API Standard 521 new alternative method to evaluate fire relief for pressure relief device sizing and depressuring system design

Since the 1950's, API Standards have provided guidance on determining relief loads for equipment exposed to pool fires. The API method is empirical based on tests performed in the 1940's. There is increasingly widespread interest in analytical methods based on heat transfer principles to model fire heat input. The API committee agreed to include an analytical method in the 6th edition of API Standard 521 to establish relief loads for pressure relief devices and to design depressuring systems for the fire scenario. The analytical method provides more flexibility than the empirical method but has limitations (e.g., too many permutations are possible leading to potential under-sizing of the pressure relief device).This paper discusses the basis for the empirical method in API Standard 521 and provides comparisons of the empirical and analytical method with two more recent large-scale pool fire tests. This pool fire test data indicates that the empirical method will provide a conservative estimate of pool fire heat input for most applications and is still the method of choice when designing pressure relief systems. However, these recent tests indicate the empirical method needs to be modified when a vessel or equipment is partially confined by adjacent embankments or walls equal or greater than the vessel height. In such cases, the wetted area exponent should be 1.0 instead of 0.82.The analytical method is useful in determining time-versus-temperature profiles for heating unwetted vessels of varying wall thicknesses and materials of construction. These profiles, which depend upon the type of fire (e.g., unconfined pool fire, jet fire, etc.), can be combined with tensile strength and stress-rupture data to specify a depressuring system's pressure-versus-time profile. This will minimize failure and/or mitigate the effects of failure due to overheating from fire exposure.     

Compression system check-valve failure hazards

Processes that utilize multistage compression systems (olefins plant compression systems, gas processing, integrated refrigeration systems, etc.) have the potential for overpressure due to single or multiple check-valve failure. Catastrophic equipment failure resulting from overpressure can potentially occur due to compression system discharge, interstage, and/or suction check-valve failure, coincident with compressor shutdown. Depending on system design and application, overpressure values approaching or exceeding 300% of equipment design are possible, while for some equipment, even limited overpressure can result in catastrophic vessel failure due to brittle fracture. Additional hazards associated with compression system fail-to-check scenarios include risks associated with excessive flare loading and compressor rotor reverse rotation. In the case of an ethylene refrigeration compressor at a typical ethylene plant, rotor reverse rotation can potentially exceed overspeed limits.This paper provides risk assessment results based on analyses performed on the three primary compression systems in six ethylene plants. The methodologies used for risk identification screening, detailed risk assessment and evaluation of system dynamics are all presented. Alternative methods for mitigating risks are also discussed, along with check-valve reliability data. An overview of applicable overpressure protection requirements defined in the ASME Boiler and Pressure Vessel Code is provided. This paper will be of interest to anyone who designs or operates multistage compression systems in the chemical, petrochemical or refining industries.     

Influence of laneway support spacing on methane/air explosion shock wave

A laneway support system provides an available way to solve problems related to ground movements in underground coal mines, but also poses another potential hazard. Once a methane/air explosion occurs in a laneway, inappropriate design parameters of the support system, especially the support spacing, likely have a negative influence on explosion disaster effects. The commercial software package AutoReaGas, a computational fluid dynamics code suitable for gas explosions, was used to carry out the numerical investigation for the methane/air explosion and blast process in a straight laneway with different support spacing. The validity of the numerical method was verified by the methane/air explosion experiment in a steel tube. Laneway supports can promote the development of turbulence and explosion, and also inhibit the propagation of flame and shock wave. For the design parameters in actual laneway projects, the fluid dynamic drag due to the laneway support plays a predominant role in a methane/air explosion. There is an uneven distribution of the peak overpressure on the same cross section in the laneway, and the largest overpressure is near the laneway walls. Different support spacing can cause obvious differences for the distributions of the shock wave overpressure and impulse. Under comparable conditions, the greater destructive effects of explosion shock wave are seen for the laneway support system with larger spacing. The results presented in this work provide a theoretical basis for the optimized design of the support system in coal laneways and the related safety assessments.     

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.     

Characteristic overpressure–impulse–distance curves for the detonation of explosives, pyrotechnics or unstable substances

A number of models have been proposed to calculate overpressure and impulse from accidental industrial explosions. When the blast is produced by explosives, pyrotechnics or unstable substances, the TNT equivalent model is widely used. From the curves given by this model, data are fitted to obtain equations showing the relationship between overpressure, impulse and distance. These equations, referred to here as characteristic curves, can be fitted by means of power equations, which depend on the TNT equivalent mass. Characteristic curves allow determination of overpressure and impulse at each distance.     

Computer simulation of shock waves transmission in obstructed terrains

Generation and transmission of blast waves in real terrains is of major importance for risk analysis procedures involving accidental explosion scenarios. The problem arises from the impact of overpressure wave on people and structures that may be lethal or catastrophic under certain conditions. In this paper, a CFD simulation of shock wave propagation in obstructed terrain is attempted. Overpressure histories as well as a series of critical parameters, namely the positive and negative peak overpressure, the arrival time, and the positive and negative phase duration at specific points within the domain were obtained during the simulation. Their comparison with experimental measurements from field-scale high explosive blast tests performed by HSE showed a reasonably good agreement indicating that CFD computer programs provide reliable tools for estimating explosive shocks in complex terrains.     

Experimental study on unconfined methane explosion: Explosion characteristics and overpressure prediction method

Explosion accidents have become the main threat for the high-efficiency use of cleaner gas energy sources, such as natural gas. During an explosion, obstacle causing flame acceleration is the main reason for the increase of the explosion overpressure, which still remains to be fully understood. In this research, field experiments were conducted in a 1 m³ cubic frame apparatus to investigate the effect of built-in obstacles on unconfined methane explosion. Cage-like obstacles were constructed using square steel rods with different cross section size. The results demonstrated that the flame could get accelerated due to the hydrodynamic instability and obstacle-induced turbulence, which enhanced the explosion overpressure. In the near field, the overpressure wave travelled slower and the maximum overpressure could almost keep constant. Reducing the cross section size, or increasing the obstacle height or the obstacle number per layer could determine the rise of the maximum overpressure, the maximum pressure rising rate and the overpressure impulse. For uniformly constructed obstacles, self-similar theory was chosen to measure the influence of the hydrodynamic instability, and a parameter β was adopted to measure the flame acceleration caused by obstacle-induced turbulence, the value of which was 2 in this research. Based on the acoustic theory, an overpressure prediction model was proposed and the predicted results agreed with the measured values better than previous models, such as TNT equivalency model and TNO multi-energy model.     

Propane-air mixture deflagration hazard with different ignition positions and restraints in large-scale venting chamber

In order to better assess the hazards of explosion accidents, propane-air mixture deflagrations were conducted in a large-scale straight rectangular chamber (with a cross-section of 1.5 m × 1.5 m, length of 10 m, and total volume of 22.5 m³). The effect of initial volume, ignition position, and initial restraints on the explosion characteristics of the propane-air mixtures was investigated. The explosion overpressure, flame propagation, and flame speed were obtained and the computational fluid dynamics (CFD) software was used to simulate the flame-propagation process and field flow for auxiliary analysis. The hazards of large-scale propagation explosion under weak and strong constraints were evaluated and the different phases of flame propagation under weak and strong constraints were discriminated. Results indicate that the hazards caused by propane deflagration under weak constraint are mainly caused by flame spread. And the maximum overpressure under strong constraint appeared at the front part of the chamber under the large-scale condition, which is consistent with the previous small-scale test. Moreover, the simulations of flame structures under weak and strong constraint are in good agreement with experimental results, which furthers the understanding of large-scale propane deflagration under different initial conditions in large-scale spaces and provides basic data for three-dimensional CFD model improvement.     

A comprehensive approach to API RP 752 and 753 building siting studies

Facility siting studies are an important part of process safety, and are required for facilities that fall under OSHA’s PSM program. Facility siting is frequently interpreted as performing a building siting study which adheres to the guidance given in API RP 752. Building siting may also consider siting of temporary or portable buildings based on the guidance in API RP 753. While both API RP 752 and API RP 753 provide a framework and some guidance for performing building siting studies, they do not provide detailed methodologies or provide guidance on performing a detailed analysis. As a result many building siting studies are inconsistent in their overall approach, or in the way they address hazards. Due to the recent scrutiny applied to building siting studies, more attention has been given to provide evaluations which correctly describe the range of hazards that may affect an occupied building at a petrochemical facility. This paper outlines a comprehensive methodology for performing building siting studies at such facilities. The methodology addresses the applicable hazards and the available tools by which the potential impacts to building occupants can be evaluated.     

A methodology to predict shock overpressure decay in a tunnel produced by a premixed methane/air explosion

A methodology for estimating the blast wave overpressure decay in air produced by a gas explosion in a closed-ended tunnel is proposed based on numerical simulations. The influence of the tunnel wall roughness is taken into account in studying a methane/air mixture explosion and the subsequent propagation of the resulting shock wave in air. The pressure time-history is obtained at different axial locations in the tunnel outside the methane/air mixture. If the shock overpressure at two, or more locations, is known, the value at other locations can be determined according to a simple power law. The study demonstrates the accuracy of the proposed methodology to estimate the overpressure change with distance for shock waves in air produced by methane/air mixture explosions. The methodology is applied to experimental data in order to validate the approach.     

The application of pressure–impulse curves in a blast exceedance analysis

The magnitude of damage due to a vapor cloud explosion can be estimated in many ways, ranging from look-up tables to quantitative risk analysis. An explosion overpressure analysis is a routine part of compliance with the American Petroleum Institute (API) Recommended Practice (RP) 752 when evaluating occupied buildings in a facility that processes flammable or reactive materials. In many cases, a risk-based approach is useful because consequence modeling studies often indicate major problems for buildings at existing facilities. One of the most common risk-based methods, overpressure exceedance, incorporates a wide range of potential explosion scenarios coupled with the probability of each event to develop the probability of exceeding a given overpressure at specific locations. But this and other methods that only use overpressure may not represent an accurate building response. By combining the risk-based methodology of the exceedance analysis with pressure and impulse data in the form of pressure–impulse (P–I) curves, a better measure of building damage can be generated. P–I curves for blast loading determination have been in use for decades, and allow the user to determine levels of damage based on a predicted overpressure and its corresponding impulse. Curves have been published for entire buildings, individual structural members, window breakage, and even consequences to humans. This paper will explore application of P–I curves for building damage, and will highlight some of the benefits, as well as some of the potential problems, of using P–I curves.     

Effect of bifurcation on premixed methane-air explosion overpressure in pipes

It is well known that bifurcation structures have a significant influence on gas explosions in pipelines or roadways. In this work, three different types of bifurcation, namely, bifurcation with two right angles (BTRAs), bifurcation with two obtuse angles (BTOAs), and bifurcation with an obtuse angle and an acute angle (BOAA), were used to study the effect of bifurcation on premixed methane–air explosion overpressure in pipes. The effect of the position of bifurcation on gas explosions was also discussed. Our results suggest that the peak overpressure evolution in pipes exhibits a downtrend before the bifurcation, a sharp increase after the bifurcation until reaching the maximum, and a downward trend when propagating into the pipe end. It was also found that gas-explosion propagation was affected by the joint action of turbulence induced by obstacles and the abrupt increase of the cross-sectional area. In addition, the bifurcation’s position had only a small effect on the maximum peak overpressure in pipes.     

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

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.     

Experimental study on explosion characteristics of ethanol-gasoline blended fuels

In the present work, a series of experiments have been performed to analyze the explosion characteristics of ethanol-gasoline with various blended ratios (0%, 5%, 10%, 15%, 30%, 50%, 70%, 80%, and 100%). A vented rectangular vessel with a cross-section of 100 mm × 100 mm, 600 mm long and a 40 mm diameter vent on the top is used to carry out the experiments. The flame propagation is recorded by a phantom high-speed camera with 5000 fps, while the histories of the explosion overpressure are measured by two PCB pressure sensors and the explosion sound pressure level is obtained by a CRY sound sensor. The results indicate that the maximum overpressure and flame propagation speed increases linearly as the blended ratio increases when the initial volume of blended fuel is 1.0 mL; While the change of explosion overpressure and flame propagation speed shows a trend of decreasing at first and then increasing as the concentration increases to 1.8 mL. It is also found that the peak of the sound pressure level exceeds 100 dB under all tests, which would damage the human's hearing. What's more, relationships between explosion overpressure and sound pressure level are examined, and the change of the maximum overpressure can be reflected to some extent by the measurement of the maximum sound pressure level. The study is significant to reveal the essential characteristic of the explosion venting process of ethanol-gasoline under different initial blended ratios, and the results would help deepen the understanding of ethanol-gasoline blended fuels explosion and the assessment of the explosion hazardous.     

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.     

Turbulent deflagrations of mildly flammable refrigerant-air mixtures

With current concerns around global climate change, new hydrofluorocarbons with low Global Warming Potential (GWP) are being evaluated as alternative refrigerants. These alternative refrigerants, however, may be mildly flammable (as defined by the A2L safety group classification) and pose safety concerns for the heating, ventilation, air conditioning, and refrigeration (HVAC/R) industry. Consequently, careful assessments of different flammability characteristics and risks for these refrigerants are essential for their safe use in actual applications. In this study, deflagration propagation measurements for different mildly flammable refrigerants, including difluoromethane (R-32) and 2,3,3,3-tetrafluoropropene (R-1234yf), were undertaken in different geometries including a 9.1-m long conduit test rig and a closed cubical 12.5 m³ volume. Different tests were conducted for full volume deflagrations as well as with and without obstructions. Turbulent deflagration speeds for well-mixed, refrigerant-air mixtures have been shown to be orders of magnitude larger than their corresponding laminar flame speed values that are used in classifying flammable refrigerants in safety standards. Testing has also quantified the resulting severity as measured by the event overpressure which was shown to worsen with increased congestion or confinement as a consequence of increased induced turbulence. This work illustrates the importance for severity evaluations for actual large-scale or congested geometries of concern in practical applications. Even for mildly flammable refrigerants characterized by laminar flame speeds <2 cm/s, which is lower than the 10 cm/s limit for A2L refrigerants, relatively fast deflagrations can be generated for very congested geometries where downstream turbulence is generated as the flame front passes over obstacles in these situations.     

Effects of cross-wise obstacle position on methane–air deflagration characteristics

A vented chamber, with internal dimensions of 150 mm × 150 mm × 500 mm, is constructed in which the premixed methane–air deflagration flame, propagating away from the ignition source, interacts with obstacles along its path. Three obstacle configurations with different cross-wise positions are investigated. The cross-wise obstacle positions are found to have significant effects on deflagration characteristics, such as flame structure, flame front location, flame speed, and overpressure transients. The rate of flame acceleration, as the flame passes over the last obstacle, is the highest at the configuration with three centrally located obstacles, whereas the lowest is observed at the configuration with three obstacles mounted on one side of the chamber. Compared with the side configuration, the magnitude of overpressure generated increases by approximately 80% and 165% for the central and staggered configurations, respectively. Furthermore, flame propagation speeds and generated overpressures for both the central and staggered configurations are greater, which should to be avoided to reduce the risk associated with turbulent premixed deflagrations in practical processes.     

Security Risk Assessment Methodology for the petroleum and petrochemical industries

The American National Standards Institute (ANSI)/American Petroleum Institute (API) Standard 780 Security Risk Assessment (SRA) Methodology was published in June 2013 as a U. S. standard for security risk assessments on petroleum and petrochemical facilities. The standard represents a model standard for evaluating all security risks of petroleum and petrochemical infrastructure and operations and assists industries in more thoroughly and consistently conducting SRAs. The 2013 Standard is an update from the previous API/NPRA SRA Methodology (2004) and focuses on expanding functional utility without changing the basic methodology.The methodology can be applied to a wide range of assets even beyond the typical operating facilities of the industry. This includes refining and petrochemical manufacturing operations, pipelines, and transportation operations including truck, marine, and rail, as well as worker and executive security, housing compounds, and remote operational sites. The new standard describes the most efficient and thorough approach for assessing security risks widely applicable to the types of facilities operated by the industry and the security issues they face. It is voluntary but has been adopted by the Kingdom of Saudi Arabia Ministry of Interior High Commission for Industrial Security as the mandatory security risk assessment methodology for industrial facilities.This paper examines the key elements of the ANSI/API SRA process and discusses how forward thinking organizations may use risk-based performance metrics to systematically analyze facility security postures and identify appropriately scaled and fiscally responsible countermeasures based on current and projected threats. The AcuTech Consulting Group developed the methodology under contract to the API, and the author was the project manager for the project.     

Explosions of gasoline–air mixture in the tunnels containing branch configuration

In order to investigate the effects of branch tunnels on explosion propagation, experiments were performed in five different configuration tunnels (straight configuration and configurations with 1 branch, 2 branches, 3 branches and 4 branches). Pressure and flame transducers were used to record the history of the pressure development and track the velocity of the flame front. It was shown that the branch tunnels had ability to enhance the maximum overpressure, rate of overpressure rise, and deflagration index (K_G) of the gasoline–air mixture explosion due to the turbulence induced by the branch tunnels. The overpressure rise rate and K_G of the explosion increased as a function of the number of branch tunnels. Experiments also showed that the maximum flame speed increased as the branch number increasing from 0 to 3 due to the enlargement of turbulence induced by the branch tunnels. However, an increase of branch number did not always lead to an enhancement of flame speed because the heat loss was intensified resulting from the increase of flame surface caused by the branch tunnels. When the number of branch tunnels exceeded 3, the maximum flame speed dropped.     

Combustion characteristics of pure aluminum and aluminum alloys powders

In this work, the explosion and combustion characteristics of aluminum and some aluminum alloys AlSi7Mg0.6, AlSi10Mg, AlMg5 under powders conditioning were studied. The idea was to compare the combustion of pure aluminum and aluminum alloys. The Minimum Ignition Energy (MIE) and explosion severity ΔP_max and (dP/dt)_max which represents the dust explosion parameters were measured for all powders using Hartman tube and 20 L spherical bomb. The particles temperature and flame temperature were determined by using IR pyrometer and spectroscopy respectively. The results showed that pure aluminum was more sensitive and severe than its alloys. MIE were: 4 mJ for pure aluminum, 13–23 mJ for aluminum alloys. For severity parameters, the overpressure ΔP_max were around 7–8 bars with maximum rate of pressure rise at 1170 bar/s for aluminum and 5–7 bars with 250–360 bar/s for alloys. However, it has been observed that flame temperatures were similar for aluminum and alloys and vary around 2800–3300 K as a function of concentration.