition opposite the vent, as a function of the vent static burst pressure, P stat , from 35 to 450 mb. Three different K v (V 2/3 /A v ) of 3.6, 7.2 and 21.7 were investigated for 10% methane–air and 7.5% ethylene–air. It was shown that the dynamic burst pressure, P burst , was higher than P stat with a proportionality constant of 1.37. For 10% methane–air P burst was the controlling peak pressure for K red > P burst in the literature and in EU and US standards. For higher K v the overpressure due to flow through the vent, P fv, was the dominant overpressure and the static burst pressure was not additive to the external overpressure. Literature on the influence of P stat at low K v was shown to support the present finding and it is recommended that the influence of P stat in gas venting standards is revised.

PLS-based EWMA fault detection strategy for process monitoring

Abstract: Fault detection (FD) and diagnosis in industrial processes is essential to ensure process safety and maintain product quality. Partial least squares (PLS) has been used successfully in process monitoring because it can effectively deal with highly correlated process variables. However, the conventional PLS-based detection metrics, such as the Hotelling's T 2 and the Q statistics are ill suited to detect small faults because they only use information from the most recent observations. Other univariate statistical monitoring methods, such as the exponentially weighted moving average (EWMA) control scheme, has shown better abilities to detect small faults. However, EWMA can only be used to monitor single variables. Therefore, the main objective of this paper is to combine the advantages of the univariate EWMA and PLS methods to enhance their performances and widen their applicability in practice. The performance of the proposed PLS-based EWMA FD method was compared with that of the conventional PLS FD method through two simulated examples, one using synthetic data and the other using simulated distillation column data. The simulation results clearly show the effectiveness of the proposed method over the conventional PLS, especially in the presence of faults with small magnitudes.

DDT and detonation propagation limits in an obstacle filled tube

Abstract: Experiments with hydrogen–air and ethylene–air mixtures at atmospheric pressure were carried out in a 6.1 m long, 0.1 m diameter tube with different obstacle configurations and ignition types. Classical DDT experiments were performed with the first part of the tube filled with equally spaced 75 mm (44% area blockage ratio) orifice-plates. The DDT limits, defining the so-called quasi-detonation regime, where the wave propagates at a velocity above the speed of sound in the products, were found to be well correlated with d / λ = 1, where d is orifice-plate diameter and λ is the detonation cell size. The only exception was the rich ethylene limit where d / λ = 1.9 was found. In a second experiment detonation propagation limits were measured by transmitting a CJ detonation wave into an obstacle filled (same equally spaced 44% orifice plates) section of the tube. An oxy-acetylene driver promptly initiated a detonation wave at one end. In this experiment the quasi-detonation propagation limits were found to agree very well with the d / λ = 1 correlation. This indicates that the d / λ = 1 represents a propagation limit. In general, one can conclude that the classical DDT limits measured in an orifice-plate filled tube are governed by the wave propagation mechanism, independent of detonation initiation (DDT process) that can occur locally in the obstacles outside these limits. For rich mixtures, transmission of the quasi-detonation into the smooth tube resulted in CJ detonation wave. However, in a narrow range of mixtures on the lean side, the detonation failed to transmit in the smooth tube. This highlights the critical role that shock reflection plays in the propagation of quasi-detonation waves.

Medium-scale experiments on vented hydrogen deflagration

Abstract: A series of medium-scale experiments on vented hydrogen deflagration was carried out at the KIT test side in a chamber of 1 × 1 × 1 m 3 size with different vent areas. The experimental program was divided in three series: (1) uniform hydrogen–air mixtures; (2) stratified hydrogen–air mixtures within the enclosure; (3) a layer deflagration of uniform mixture. Different uniform hydrogen–air mixtures from 7 to 18% hydrogen were tested with variable vent areas 0.01–1.0 m 2 . One test was done for rich mixture with 50% H 2 . To vary a gradient of concentration, all the experiments with a stratified hydrogen–air mixtures had about 4%H 2 at the bottom and 10 to 25% H 2 at the top of the enclosure. Measurement system consisted of a set of pressure sensors and thermocouples inside and outside the enclosure. Four cameras combined with a schlieren system (BOS) for visual observation of combustion process through transparent sidewalls were used. Four experiments were selected as benchmark experiments to compare them with four times larger scale FM Global tests ( Bauwens et al., 2011 ) and to provide experimental data for further CFD modelling. The nature of external explosion leading to the multiple pressure peak structure was investigated in details. Current work addresses knowledge gaps regarding indoor hydrogen accumulations and vented deflagrations. The experiments carried out within this work attend to contribute the data for improved criteria for hydrogen–air mixture and enclosure parameters to avoid unacceptable explosion overpressure. Based on theoretical analysis and current experimental data a further vent sizing technology for hydrogen deflagrations in confined spaces should be developed, taking into account the peculiarities of hydrogen–air mixture deflagrations in presence of obstacles, concentration gradients of hydrogen–air mixtures, dimensions of a layer of flammable cloud, vent inertia, etc.

Safety study of an LNG regasification plant using an FMECA and HAZOP integrated methodology

Abstract: A safety analysis was performed to determine possible accidental events in the storage system used in the liquefied natural gas regasification plant using the integrated application of failure modes, effects and criticality analysis (FMECA) and hazard and operability analysis (HAZOP) methodologies. The goal of the FMECA technique is the estimation of component failure modes and their major effects, whereas HAZOP is a structured and systematic technique that provides an identification of the hazards and the operability problems using logical sequences of cause-deviation-consequence of process parameters. The proposed FMECA and HAZOP integrated analysis (FHIA) has been designed as a tool for the development of specific criteria for reliability and risk data organisation and to gain more recommendations than those typically provided by the application of a single methodology. This approach has been applied to the risk analysis of the LNG storage systems under construction in Porto Empedocle, Italy. The results showed that FHIA is a useful technique to better and more consistently identify the potential sources of human errors, causal factors in faults, multiple or common cause failures and correlation of cause-consequence of hazards during the various steps of the process.

Major accident hazard in bioenergy production

Abstract: Some recent accidents involving the bioenergy production and feedstock supply chain raised concern on the safety of such technologies. A survey of major accidents related to the production of bioenergy (intended as biomass, bioliquids/biofuels and biogas) was carried out, and a data repository was built, based on past accident reports available in the open literature and in specific databases. Data analysis shows that major accidents are increasing in recent years and their number is growing faster than bioenergy production. The results obtained represent an early warning concerning the major accident hazard of bioenergies, and suggest the importance of risk awareness and safety culture in bioenergy production, in the perspective of a safe and sustainable exploitation of renewable resources.

Dynamic Bayesian network modeling of reliability of subsea blowout preventer stack in presence of common cause failures

Abstract: A subsea blowout preventer (BOP) stack is used to seal, control, and monitor oil and gas wells It can be regarded as a series–parallel system consisting of several subsystems This paper develops the dynamic Bayesian network (DBN) of a parallel system with n components, taking account of common cause failures and imperfect coverage Multiple-error shock model is used to model common cause failures Based on the proposed generic model, DBNs of the two commonly used stack types, namely the conventional BOP and modern BOP, are developed In order to evaluate the effects of the failure rates and coverage factor on the reliability and availability of the stacks, sensitivity analysis is performed

Sources of underground CO: Crushing and ambient temperature oxidation of coal

Abstract: As a harmful gas in underground coal mine, CO seriously threatened the safety of miners. Currently, the spontaneous combustion of residual coal in goaf is generally considered as the main source of underground CO. CO gas is also widely used as an indicator gas in fire prediction in mines. However, high concentrations of CO are also detected in some mines without spontaneous combustion of coal. Therefore, in the paper, with four ranks of coal, we studied other two potential CO sources: crushing and oxidation at ambient temperature. The more completely crushed coal produces more CO. The concentration of generated CO is inversely proportional to moisture content in coal. Therefore, the addition of water can inhibit the generation process of CO during the crushing process of coal. Lignite with low metamorphic grade can be oxidized to produce CO at ambient temperature (25 °C), and anthracite with high coal rank can be only oxidized to produce CO at 60 °C. Infrared spectra indicated that the coal with rich aliphatic hydrocarbons and oxygen-containing functional groups are more susceptible to oxidation at room temperature. Moreover, the smaller particle size of coal is more beneficial to the oxidation at ambient temperature to generate CO. CO generation during coal oxidation is also closely related to the ventilation rate.

Ammonium nitrate thermal decomposition with additives

Abstract: Runaway reactions present a potentially serious threat to the chemical process industry and the community; such reactions occur time and time again often with devastating consequences. The main objective of this research is to study the root causes associated with ammonium nitrate (AN) explosions during storage. The research focuses on AN fertilizers and studies the effects of different types of fertilizer compatible additives on AN thermal decomposition. Reactive Systems Screening Tool (RSST) has been used for reactivity evaluation and to better understand the mechanisms that result in explosion hazards. The results obtained from this tool have been reported in terms of parameters such as “onset” temperature, rate of temperature and pressure rise and maximum temperature. The runaway behavior of AN has been studied as a solid and solution in water. The effect of additives such as sodium sulfate (Na 2 SO 4 ) and potassium chloride (KCl) has also been studied. Multiple tests have been conducted to determine the characteristics of AN decomposition accurately. The results show that the presence of sodium sulfate can increase the “onset” temperature of AN decomposition thus acting as AN thermal decomposition inhibitor, while potassium chloride tends to decrease the “onset” temperature thus acting as AN thermal decomposition promoter.

Improved far-field blast predictions from fast deflagrations, DDTs and detonations of vapour clouds using FLACS CFD

Abstract: The CFD tool FLACS was developed from 1982 with a primary goal to predict gas explosion loads inside oil platform modules. The prediction of far-field blast loads was of secondary importance as any scenario creating a substantial far-field blast would already have collapsed the module where it originated. For the same reason the potential for a deflagration-to-detonation-transition (DDT) was not initially of interest. Over the past decade use of FLACS has been more widespread, and the tool is now frequently used to predict explosions on onshore facilities and FPSOs/FLNGs, where far-field blast loads and evaluation of DDT potential may be of significant interest. Previous work by Hansen et al. (2010) has highlighted a weakness in FLACS when predicting the far-field blast from strong gas explosions and, when using FLACS according to guidelines, far-field blast pressures will often be significantly underpredicted. For scenarios involving DDT this effect will be particularly strong. The current study will present a way to obtain more accurate far-field blast predictions by modified parameter settings in FLACS for strong deflagrations. Using modified settings, it is also possible, with good precision, to predict flame speeds, pressures and far-field blast from DDT-scenarios and directly initiated gas detonations, physics which are beyond the accepted capabilities of FLACS. Selected full-scale experiments from the DNV GL test site at Spadeadam will be used to compare with the simulations. Convincing evidence for DDT in large scale natural gas experiments (91% methane) was found in simulations of one of these tests.

Reactive chemical hazards of diazonium salts

Abstract: Many diazonium salts are thermally unstable and sensitive to friction and shock. Most diazonium salts are known for their violent decomposition hazard in the solid state. There are many industrial and laboratory incidents caused by this group of chemicals. For safety purposes, the hazards related to the preparation and the handling of diazonium salts are discussed. Twelve cardinal rules are provided: 1. Use only a stoichiometric amount of sodium nitrite when generating diazonium salts, avoiding excess sodium nitrite. 2. Check for the excess of nitrous acid by starch–potassium iodide papers and neutralize it. 3. Minimize the presence of nitrous acid by combining amine and acid first, then subsequently adding the sodium nitrite. 4. Keep the temperature below 5 °C. 5. Always vent the gases generated. 6. Determine the thermal stability of diazonium compounds in your system. 7. Understand the explosive properties of diazonium salts. If unknown, always assume they are explosive. 8. Never allow the undesired precipitation of diazonium salts out of solution. 9. Analyze the residual diazo compounds in the final product, especially for new process conditions. 10. Quench the remaining diazonium salts before any further treatments. 11. Isolate no more than 0.75 mmol of explosive diazonium salts at one time; also consider the addition of an inert material to stabilize the diazonium salts. 12. Use a plastic spatula when handling the solid. The dried powder should not be “scratched” with a metal spatula or ground finely. An example of a testing strategy and data interpretation is provided for a process which has multiple steps and two diazonium compounds. Differential Scanning Calorimetry (DSC) and Heat of Mixing calorimetry (HOM) successfully serve as efficient tests to screen thermal stability and gas generation, identifying the candidates for advanced tests.

Effects of hydrogen addition on propagation characteristics of premixed methane/air flames

Abstract: An experimental study has been conducted to investigate the effects of hydrogen addition on the fundamental propagation characteristics of methane/air premixed flames at different equivalence ratios in a venting duct. The hydrogen fraction in the methane–hydrogen mixture was varied from 0 to 1 at equivalence ratios of 0.8, 1.0 and 1.2. The results indicate that the tendency towards flame instability increased with the fraction of hydrogen, and the premixed hydrogen/methane flame underwent a complex shape change with the increasing hydrogen fraction. The tulip flame only formed when the fraction of hydrogen ranged from 0 to 50% at an equivalence ratio of 0.8. It was also found that the flame front speed and the overpressure increased significantly with the hydrogen fraction. For all equivalence ratios, the stoichiometric flame ( Φ = 1.0) has the shortest time of flame propagation and the maximum overpressure.

Analysis of the boiling liquid expanding vapor explosion (BLEVE) of a liquefied natural gas road tanker: The Zarzalico accident

Abstract: The road accident of a tanker transporting liquefied natural gas (LNG) originated a fire and, finally, the BLEVE of the tank. This accident has been analyzed, both from the point of view of the emergency management and the explosion and fireball effects. The accidental sequence is described: fire, LNG release, further safety valves release, flames impingement on vessel unprotected wall, vessel failure mode, explosion and fireball. According to the effects and consequences observed, the thermal radiation and overpressure are estimated; a mathematical model is applied to calculate the probable mass contained in the vessel at the moment of the explosion. The peak overpressure predicted from two models is compared with the values inferred from the accident observed data. The emergency management is commented.

CO2 corrosion control in steel pipelines. Influence of turbulent flow on the performance of corrosion inhibitors

Abstract: Corrosion associated with aqueous environments containing carbon dioxide (CO2) and/or hydrogen sulphide (H2S), is a well-known phenomenon in oil and gas industries. This type of corrosion is of particular importance in transportation through steel pipelines. This transportation process could involve the movement of a complex mixture of gas and liquids. This moving mixture is in close contact with the inner surface of the steel pipelines and corrosion can occur. It has been demonstrated that this corrosion is influenced by flow. In oil and gas industries, film-forming corrosion inhibitors are the main tool used to control inner corrosion in pipelines. The movement of the environment generates mechanical shear stresses on the surface of the steel that can interfere with the formation of the film. This phenomenon is frequently not taken into account in corrosion control strategies and could cause problems. Despite the importance of this, there are few scientific studies available, which can provide control criteria. This work presents some ideas developed in order to understand the influence of flow on the corrosion process, making emphasis in the corrosion process associated with carbon dioxide (CO2).

Lower explosion limit of hybrid mixtures of burnable gas and dust

Abstract: Hybrid mixtures – mixtures of burnable dusts and burnable gases – pose special problems to industries, as their combined Lower Explosion Limit (LEL) can lie below the LEL of the single substances. Different mathematical relations have been proposed by various authors in literature to predict the Lower Explosion Limit of hybrid mixtures (LELhybrid). The aim of this work is to prove the validity or limitations of these formulas for various combinations of dusts and gases. The experiments were executed in a standard 20 L vessel apparatus used for dust explosion testing. Permanent spark with an ignition energy of 10 J was used as ignition source. The results obtained so far show that, there are some combinations of dust and gas where the proposed mathematical formulas to predict the lower explosible limits of hybrid mixtures are not safe enough.