Enhanced seismic performance of non-standard bolted flange joints for petrochemical piping systems

This paper presents an experimental test campaign carried out on a number of seismically enhanced Bolted Flange Joints. In particular, two non-standard Bolted Flange Joints, comparatively thinner than standard ones, were designed and their performance was evaluated through several monotonic and cyclic tests. Experimental results exhibited a favourable performance of the examined joints under bending and axial loading and moderate internal pressure; a good capacity in terms of strength, ductility, energy dissipation and leakage was observed. A comparison between experimental results and Code-based design loads proved the usability of the proposed joints during and after Operating Basis Earthquake ground motions. Finally, a comparison between capacity and seismic demands of these joints adopted in a piping system of a realistic Case Study suggested their suitability for seismic applications as well as some building code deficiency with respect to response modification factors.     

Development of double-variable seismic fragility functions for oil refinery piping systems

Seismic risk assessment of piping systems, as a group of vulnerable facilities in oil refineries, is mostly based on the single-variable fragility curves. However, it is well-known that the fragility curves, developed based on a single intensity measure (IM), are not much reliable. For increasing the confidence level of seismic risk assessment of piping systems, it was tried, in this study, to develop double-variable fragility functions by using peak ground acceleration (PGA) and peak ground velocity (PGV) together as the IMs. For this purpose, the piping system of the ISOMAX Unit of Tehran oil refinery was considered, and modeled by a powerful finite element analysis program under various loadings, including gravity, pressure and seismic loads. For seismic analyses 157 set of three-component earthquake records were employed, with PGA and PGV values varying respectively from around 0.1 g–0.6 g and 10 cm/s to 60 cm/s. By using the nonlinear time histories analyses results, two single-IM fragility curves and one double-IM fragility surface were developed based on the probability of exceedance of the maximum created stress, considered as the ‘damage index’, from the allowable stress. The results indicate that using PGA and PGV jointly, as the IMs in the development of fragility functions, provides more reliable vulnerability estimations. For example, the single-IM fragility function gives, for PGA = 0.2 g, a probability of exceedance of 75%, while by using the double-IM fragility function this probability may change from 30% for PGV = 10 cm/s to 95% for PGV = 60 cm/s.     

Seismic fragility analysis of a coupled tank-piping system based on artificial ground motions and surrogate modeling

The catastrophic consequences of recent NaTech events triggered by earthquakes highlighted the inadequacy of standard approaches to seismic risk assessment of chemical process plants. To date, the risk assessment of such facilities mainly relies on historical data and focuses on uncoupled process components. As a consequence, the dynamic interaction between process equipment is neglected. In response to this gap, researchers started a progressive integration of the Pacific Earthquake Engineering Research Center (PEER) Performance-Based Earthquake Engineering (PBEE) risk assessment framework. However, a few limitations still prevent a systematic implementation of this framework to chemical process plants. The most significant are: (i) the computational cost of system-level simulations accounting for coupling between process equipment; (ii) the experimental cost for component-level model validation; (iii) a reduced number of hazard-consistent site-specific ground motion records for time history analyses.In response to these challenges, this paper proposes a recently developed uncertainty quantification-based framework to perform seismic fragility assessments of chemical process plants. The framework employs three key elements: (i) a stochastic ground-motion model to supplement scarcity of real records; (ii) surrogate modeling to reduce the computational cost of system-level simulations; (iii) a component-level model validation based on cost-effective hybrid simulation tests. In order to demonstrate the potential of the framework, two fragility functions are computed for a pipe elbow of a coupled tank-piping system.     

1st international round robin test on safety characteristics of hybrid mixtures

There is no applicable existing standard for the determination of safety characteristics for hybrid mixtures. While developing a new standard in a joint research project in Germany first results from parameter studies led to a standard procedure that can be adopted by laboratories that are already testing dusts in the so called 20L-sphere with as little additional effort as necessary. In fact, one of the main objectives of this research project was to keep modifications and adjustments from the generally accepted dust testing procedures as easy and minimal as possible so as to limit potential deviations from one laboratory to another.In this first round robin test on hybrid mixtures ever, with methane as gas component and a specific corn starch as dust sample, the practicality of the whole procedure, the scattering of the results and the deviation between the testing apparatuses is investigated. This paper summarizes the experimental procedure adopted and objectives of the first round-robin phase involving three of the four original German companies, plus volunteering laboratories from Australia, Belgium, Czech Republic, France, Poland and P.R. China. The results will have an impact on the new standard and may lead to robust data for later simulation purposes.     

Making hybrid mixture explosions a common case

Explosions of gas-dust hybrid mixtures have long been considered as particular cases encountered in specific industrial contexts. However, it should be reminded that during the explosion of an organic powder, the presence of a hybrid mixture composed of the dust itself and its pyrolysis gases is compulsory. On these premises, an experimental study to determine the role of cellulose pyrolysis products (gaseous, condensable and solid) on the global phenomenon is presented. Hybrid mixture explosion tests were exploited to carry out the investigation. The G-G furnace and the 20 L sphere were employed. Several experimental strategies were chosen to demonstrate the impact of pyrolysis reaction on the explosion of organic powders: i) the fuel equivalence ratio of the reactive mixture (case 1), or ii) the mass of reactants (case 2) were respectively kept constant, iii) the effects of water vapor, char and tar were tested. They were next compared to identify the most suitable one. The two first experimental approaches lead to significantly different results: only case 2 keeps the maximum explosion pressure almost constant, but maximum rate of pressure rises and deflagration index greatly decrease when the pyrolysis gases concentration decreases, which highlights the importance of the pyrolysis reaction on the explosion kinetics. It should also be stressed that the maximum explosion severity is not obtained for the pure gases but when a small dust content is added. The same evolution is observed when a small amount of char is introduced to pyrolysis gases, which underlines the influence of the radiative transfer. Adding small amounts of tar to cellulose tends to increase its explosion severity. However, this impact is less than that generated by the addition of pyrolysis gases.     

Seismic response mitigation of chemical plant components by passive control techniques

This paper deals with the applicability of seismic passive control in major-hazard chemical installations. The objective is to show numerically and experimentally the applicability of Passive Control Techniques (PCT) in industrial plants. Consequently, the main components of a process plant are classified and collected into a limited number of classes; for each class, the main damages caused by past earthquakes are described and the most vulnerable components are identified. A synthesis of the effects of earthquakes on the different typologies of process components is also presented and the most suitable innovative seismic protection systems, in particular passive control techniques (PCT), are acknowledged. Finally, the effectiveness of PCT in reducing the seismic response of process plant components is proved by three representative case studies: a base isolated above-ground storage tank, a distillation column connected by elastoplastic dampers to the adjacent service frame and an application of non-conventional Tuned Mass Dampers to a support frame.     

混合质量阻尼器(HMD)抗震控制研究

建筑物的倒塌是地震造成破坏的主要形式之一 ,它导致大量的人员和财产损失。不断改进建筑物的抗震设计方法是传统的抗震减灾措施。随着结构振动控制领域的不断发展 ,它为建筑抗震减灾提供了一个新的途径。根据建筑结构抗震设计“三水准”的设防准则 ,混合质量阻尼器 (HybridMassDamper ,HMD)被应用于建筑抗震减灾中 ,对于发生频度较高的低烈度地震 ,主要通过调谐质量阻尼器 (TunedMassDamper ,TMD)控制结构的振动 ;而当发生烈度较高的地震或TMD不能满足控制目标要求时 ,启动作动器施加主动控制力 ,用主动控制力驱动TMD的附加质量块 ,提供给主结构更大的控制力 ,把TMD转化为主动质量阻尼器 (ActiveMassDemper ,AMD) ,取得预期的控制效果。理论分析和仿真计算表明 ,HMD适用地震激励的范围广 ,控制效果显著     

An experimental study of flame acceleration and deflagration to detonation transition in representative process piping

The paper summarizes the results of experimental tests and accompanying analyses to investigate the factors that govern flame acceleration and potential transition to detonation in a relatively long unobstructed piping system. The overall aim of the work was to obtain sufficient experimental data so as to be able to develop and evaluate methodologies for classifying and predicting potential detonation flame acceleration and deflagration to detonation transition (DDT) hazard in industrial process pipes and mixtures. The present results show that the flame acceleration process in an unobstructed pipe exhibit three distinct phases: an initial establishment phase; a second rapid acceleration phase and a final transition to detonation phase. Test results with ethylene indicate that the acceleration process is not sensitive to initial pressure (all other parameters remaining constant) but can be sensitivity to initial pipe wall temperature or possibly mixture humidity. The presence of bends increases the local rate of turbulent combustion, an effect attributed to the additional turbulence generated downstream of the bend. For straight pipes, detonation was only observed to develop for hydrogen–air and ethylene–air mixtures. Detonation was not observed with methane, propane or acetone as fuel in the present piping apparatus.     

京沪高速铁路地震预警系统的方案及关键参数研究

京沪高速铁路及沿线区域跨越 4个主要的地震带 ,带内地震活动活跃 ,地震是对高速列车行车安全危害最大的自然灾害。在对京沪高速铁路及沿线区域地震危险性调查的基础上 ,对地震预警系统的构成、监测设备的设置方案及报警模式等一些关键问题进行了研究。通过对京沪高速铁路各类典型构筑物的大量的地震响应统计分析 ,给出了机械式地震仪的预警水平 ,并提出了适于P波检测的M -R判别标准 ,为京沪高速铁路安全监控系统中地震预警系统的建设提供理论依据。     

Theoretical evaluation of lower explosion limit of hybrid mixtures

Lower explosion limits of hybrid fuel mixtures are usually determined through time consuming and expensive experiments. Although, mathematical expressions like Le-Chatelier's Law and Bartknecht curve have been used by many researchers to predict the LEL of hybrid mixtures, significant deviations remain unexplained. This research work, presents a more sophisticated and general approach for the determination of LEL of hybrid mixtures.Assuming that the combustion kinetics of pure species are independent and unchanged by the presence of other combustible species, complete conversion of the reactants and no heat losses, a simple mathematical model has been derived from the enthalpy balance of the whole system. For the experimental validation of the modelled values, modified version of 20L sphere has been employed, following the European standard (EN 14034-3: 2011) as experimental protocol. Hybrid mixtures of three dusts with two gases were selected for the scope of this publication. By analyzing the modelled as well as the experimental values, it can be concluded that the LEL values of the individual components in the hybrid mixture set the upper and lower limit for the LEL of the hybrid mixture provided the total amount of fuel in the system is considered as the concentration of the hybrid mixture. Moreover, the amount of dust or gas required to render the hybrid mixture flammable mainly depends on the energy contribution upon combustion of the individual species to raise the temperature of the whole system from ambient to the flame temperature.Le-Chatelier's Law and Bartknecht curve are empirical relations, which might hold true for a first-order approximation of LEL of hybrid mixtures, but do not represent the most conservative values of LEL reported in literature. This implies that there is a non-zero probability of occurrence of an explosible mixture in the non-explosible concentrations ranges defined by these relations. Considering these arguments, the authors suggest to employ the model presented in this paper – which presents reasonably conservative values of LEL of hybrid mixtures – for theoretical calculation of LEL of hybrid mixtures, when no precise experimental data is available.     

Comparative study on standardized ignition sources used for explosion testing

For the determination of safety characteristics of gases, vapors and dusts different types of ignition sources are used in international standards and guidelines. The paper presents test results of a comparative calorimetric and visual study between four different types of ignition sources. The ignition procedures were analyzed visually with a high-speed camera and electric recordings. In addition to that, the influence of the electrode-orientation, -distance as well as ignition energy on the reproducibility of the exploding wire igniter was tested.The exploding wire is already in use for standardized determination of safety characteristics of gases, first tests on the suitability of the exploding wire igniter for dust testing have been carried out but are not standardized yet. Using the exploding wire, the ignition energy can be varied from 2 J to 10 000 J (2 x 5000 J) and thus it could be used for gases, vapors, dusts and hybrid mixtures. Moreover it can be used at high initial pressures and it is the only ignition source with an easily measurable ignition energy release. Furthermore, it does not introduce another chemical reaction into the system.Finally, a proposal for a standard ignition source for explosion tests on hybrid mixtures is derived from the test results.     

Moderation of dust explosions

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.     

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.     

Bolted flange joints equipped with FBG sensors in industrial piping systems subjected to seismic loads

The vulnerability of major-hazard industrial plants to natural hazards has been recognized as an emergent issue whose importance is underlined by the Sendai Framework, established immediately after the Tohoku earthquake of 2011, in Japan. Hence, seismic risk analysis is of paramount importance as testified by the intense research activity that characterized the last years. In this respect, structural health monitoring can represent a valuable tool able to strongly help the decision-making phase. Along this main vein, optical fibers (OFs) represent a class of sensors able to both monitor critical conditions, as leakage of hazardous material, and activate safety barriers, if any. More precisely, optical fibers represent an economic solution, whose characteristics appear particularly suitable for dangerous environments like major-hazard plants. However, investigations relevant to their use for seismic monitoring of chemical/petrochemical plants are rather limited, especially when subject to strong dynamic excitations. As a result, this paper deals with the analysis of optical fiber Bragg gratings (FBGs) applied to bolted flange joints (BFJ) under cyclic loadings. More precisely, two experimental programs, i.e., a cyclic test on a single BFJ and a series of shaking table tests on BFJs of a multicomponent system, demonstrated the effectiveness of the proposed monitoring systems in detecting hazardous conditions and, thus, their potential use in conjunction with safety barriers.     

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.     

尾矿库溃坝离心机振动模型试验研究

为研究强震作用下尾矿库溃坝动力反应及溃坝演化规律,在清华大学离心机上进行尾矿库溃坝自重加载条件下离心振动模型试验。试验采用离心场图像采集系统、非接触位移测量系统及动态注水系统,采用Kobe波作为地震输入,测量模型加速度、孔隙压力、面板应力变形、坝体位移及其发展变化过程。试验结果表明:地震输入条件下的模型加速度近似均匀分布,尾矿库浸润线的位置随着水位的升高而逐渐上升,孔隙压力增大使得尾矿库坝体强度降低,但在水平地震下,仍能保持稳定。在蓄水过程中,尾矿库坝体产生明显的变形,出现了局部滑坡,但在地震作用下产生的变形较小,并且应变反应波形较为一致,表明尾矿库结构模型地震反应的整体性较好,具有良好的抗震稳定性。     

新疆克孜尔水库地震风险分析及防范研究

克孜尔水库地震风险防范系统是在强震台阵、F2活动断层监测设备完善、观测分析中心及抗震风险防范中心等硬件建设的基础上,通过在GIS平台上建立构造纲要、潜在震源区、峰值加速度区划、大坝所在位置等专题图层,完善地震传输系统、大坝数字减灾系统等软件建设。把强震监测信息系统技术应用于水库地震风险防范决策支持和实际运行科学管理,实现可在线处理子台传输过来的地震加速度时程曲线。分析各测点场地最大加速度值、水工结构的动力放大系数、场地卓越频率、结构自振频率、地震持续时间及水库诱发地震判别等重要参数,为各项决策提供可靠的快速支持,从而建立国内首座在活动断层上直接建坝的克孜尔水库大坝的震后快速报警体系和初步数字减灾系统,形成有效的震后快速修复措施,为深入开展活动断层上筑坝技术研究奠定基础。     

The effectiveness of statistical testing when applied to logic systems

In this paper we demonstrate the effectiveness of statistical testing for error detection on the example of a Programmable Logic System (PLS). Statistical testing was introduced into this project as a complementary testing technique with the potential to quantify system reliability, after a variety of acceptance tests had been performed. An appropriate statistical testing algorithm was devised and implemented, which is described in detail in this paper. We compare the results of statistical testing with those of a variety of other testing methods employed on the PLS. In terms of differences detected per number of tests, statistical testing showed an outstanding effectiveness. Furthermore, it detected a problem, which was missed by all other testing techniques. This together with its potential for reliability quantification illustrates its importance for system validation as part of a risk-based safety-case.     

Nex-Hys: minimum ignition temperature of hybrid mixtures

Although the minimum ignition temperature is an important safety characteristic and of practical relevance in industrial processes, actually only standard operation procedures are available for pure substances and single-phase values. Nevertheless, combinations of substances or mixtures are used in industrial processes and up to now it is not possible to provide a standardised minimum ignition temperature and in consequence to design a process safely with regard to the substances used.In order to get minimum ignition temperatures for frequently used hybrid mixtures, first, the minimum ignition temperatures and ignition frequencies were determined in the modified Godbert-Greenwald furnace for two single phase solids and a liquid substance. Second, minimum ignition temperatures and ignition frequencies were determined for several combinations as hybrid mixture of dust and liquid.In parallel to the determination of ignition temperatures a new camera and computer system to differentiate ignition from non-ignition is developed. First results are promising that such a system could be much less operator depended.By a high number of repetitions to classify regions of ignition the base is laid to decide about a new procedure for a hybrid standard and updating existing ones, too. This is one of the necessary aims to be reached in the Nex-Hys project.A noticeable decrease of minimum ignition temperatures below the MIT of the pure solids was observed for the one hybrid mixture tested, yet. Furthermore more widely dispersed area of ignition is shown. In accordance to previously findings, the results demonstrate a strong relationship between likelihood of explosion and amount of added solvent. In consequence the hybrid mixture is characterized by a lower minimum ignition temperature than the single dust.     

高压输电线铁塔地震时程弹性数值模拟

地震对高压输电线铁塔的安全性能有重要影响。通过建立高压输电线铁塔模型,采用有限元方法对受7级和8级地震影响的高压输电线铁塔的力学行为进行数值模拟与分析。计算结果表明:在地震作用下高压输电线铁塔t=3-4s时加速度最大,其应力也相应较大;在7级地震时最大应力值远小于材料的许可应力,高压输电线铁塔在7级地震过程中是安全的,但是8级地震时,最大应力值已经达到234MPa,超过Q345许可应力230MPa,高压线铁塔就处于不安全运行状态。