A closer look at BLEVE overpressure

The overpressure produced by the boiling liquid expanding vapor explosion (BLEVE) is still not well understood. Various methods have been published on the overpressure modeling in the far field. They mostly differ by the modeling of the expansion energy, used to scale the distance to the source where the overpressure needs to be calculated. But these methods usually include a experimentally fitted reduction factor, and are mostly overestimating the overpressures. Today there is a growing interest in modeling the BLEVE overpressure in the near field, for studying the blast effect on critical infrastructure such as bridges and buildings. This requires a much better understanding of the BLEVE blast. This paper goes deeper in the understanding of the physical phenomenon leading to the BLEVE blast wave generation and propagation. First, mid-scale BLEVE experiments in addition to new experimental data for near field blast from a small scale supercritical BLEVE are analyzed. And second, an analysis method of the shocks observed in the experiments is presented based on fundamental gas dynamics, and allows the elaboration of a new modeling approach for BLEVE overpressure, based on the calculation of the initial overpressure and radius of the blast.     

On the response of 500 gal propane tanks to a 25% engulfing fire

This paper presents detailed data on the thermal response of two 500 gal ASME code propane tanks that were 25% engulfed in a hydrocarbon fire. These tests were done as part of an overall test programme to study thermal protection systems for propane-filled railway tank-cars.

The fire was generated using an array of 25 liquid propane-fuelled burners. This provided a luminous fire that engulfed 25% of the tank surface on one side. The intent of these tests was to model a severe partially engulfing fire situation.

The paper presents data on the tank wall and lading temperatures and tank internal pressure. In the first test the wind reduced the fire heating and resulted in a late failure of the tank at 46 min. This tank failed catastrophically with a powerful boiling liquid expanding vapour explosion (BLEVE). In the other test, the fire heating was very severe and steady and this tank failed very quickly in 8 min as a finite rupture with massive two-phase jet release. The reasons for these different outcomes are discussed. The different failures provide a range of realistic outcomes for the subject tank and fire condition.     

Off-site emergency scenario, a case study from a LPG Bottling Plant

After Bhopal disaster, emergency planning in an industrial area has become inevitable. The off-site emergency plan is an integral part of any major hazard control system. Boiling Liquid Expanding Vapour Explosion (BLEVE) leads to fatal consequences. This paper highlights some salient features of the emergency scenario, which ultimately leads to fireball with enormous pressure wave all around.     

Calculating overpressure from BLEVE explosions

Although a certain number of authors have analyzed the prediction of boiling liquid expanding vapour explosion (BLEVE) and fireball effects, only very few of them have proposed methodologies for predicting the overpressure from such explosions. In this paper, the methods previously published are discussed and shown to introduce a significant overestimation due to the erroneous thermodynamic assumptions—ideal gas behaviour and isentropic vapour expansion—on which they are based (in fact, they give the maximum value of overpressure which can be caused by a BLEVE). A new approach is proposed, based on the—more realistic—assumption of an adiabatic and irreversible expansion process; the real properties of the substance involved in the explosion are used. The two methods are compared through the application to a given case.     

Case study: Assessment on large scale LPG BLEVEs in the 2011 Tohoku earthquakes

After the 2011 Tohoku earthquakes, several chemical and oil complexes on the Pacific Ocean shoreline of northeast Japan experienced massive losses. In Chiba, a refinery operated by Cosmo Oil lost 17 LPG storage vessels which were either heavily damaged or totally destroyed by fires and explosions in the refinery. These large vessels ranged in size from 1000 to 5000 m³. The estimated volume of LPG at the time of the incident was between 400 and 5000 m³ for each vessel. Five boiling liquid expanding vapor explosions (BLEVEs) of LPG occurred, resulting in huge fire balls measuring about 500 m in diameter.A BLEVE is defined as the explosive release of expanding vapor and boiling liquid when a container holding a pressure-liquefied gas fails catastrophically. It is thus important to estimate the physical properties of superheated liquids: the thermodynamic and transport properties, the intrinsic limits to superheating and depressurization, and the nature of thermodynamic paths. Also it is hoped to provide better understanding of the vessels designed, manufactured, installed, and operated to reduce or eliminate the probability that a sequence of events will result in BLEVE or loss of primary containment. Knowledge of these matters is still incomplete. The objective of this research is to estimate the significant BLEVE phenomenon in very large scale spherical vessels based on published information in Japan. There are some models predicting BLEVEs. However, it is essential to know if this is true for very large scales such as spheres since validation is usually rare to provide confidence in estimating the superheated liquids behaviors. To this end, comparing with the information on this event, the conditions in the five LPG vessels at the time of the BLEVE were determined in terms of: duration of vessel failure (time to BLEVE); mass fraction in the vessel with time; temperature distribution in the liquid and vapor region and pressure within the vessel (e.g. initial pressure and internal high-speed transient pressure during failure), by means of a computer program AFFTAC Analysis of Fire Effects on Tank Cars, which solves heat conduction, stress and a failure model of the tank, a thermodynamic model of its fluid contents, and a flow model for the lading flowing through the safety relief device. Subsequently, the consequences from the sphere BLEVE, such as the expected fireball diameter and duration and the expected blast overpressure produced by the BLEVE failures, are also subjects of active research. Here the blast using the methods of PHAST and SFPE Handbook of Fire Protection Engineering was calculated.Results suggest that methodologies here used gave reasonable estimations for such real and huge BLEVEs in a validated way, which may provide valuable guidance for risk mitigation strategy with regard to LPG facility in design, emergency planning, resiliency, operations, and risk management.     

BLEVE: The case of water and a historical survey

After a short update of the current more accepted definition of BLEVE, the special features of water BLEVEs are analyzed. The stronger overpressure wave generated in the case of water as compared to that of other substances is justified in terms of volume change. Through a comparison with liquefied pressurized propane, three possibilities are analyzed: the simultaneous contribution of both the liquid and the preexisting vapor, the contribution of the liquid flash vaporization, and the contribution of the pre-existing vapor. Also a historical survey on a set of 202 BLEVE accidents –the largest sample of BLEVE accidents surveyed until now– is presented. LPG was the most common substances in this set of accidents. However, water and LNG (11% of water and 4% of LNG in the studied cases) have also been involved. Impact failure (44.8%) and human factor (30.3%) were the most common causes of BLEVEs. Transport, storage, process plants, and transfer were the activities in which more accidents occurred.     

Small-scale physical explosions in shock tubes in comparison with condensed high explosive detonations

A series of small-scale experiments involving physical explosions in a 1.6 l pressure vessel was carried out. Explosions were initiated by spontaneous rupture of an aluminium membrane on one side of the vessel at a pressure in the range 1–1.2 MPa. The pressure waves released were measured at different distances along two separate shock tubes, one 10 m long and 200 mm in diameter (closed at one end by the high pressure vessel) and the other 15 m long and 100 mm in diameter.TNT equivalency was used for predicting the blast wave characteristics after vessel rupture. TNT equivalency was used because equations for prediction of peak pressure and impulse of the blast wave in 1-D geometry after detonations of condensed explosives are known. Some experiments with an equivalent amount of real explosive were carried out for comparison with the theoretical and experimental data obtained. The applicability of the TNT equivalency method presented for calculations of maximum pressure and shock wave impulse generated after rupture of the pressure vessel in 1-D geometry is discussed.     

基于随机抽样推测法的LPG储槽2次爆炸事故的模型研究

在借鉴LPG储槽2次爆炸事故后果不确定分析成果的基础上,对事故过程中的不确定参数进行重新分析与选择,将孔洞上方液位高度h0,气云的TNT当量系数α,泄漏开始到点火源出现之前的持续时间t亦作为不确定分析的参数,并利用随机抽样推测的不确定分析方法,对VCE与BLEVE 2次事故后果进行重新分析,获得了与前人研究成果差异较大的结果,并由此分析这些参数对于事故后果影响的显著性。同时对2次爆炸事故的伤害距离进行了研究与分析,由于LPG的闪蒸以及参数α的影响,本案例中LPG泄漏量为总量的80%-90%以上时,2次事故的死亡半径相等且达到最小。     

Prediction of BLEVE mechanical energy by implementation of artificial neural network

In the event of a BLEVE, the overpressure wave can cause important effects over a certain area. Several thermodynamic assumptions have been proposed as the basis for developing methodologies to predict both the mechanical energy associated to such a wave and the peak overpressure. According to a recent comparative analysis, methods based on real gas behavior and adiabatic irreversible expansion assumptions can give a good estimation of this energy. In this communication, the Artificial Neural Network (ANN) approach has been implemented to predict the BLEVE mechanical energy for the case of propane and butane. Temperature and vessel filling degree at failure have been considered as input parameters (plus vessel volume), and the BLEVE blast energy has been estimated as output data by the ANN model. A Bayesian Regularization algorithm was chosen as the three-layer backpropagation training algorithm. Based on the neurons optimization process, the number of neurons at the hidden layer was five in the case of propane and four in the case of butane. The transfer function applied in this layer was a sigmoid, because it had an easy and straightforward differentiation for using in the backpropagation algorithm. For the output layer, the number of neurons had to be one in both cases, and the transfer function was purelin (linear). The model performance has been compared with experimental values, proving that the mechanical energy of a BLEVE explosion can be adequately predicted with the Artificial Neural Network approach.     

Lessons learned from a supercritical pressure BLEVE in Nihon Dempa Kogyo Crystal Inc.

On December 7, 2009, a 50-foot-tall high-pressure vessel ruptured in the Nihon Dempa Kogyo Crystal, Inc. facility in Belvidere, Illinois. Several projectiles rapidly traveled outward from the facility, killing a truck driver 650 feet away and injuring an employee in another building 435 feet away. This paper summarizes the lessons learned from this incident both on causal and consequential aspects. Stress corrosion cracking was identified as the failure mechanism by the U.S. Chemical Safety and Hazard Investigation Board. After analyzing the operating conditions and the aftermath, this incident has been identified as a Boiling Liquid Expanding Vapor Explosion (BLEVE) under a supercritical pressure. A consequence analysis of the incident is performed where overpressure and fragment distance are calculated, together with safety distance estimation. Additionally, other safety-related problems, such as safety culture, management inside the corporation, and communication between this facility and the government are discussed.