Seismic risk assessment of storage tanks in Turkish industrial facilities

In 1999, two earthquakes in northwest Turkey caused heavy damage to a large number of industrial facilities. This region is the most industrialized in the country, and heavy damage has a significant economic influence. Industrial storage tanks, ruptured by earthquakes, exascerbate damage through the spread of fire. Storage tanks are uniquely structured, tall cylindrical vessels, some supported by relatively short reinforced concrete columns. The main aim of this study is to evaluate the earthquake performance of Turkish industrial facilities, especially storage tanks in terms of earthquake resistance. Modeling a typical storage tank of an industrial facility helps to understand the structure’s seismic response. A model tank structure was modelled as a solid with lumped mass and spring systems. Performance estimation was done with 40 different earthquake data through nonlinear time history analyses. After the time history analyses, fragility analyses produced probabilistic seismic assessment for the tank model. For the model structure, analysis results were evaluated and compared. In the study, vulnerability of storage tanks in Turkey was determined and the probabilistic risk was defined with the results of the analysis.     

CFD simulation of pool fires situated at differing elevation

When two or more pool fires happen to burn so close to each other that they interact, they are termed ‘multiple pool fires’ (MPF). Past accident analysis reveals that MPFs occur quite frequently in chemical process industries. Controlled experiments done so far to study MPFs have indicated that MPFs lead to increase in the fuel burning rate, flame height and heat release rate (HRR) but the nature and the extent of the impacts of different factors on these manifestations is as yet poorly understood. In this context computational fluid dynamics (CFD) appears to be a tool which can enable more detailed and realistic simulation of MPFs than other possible approaches, especially due to its ability to closely approximate the underlying physical phenomena. In tank farms there are situations where different storage tanks are placed at different elevations yet close to each other. If such tanks happen to catch fire, the resulting fires may influence each other in a manner that may be a function of the difference in the tanks’ elevation. However no CFD study has been carried out which addresses this type of situation. Hence an attempt has been made to employ CFD to study MPFs involving two pools with fuel surfaces are at different elevations. Results reveal that good correlation is possible between the experimental findings and the CFD simulations.     

Improved models of failure time for atmospheric tanks under the coupling effect of multiple pool fires

Fire accidents of chemical installations may cause domino effects in atmospheric tank farms, where a large amount of hazardous substances are stored or processed. Pool fire is a major form of fire accidents, and the thermal radiation from pool fire is the primary hazard of domino accidents. The coupling of multiple pool fires is a realistic and important accident phenomenon that enhances the propagation of domino accidents. However, previous research has mostly focused on the escalation of domino accidents induced by a single pool fire. To overcome the drawback, in this study, the failure of a storage tank under the coupling effect of multiple pool fires was studied in view of spatial and temporal synergistic process. The historical accident statistics indicated that the accident scenario of two-pool fires accounted for 30.6% in pool fires. The domino accident scenario involving three tanks is analyzed, and the typical layout of tanks is isosceles right triangle based on Chinese standard “GB50341-2014”. The thermal response and damage of a target tank heated by pool fires were numerically investigated. The volume of 500 m³, 3000 m³, 5000 m³ and 10000 m³ were selected. Flame temperature was obtained by FDS, and then was input onto the finite element model. The temperature field and stress field of target tanks were simulated by ABAQUS. The results showed that the temperature rise rate of the target tanks under multiple pool fires was higher than that under a single pool fire. The failure time of the tank under the coupling effect of multiple fires was lower than that under the superposition of multiple fires without the first stage. The stress and yield strength were compared to judge the failure of the target tank. The model of failure time for the tank under the coupling effect of pool fires was established. Through the verification, the deviation of this model is 4.02%, which is better than the deviation of 15.76% with Cozzani's model.     

The effect of changing the fuel of the LASTFIRE test

The LASTFIRE test is intended for the evaluation of foams used in extinguishing fires of flammable and combustible liquids in storage tanks in refinery and oil related facilities. The purpose of this study is to find, experimentally, an alternative fuel to be used in the LASTFIRE test, as a replacement for the heptane fuel, which is normally used in this test. Beside heptane, three other fuels are tested in the current study: diesel, jet A1 and kerosene. The study involved performing the LASTFIRE test, using each of the fuels and then comparing the results. The same foam is used as an extinguishing agent for all the tests and for each fuel, tests are conducted three times with separate foam discharging nozzles: semi-aspirated, aspirated and system. Using a commonly used scoring system, the results of the four fuels are evaluated. Any replaceable fuel should obtain the similar score as that is obtained by heptane. The study shows that none of the three alternatives has been judged to be suitable to replace heptane, in the LASTFIRE test.     

储罐两环段喷淋圈管对供给强度的影响

国内储罐火灾爆炸事故时有发生,储罐消防冷却系统实施有效的冷却是控制火势和扑救初期火灾的主要因素之一。为了研究油罐消防喷淋系统在灭后冷却中的影响,本文选取4座5×10~3内浮顶罐组,开展消防冷却水系统喷洒实验,通过测试分析发现:实际的冷却水供给强度不满足规范的要求,并探讨了储罐固定冷却水系统供给强度不足的原因,结合分析的原因建议对规范中着火罐和临近罐供水强度要求统一均为2.5 L/(min·m^2),其冷却水喷淋圈管设置应为四段以上。     

Floating roof storage tank boilover

Storage tanks are important facilities for the major hazard installations (MHIs) to store large quantity of crude oil. There is several fire types can occur with large diameter open top floating roof storage tanks. Boilover is considered one of the most dangerous fires in large-scale oil tank. The world has witnessed many incidents due to boilover in floating roof storage tank. Boilover problem has been studied in experiments and by models to understand how to control the boilover phenomena. An experimental study has been carried out in Jebel Dhanna (JD) terminal area by Abu Dhabi Company for Onshore Oil Operations (ADCO) with support of Resource Protection International (RPI) consultant. 2.4 m diameter and 4.5 m diameters pans have been used to study the characteristics of the large oil-tank fires (i) to gain more knowledge of the boilover phenomenon of crude oil (ii) verify if the crude oil stored by ADCO would boilover (ii) estimation of rate of hot-zone growth and the period needed from ignition to boilover (iii) estimation of radiant heat and consequences of boilover. This paper presents an overview on the floating roof storage tank boilover. The paper also presents briefly boilover experimental research study carried out by ADCO.     

Shake table study of annular baffles in steel storage tanks as sloshing dependent variable dampers

Aboveground steel storage tanks are widely utilized in industrial areas such as oil refineries, petrochemical complexes, oil depots, and etc. Assurance of these infrastructure facilities in high seismic areas is a very important engineering consideration. High amplitude fluid sloshing is one of the widespread causes of steel oil storage tanks during strong earthquakes addressed as an important failure mode. This phenomenon generates additional forces impacting the wall and roof of the tanks. Annular baffles can be used as slosh damping devises to control liquid sloshing within a tank. The main objective of this paper is experimental study of annular baffle effects as anti-sloshing damping devices to reduce fluid wave sloshing height in steel storage tanks typically used in oil and petrochemical complexes during an earthquake. Shake table tests have been used on a reduced scale model steel storage tank in two cases of with and without annular baffles. Three real earthquake ground motion records are used as input base motion. Based on the experimental test results, dynamic characteristics of studied tank models with different filling levels and different baffle dimensions and arrangements have been obtained and summarized in this paper. Also, sloshing heights and convective mode damping values are determined from the test results and compared with API650 code recommendations and recommended equations by other researchers. Generally, the results of this study indicate significant effects of the annular baffles in reducing the fluid wave sloshing height as sloshing dependent variable dampers.     

The study of burning behaviors and quantitative risk assessment for 0# diesel oil pool fires

The liquid fuel safety issues on fuel storage, transportation and processing have gained most attention because of the high fire risk. In this paper, some 0# diesel pool fire experiments with different diameters (0.2–1 m) were conducted with initial fuel thicknesses of 2 cm and 4 cm, respectively, to obtain liquid fuel combustion characteristics. Some key parameters including mass burning rate, flame height and the flame radiative heat flux, associated with fire risk, were investigated and determined. Subsequently, a detail quantitative risk assessment framework for 0# diesel pool fire is proposed based on the 0# diesel burning characteristics. In the framework, the probability of personal dead and the facility failure are calculated by the vulnerability models, respectively. In the end, 10 special tank fire scenarios were selected to show the whole risk calculation process. The tank diameter and the distance to pool fires were paid more attention in the cases. The safety distances in the cases are provided for the persons and nearby facilities, respectively. The paper enriches the basic experimental data and the provided framework is useful to the management of 0# diesel tank areas.     

Thermal radiation calculation of complex surface based on Triangulation and Gauss Integral Method

To solve the problem of thermal radiation in complex geometric scenes, a finite element method based on Delaunay triangulation and three-point Gauss integral is proposed. The calculated value is compared with model existing theoretical solution of view factor, and the results show that the errors are within 3%. The method is applied to calculate the thermal radiation of combustion between adjacent liquefied petroleum gas tanks. The geometric model of conical flame and adjacent spherical tanks is also established. The result shows the maximum heat flux received by adjacent spherical tanks is 11.3 kW/m² when the flame temperature is 1470 K without wind.     

An experimental study on the burning rate of a continuously released n-heptane spill fire on an open water surface

Spill fires are common during oil product storage and transportation after a loss of containment. Since the burning fuel is moving and the fuel depth is quite shallow, the burning rate in a spill fire is different from that of a pool fire with a static burning zone. Unlike pool fires, which have been studied for decades and have well-established correlations for burning rate, research on spill fires is inadequate. In this paper, continuously released n-heptane spill fire experiments were conducted on open water surfaces with varying fuel discharge rates. The pool diameters were measured, and the spill fire burning rates were estimated based on a dynamic balance between fuel supply and combustion. The burning rates in n-heptane pool fires from the literature were reviewed and compared with the estimated burning rates in spill fires of the same dimension. The spill fire burning rate was found to be close to that in a pool fire during the initial burning phase but lower than that in a bulk burning pool fire and that in a “fuel-level-controlled” pool fire. The distinction between the burning rates of spill fires and pool fires is explained by the heat balance analysis of the fuel layer. A model for the spill fire burning rate was proposed accordingly. The results calculated with the presented model are closer to the measured data than those calculated with pool fire models.     

Blast damage to storage tanks and steel clad buildings

The 2005 Buncefield vapour cloud explosion showed the huge cost associated with blast damage to commercial property surrounding a major explosion incident. In most cases there was serious disruption to business activity; in many cases the buildings had to be demolished or abandoned for long periods until extensive repairs were carried out.Another key feature of this and other recent vapour cloud explosions has been the damage done to storage tanks. The blasts almost invariably cause immediate top and bund fires in any tanks surrounded by the vapour – even if they contain relatively high flashpoint materials such as diesel.The first part of this paper describes the patterns of damage observed in buildings in the industrial estates around Buncefield. Methods for assessing the degree of external and internal damage are presented.The second part of the paper deals with failure modes and ignition of various types of liquid storage tank during vapour cloud explosions. Again, the Buncefield data provides excellent examples that illustrate the importance of tank design, fill level, location relative to the cloud, etc.     

Simulating on rollover phenomenon in LNG storage tanks and determination of the rollover threshold

Rollover is a potential risk to the safety of LNG storage tanks during the LNG storage process, so study of its prevention method is very important. In this paper, rollover phenomenon in a liquefied natural gas (LNG) storage tank is modeled physically and mathematically. Its evolution is simulated using FLUENT™ software from the breakdown of stratification to the occurrence of rollover. Results show that the evolution consists of three phases: the initial phase where rollover occurs near the side wall of the storage tank; the turbulent phase where rollover transfers to the center of the tank; and the final phase where new layers evolve. Based on these phases, rollovers in 160,000, 30,000, and 5000 m³ LNG storage tanks are simulated at varying initial density differences, and a rollover coefficient is defined to describe rollover intensity. The simulations show that the rollover coefficient initially increases within a small scope and then increases rapidly with the increment of initial density difference. This turning point is chosen to be the rollover threshold, which is regarded as the critical density difference in this study. The critical density differences obtained from the simulation results of the 160,000, 30,000, and 5000 m³ LNG storage tanks are 3, 5, and 7 kg/m³, respectively, which can be used as their rollover criteria to ensure the safety of LNG storage tanks.     

Fire and explosion risk assessment for large-scale oil export terminal

Now in Russian Federation and other countries large-scale oil terminals (volume of one tank exceeds 100 000 m³, total volume of tanks exceeds 300 000 m³) are designed and constructed. Therefore fire safety of such objects becomes a very important task, solution of which is hardly possible without detail fire risk assessment. This study is aimed to a solution of this problem. Potential, individual and social risks were calculated. The potential risk was defined as a frequency of occurrence of hazardous factors of fires and explosions in a given point of space (the so-called risk contours). The individual risk was defined as a frequency of injuring a given person by hazardous factors of fires and explosions. Time of presence of this person in hazardous zones (near the hazardous installation) is taken into account during calculations of the individual risk. Social risk was defined as a dependence of frequency of injuring a given number of people by hazardous factors of fires and explosions on this number. In practice the social risk is usually determined on injuring not less than 10 people.

The oil terminal under consideration includes the following main parts: crude oil storage consisting of three tanks of volume 100 000 m³ each, input crude oil pipeline of diameter 0.6 m, crude oil pumps, output crude oil pipeline of diameter 0.8 m, auxiliary buildings and facilities. The following main scenarios of tank fires have been considered: rim seal fire, pool fire on a surface of a floating roof, pool fire on a total cross-section surface of the tank, pool fire in a dyke, explosions in closed or semiclosed volumes. Fires and explosions in other parts of the terminal are also taken into account. Effects of escalation of accidents are considered.

Risk contours have been calculated both for the territory of the terminal and for the neighbouring space. The potential risk for the storage zone is near 10⁻⁴–10⁻⁵ year⁻¹, and at a distance 500 m from the terminal the potential risk values do not exceed 10⁻⁶ year⁻¹. The values of the individual risk for various categories of workers are in the range of 10⁻⁵–10⁻⁶ year⁻¹. Because of low number of the workers on the terminal and large distances to towns and villages the social risk value is negligible. These risk values are consistent with practice of the best oil companies, and fire hazard level of the terminal can be accepted as tolerable.     

大型原油商业储备油库火灾危险性数值模拟分析

石油储备油库多向大型化、复杂化方向发展,发生事故时扑救非常困难。为了深入探讨巨型油罐火灾发展趋势与规律、事故危害后果,结合宁夏惠安堡原油商业储备油库这一工程实例,采用基于大涡模拟的FDS模型作为模拟计算平台,对巨型油罐火灾的燃烧过程进行数值模拟计算。通过分析计算,得到烟气分布、温度分布、热辐射强度分布等火灾过程参数的变化趋势,以及在有风和无风状态下着火罐对相邻油罐的影响,探讨现行建设工程消防技术标准就储罐防火间距、火灾时对邻近罐体冷却设计要求运用于巨型储油罐时的消防安全状况,为巨型储油罐消防安全科学合理设计提供理论依据。     

Computational fluid dynamics (CFD) study of heat radiation from large liquefied petroleum gas (LPG) pool fires

Liquefied petroleum gas (LPG) is flammable and has risks of pool fires during its transportation, storage, and applications. The heat radiation by LPG pool fires poses hazards to individuals nearby and can lead to potential failures of ambient facilities. Due to the high costs and invasive nature of experiments for investigating large-scale pool fires, computational fluid dynamics (CFD) is employed in this study as the cost-effective and noninvasive method to simulate the process and analyze the characteristics of large hydrocarbon pool fires. Specifically, an experimentally validated 3-D CFD model has been built to simulate surface emissive power (SEP) and incident radiation of large-scale LPG pool fires with three different diameters and wind speeds. Steady-state simulations with P1 radiation and probability density function (PDF) combustion models were employed to obtain reliable data after the optimizations based on the comparisons with experimental data and empirical models. The comparison with benchmark experimental data demonstrates that the CFD model employed in this study can accurately predict the incident radiation of large LPG pool fires. A new SEP correlation is also proposed, which is specifically for LPG pool fires with a diameter between 10 m and 20 m. Additionally, the safe separation distances between LPG facilities and surrounded objects have been estimated based on the CFD simulation results. The high-resolution CFD model for large LPG pool fires in this work provides noninvasive and direct quantitative evidence to enhance the fundamental understanding on the safety of large LPG pool fires and can assist regulatory agencies in refining the safety limits in the cost-effective and time-saving manners.     

LNG as a potential alternative fuel - Safety and security of storage facilities

The aim of this article is to summarize the safety and security aspects of storing of Liquefied Natural Gas (LNG) as a potential alternative fuel. The contribution deals with possible scenarios of accidents associated with LNG storage facilities and with a methodology for the assessment of vulnerability of such facilities. The protection of LNG storage facilities as element of critical infrastructure should also be a matter of interest to the state. The study presents the results of determination of hazardous zones around LNG facilities in the event of various sorts of release. For calculations, the programs ALOHA, EFFECTS and TerEx were used and results obtained were compared. Scenarios modelled within this study represent a possible approach to the preliminary assessment of risk that should be verified by more detailed modelling (CFD). These scenarios can also be used for a quick estimation of areas endangered by an incident or accident. The results of modelling of the hazardous zones contribute to a reduction in risk of major accidents associated with these potential alternative energy sources.     

Study of chemical supply system of high-tech process using inherently safer design strategies in Taiwan

The photoelectric, semiconductor and other high-tech industries are Taiwan's most important economic activities. High-tech plant incidents are caused by hazardous energy, even when that energy is confined to the inside of the process machine. During daily maintenance procedures, overhauling or troubleshooting, engineers entering the interior of the machines are in direct contact with the source of the energy or hazardous substances, which can cause serious injury. The best method for preventing such incidents is to use inherently safer design strategies (ISDs); this approach can fully eliminate the dangers from the sources of hazardous energy at a facility.This study first conducts a lithography process hazard analysis and compiles a statistical analysis of the causes of the fires and losses at high-tech plants in Taiwan since 1996, the aim being to establish the necessary improvement measures by using the Fire Dynamics Simulation (FDS) to solve relevant problems. The researchers also investigate the lithography process machine in order to explore carriage improvement measures, and analyse the fires' causes and reactive materials hazardous properties, from 1996 to 2012. The effective improvement measures are established based on the accident statistics. The study site is a 300 mm wafer fabrication plant located in Hsinchu Science Park, Taiwan.After the completion of the annual maintenance jobs improvement from September 2011 to December 2012, the number of lithography process accidents was reduced from 6 to 1. The accident rate was significantly reduced and there were no staff time losses for a continuous 6882 h. It is confirmed that the plant safety level has been effectively enhanced. The researchers offer safety design recommendations regarding transport process appliances, chemical storage tanks, fume cupboard devices, chemical rooms, pumping equipment, transportation pipelines, valve manual box (VMB) process machines and liquid waste discharge lines. These recommendations can be applied in these industries to enhance the safety level of high-tech plants, facilities or process systems.     

Seismic risk of atmospheric storage tanks in the framework of quantitative risk analysis

The quantitative risk assessment of industrial facilities is based on integrated procedures to quantify human, environmental and economical losses related to relevant accidents. Accordingly, seismic risk analysis has to be integrated in order to obtain reliable results.In this work, some considerations regarding the intensity and probability of occurrence of earthquakes and the vulnerability of atmospheric storage tanks subjected to seismic actions are given.Structural vulnerability based on observational data has been processed in the form of “probit analysis”, a simple and useful statistic tool. Suggestions concerning industrial seismic-related accidental scenarios are also given.     

Multi-hazard failure assessment of atmospheric storage tanks during hurricanes

Hurricane as one of the most destructive natural hazards can make a devastating impact on the industrial equipment, especially atmospheric storage tanks, leading to the release of stored chemicals and disastrous safety and environmental issues. These catastrophic consequences are caused not only by strong winds but also by the torrential rainfall and inundating floods. The objective of this study is to present a risk-based methodology for assessing and reducing the vulnerability of atmospheric storage tanks to hurricanes. Considering the shell buckling, flotation, sliding, and roof sinking as dominant failure modes of atmospheric storage tanks during hurricanes, Bayesian network (BN) has been employed to combine the failure modes while considering their conditional dependencies. The probability updating feature of the developed BN was employed to indicate that the flood is the most critical hazard during hurricanes while the impact of wind and rainfall cannot be neglected. Extending the developed BN to an influence diagram, the cost-benefit filling of storage tanks with water prior to the advent of hurricanes was shown as a viable measure for reducing the damage probability. The results show that the proposed methodology can be used as an effective decision support tool for assessing and reducing the vulnerability of atmospheric storage tanks to natural hazards.     

Effect of bubble generation on hot zone formation in tank fires

Boilover is a phenomenon that both stakeholders and fire-fighters in the petrochemical industry try to avoid. This phenomenon results in an explosion of liquid hydrocarbon materials (e.g., crude oil) due to prolonged oil tank fires. The elevated temperature provides energy to vaporize the water sub-layer, which commonly resides at bottom of storage tanks, leading to tremendous fire enlargement as fuel tends to spill over around the tank. Boilover follows the formation of an isothermal layer called ‘hot zone’, and is typically accompanied by continuing bubble appearance in the hot zone. Previous studies have suggested that bubble generation could be a driving force for boilover, as it accelerates heat mixing. However, the effect of bubble generation on the mechanism of hot zone formation has not yet been systematically studied. This work investigates the effect of bubble formation on hot zone formation by installing a metal mesh in a burning fuel container. The size of the mesh grid and the position of the mesh are varied to generate bubbles with different volumes from different depths from the fuel surface. Experimental results demonstrate that the metal mesh definitely increases the volume of bubbles, and significantly reduces the time to form a hot zone. The mesh with small grids generates more bubbles than that with large grids. Additionally, bubbles start to generate earlier when the mesh is fixed nearer the fuel surface. Experimental results provide direct evidence of the bubble effect on hot zone formation.