关于安全阀整定压力判定方法的讨论

安全阀整定压力是安全阀重要的技术指标之一。国内安全阀检验机构主要通过压力曲线拐点法或听声音法判定安全阀整定压力,国内外型式试验机构通过开高位移判定安全阀整定压力。通过比对试验发现：压力曲线拐点法或听声音法容易受到安全阀结构形式、是否有前泄及安全阀校验台试验容器和储气罐容积不能满足法规要求等因素影响检验的准确性;开高位移判定更为客观、准确。     

Performance-based earthquake evaluation of a full-scale petrochemical piping system

Assessment of seismic vulnerability of industrial petrochemical and oil & gas piping systems can be performed, beyond analytical tools, through experimental testing as well. Along this line, this paper describes an experimental test campaign carried out on a full-scale piping system in order to assess its seismic behaviour. In particular, a typical industrial piping system, containing several critical components, such as elbows, a bolted flange joint and a Tee joint, was tested under different levels of realistic earthquake loading. They corresponded to serviceability and ultimate limit states for support structures as suggested by modern performance-based earthquake engineering standards. The so called hybrid simulation techniques namely, pseudo-dynamic and real time testing with dynamic substructuring, were adopted to perform seismic tests. Experimental results displayed a favourable performance of the piping system and its components; they remained below their yielding, allowable stress and allowable strain limits without any leakage even at the Near Collapse Limit State condition for the support structure. Moreover, the favourable comparison between experimental and numerical results, proved the validity of the proposed hybrid techniques alternative to shaking table tests.     

Benchmarking of two-phase flow through safety relief valves and pipes

This paper compares calculated results for two-phase flows through safety relief valves and pipes using the TPHEM, CCFLOW and RRERSP computer programs. These studies were conducted to locate errors in the programs as well as to further our understanding of how each program worked. For most low-to-moderate viscosity flow examples, and for the frozen flow examples, the program results agreed despite differences in the calculation methods. Current thinking is that the TPHEM computer program gets better results for high viscosity flows through safety relief valves (nozzles) and for pipe down flows. This is because this program successively iterates nozzle flows to achieve results consistent with the choke pressure, temperature and quality and successively iterates pipe flows to achieve results consistent with the pipe length. Safety relief valve flows from the RRERSP computer program are reduced by the inlet pipe non-recoverable pressure loss. This effect is significant for several cases.     

汽车气制动ABS调节阀测试系统气动测试回路设计研究

针对气制动防抱死制动系统(ABS)调节阀测试系统气动回路设计进行研究;根据我国的汽车生产和检测现状,在确定气动测试回路总体方案的基础上,进行主控部分、负载回路、控制回路的设计和计算,所设计的气路检测系统可用于测试8种典型的气制动元件的密封性及动静态特性,通过不同的组合能够满足每一种阀的测试需求。该气动测试回路有效解决了简单阀类测量方法的不足,满足不了生产率及测量精度要求的问题。     

非柔性连接石化储罐配管温差应力分析与对策

储罐配管在温差作用下产生热位移会导致管壁产生热应力,未采用柔性连接的配管由于热应力集中作用可能发生破漏。针对与石油化工储罐非柔性连接的配管的安全问题,应用ANSYS有限元分析软件模拟计算石化企业典型配管的热应力分布;根据不同类型配管的分析结果,提出了工程技术与管理方面的针对性安全措施。研究结果表明:温差效应对石化储罐配管热应力影响显著,随内外温差的增加,配管应力集中的区域增大,最大热应力值增大;补偿措施能够改善配管的柔性,降低配管应力;约束载荷限制配管热膨胀从而增大配管应力;三通管是多根配管接合的区域,这种复杂管道交汇处会形成明显应力集中。研究结果对于提高石油化工非柔性连接配管安全性有一定的指导意义。     

Rear-Impact Inflicted Temporomandibular Joint Injury

Indirect injuries to the jaw can lead to a range of painful symptoms with serious consequences. These injuries are confirmed by clinical evidence but the injury mechanism is not understood. This work is an investigation into the nature of the injury process.

We have previously reported on the impact testing of a mechanistic model of a human head, neck and mandible. Results showed high angular velocities and accelerations of the mandible, but the magnitude of mouth opening lay within physiological limits. This paper reports on further impact tests using the same physical model to determine the kinematic behaviour of the temporomandibular joint (TMJ) during whiplash. In addition, human cadaveric samples were tested to quantify some structural properties of the TMJ. The results from this and data from a mathematical model of the TMJ are reported.     

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.     

Database-supported documentation and verification of pressure relief device design in chemical plants

In this paper the results of a multi-year analysis of the pressure relief devices located in several plants in major chemical sites are summarized. The analysis consisted of a systematic evaluation of existing safety valves and rupture discs including the identification of the service conditions and design cases as well as the sizing calculations of the individual device and associated piping. Furthermore, from the total amount and the hazardous potential of the effluents the necessity of retention systems is evaluated to ensure a safe disposal.Because the knowledge in the field of emergency pressure relief changed very rapidly in recent years, the design of some safety devices was not according to the state of the art. An essential part of the verification program was the recommendation of measures to find the most economical yet technically correct way to correct these deficiencies. Rather than by carrying out wholesale replacement of an incorrectly sized safety device or vent line, often a reduction of the mass flow rate to be discharged, for example, by an orifice in a supply line, is sufficient.Results of the analysis were recorded on a novel database to capture the sizing information and maintain correct pressure relief device sizing into the future. The systematic databased approach has been used for the evaluation of about 4000 safety devices so far. The procedure has been proven to enable an experienced design engineer to carry out the analysis of a great number of pressure relief devices in a time-saving, reliable and reviewable way.     

多因素下小尺度油罐火燃烧速率的研究

以正庚烷为研究对象,开展了不同因素耦合作用下小尺度油罐火燃烧特性的实验研究。结果表明:在不改变其他工况条件下,开口因子直接影响燃料燃烧速率,发现不同开口因子下燃烧速率与全开口下燃烧速率之比始终正比于对应的开口面积之比,且之间存在着相应的关系式。在实验所测两种液位6cm和8cm下,其燃烧速率变化不大,由此可发现,在该实验液位下油罐火液位高度不是影响燃烧速率的主要因素。在不同的风速下,随着风速的增加燃烧速率逐渐增加并趋于一定值,且不同开口因子下风速对燃烧速率的影响程度不同。风速对开口因子大的油罐燃烧速率的影响小于开口因子较小的油罐。     

The dynamic response of pressure relief valves in vapor or gas service,part I: Mathematical model

In order to prevent unstable operation, or “chatter”, of a pressure relief the API guidelines recommend limiting the irreversible pressure loss in the inlet line to a pressure relief valve to no more than 3% of the valve set pressure. This criterion is based on steady-state operating conditions and a typical blow-down pressure for the valve of about 7% of the set pressure. However, the stability of the valve is also influenced by other factors such as the dynamic response of the valve disk to the unsteady pressures and forces exerted by the fluid on the disk. A model for the opening lift dynamic response of a pressure relief valve in gas/vapor service is presented here which accounts for all of these effects through a set of five coupled nonlinear algebraic/differential equations. These equations are solved by a numerical method that can be implemented on a spreadsheet to predict the position of the valve disk as a function of time for given valve characteristics, operating conditions, and installation parameters. The model incorporates the influence of the various parameters on the stable/unstable nature of the disk response. An example is presented for a typical valve that illustrates the various modes of stable and unstable dynamic response that can be predicted by the model under various conditions. Two additional papers will be forthcoming: Part II – Experimental Investigation and Part III – Analysis of Data and Comparison with Model Predictions.     

Consequence risk analysis using operating procedure event trees and dynamic simulation

Faults due to human errors cost the petrochemical industry billions of dollars every year and can have adverse environmental consequences. Unquantified human error probabilities exist during process state transitions performed each day by process operators using standard operating procedures. Managing the risks associated with operating procedures is an essential part of managing the overall safety risk. Additional operator training and safety education cannot eliminate all such faults due to human errors; therefore, we propose an operating procedure event tree (OPET) like analysis with branches and events specifically designed to perform risk analysis on operating procedures. The OPET method adapts event trees to analyze the risk due to human error while performing operating procedures. We consider human error scenarios during the procedure and determine the likely consequences by applying dynamic simulation. The modified event tree provides an estimate of the error frequencies.Operating procedure steps were developed, and potential operator faults were determined for two typical equipment switching procedures found in chemical plant operations. Then, dynamic simulation using Aspen HYSYS software was applied to determine the overpressure related consequences of each fault. Finally, the error frequencies resulting from those scenarios were analyzed using operating procedure event trees. We found that a typical ethylene plant gas header would overpressure with 0.6% frequency per manual dryer switch. Since dryer switches occur from every few days up to once per shift, these results suggest that dryer switching should be automated to ensure safe and environmentally friendly operation. Process dryer switching performed manually by operators opening and closing gate valves can be automated with control valves and a distributed control system. A sample distillation column was found to overpressure with 0.85% frequency per manual reflux pump switch.     

Protective clothing for pesticide operators: part I – selection of a reference test chemical for penetration testing

A systematic approach was taken to develop a database for protective clothing for pesticide operators; results are reported as a two-part series. Part I describes the research studies that led to identification of a pesticide formulation that could serve as a reference test chemical for further testing. Measurement of pesticide penetration was conducted using different types of pesticide formulations. Six fabrics were tested using 10 formulations at different concentrations. Three formulations were subsequently selected for further testing. Analysis of the data indicated that, when compared with other formulations, mean percent penetration of 5% Prowl 3.3 EC [emulsifiable concentrate diluted to 5% active ingredient (pendimethalin)] is either similar to or higher than most test chemicals. Those results led to choosing 5% Prowl 3.3 EC as a reference test liquid. Part II of the study, published as a separate paper, includes data on a wide range of textile materials.     

Fugitive emissions in chemical processes: The assessment and prevention based on inherent and add-on approaches

Fugitive emissions are among the major concerns of industrial process releases. The emissions cause problem to various aspects including the environment, health, and economic. Early evaluation of process hazards is beneficial because process can be made inherently benign at lower cost. This paper discusses two important aspects of fugitive emissions assessment during process design – the quantification and the prevention strategies.For the quantification part, three methods are presented for fugitive emissions estimation during the process design. They are tailored to data available in simple process flow diagram (PFD), detailed PFD, and piping & instrumentation diagram (PID). Such methods are needed as early emissions estimation allows production routes and process designs with lower emissions to be selected. The fugitive emissions estimation and methods to abatement are demonstrated on a benzene process case study. Valves are found to be the major emission source with 50% of fugitive emissions of process area in a base case of petrochemical process, in which no fugitive emission reductions are yet made. Pumps without mechanical seals come second with 30% and flanges with 8% of emissions. Inherently safer design keywords can be applied to prevent fugitive emissions in the process plants. Substitution is the most applicable keyword in fugitive emission reduction of existing plants.The emission rate calculations together with estimation of health risk give a sound background for the decision making on elimination of emissions at source through equipment and piping changes. The case study presented reveals that by substituting emission prone components by inherently low-leaking ones, the plant emissions can be reduced over 90% in practice. This is created mainly by replacing rising stem valves with ball valves, installing double mechanical pump seals or hermetic pumps and making changes in sampling and relief systems. Ideally by also changing flanges to welded connections, which is not viable for various reasons, the emissions could be reduced nearly to zero.     

含环向裂纹管道三通的塑性失效载荷

采用弹塑性有限元方法，系统分析了内压载荷下含环向裂纹管道三通的塑性失效载荷。探讨了管道三通塑性失效有限元分析中的建模技术，包括变形参量选取，网格收敛性研究等。给出了塑性失效载荷随裂纹尺寸变化的规律，以及不同裂纹位置(包括肩部和腹部)对三通塑性失效载荷的影响。最后根据有限元数值解建立了简单的塑性失效载荷估算式，研究结果可为下一步含缺陷管件完整性评定提供参考数据。     

Impact of flood water on the technical condition of natural gas transmission pipeline valves

Maintaining the reliability of a transmission system's operation is an extremely important issue in the context of ensuring the continuity of gas delivery to customers. Threats to maintaining the reliability of a transmission system's operation may appear at any stage of transmission, and the most common reasons for this are corrosion, material defects or accidental damage. The paper presents the impact of flood water on transmission valves in the context of possible threats to ensuring the technical safety of gas supplies. Hazards are described which relate to the chemical composition of flood water, which may cause corrosion of valve elements and risk of loss of gas pipeline stability caused by flooding. In the context of the design of a natural gas transmission network, the strength aspects and the phenomenon of corrosion are described. The results of tests related to a specific example are presented. The finite element method (FEM) is used to build ball valve models. Two types of valves are modelled for nominal pipeline diameters of 50 mm (DN50) and 200 mm (DN200). The results of the presented analysis show that the leak tightness of the tested valve flange connections was mainly influenced by changes in their operating conditions because the occurring additional forces and moments caused significant changes in the load balance of the flange connections.     

Rating accident models and investigation methodologies

This is a report of research to identify, rate, and rank accident models and accident investigation methodologies. Models and methodologies used in 17 selected government agencies were examined. The examination disclosed 14 accident models and 17 different accident investigation methodologies in those agencies. To determine their relative merit, evaluation criteria and a rating scheme were developed from user data, statutes, applications, and work products, and each model and methodology was rated. The ratings indicated significant differences in their relative merit. The highest rated model and methodology were tested to determine if the estimated ratings were supported by observable differences in actual performance and to compare investigative results against previously reported cases. Differences found prompted further examination of the benefits and problems that would result from implementation of the preferred model and methodology. Additional exploration of comparative performance measurement techniques disclosed further differences affecting the selection decisions. The models, methodologies, criteria, ratings, rankings, test results, and initial measurement findings are summarized in this report. Issues ranging from oversimplification to ethical questions were discovered during this work. The findings strongly suggest that significant accident investigation program changes should be considered in agencies and organizations using lower-ranked accident models or investigation methodologies and that a compelling need exists for more exhaustive research into accident model and accident investigation methodology selection decisions.     

基于RBI的碳五石油树脂装置风险评估分析

从技术特点、实施效用等方面,对QRA与RBI两类风险评估技术进行比较,选择使用RBI技术方法对碳五石油树脂装置内静设备及管道实施风险评估。运用挪威船级社的ORBIT Onshore软件定量计算评估范围内设备、管道风险值,评定风险等级,辨识隐患设备,然后从后果、可能性两方面分析产生风险的主要影响因素,经分析得知碳五石油树脂装置受H2S、HCl腐蚀减薄影响轻微,但NaOH导致的碱应力腐蚀对聚合反应后序工段中部分管道设备失效可能性影响较大。最后根据装置内存在的不同损伤机理提出检验优化策略,为装置定期检验工作提供科学的决策支持。     

Torque Production Using Handwheels of Different Size During a Simulated Valve Operation Task

Opening and closing valves in industrial facilities often requires operators to use bars and wrenches as levers (cheaters) in order to overcome initial actuation forces. In order to determine more appropriate operational specifications, the maximum torque production capability was measured when 12 male participants used 4 different valve handwheels at 3 different heights and 2 different angles (in relationship to the coronal plane). The results indicate that the participants produced significantly greater torque when the largest of the 4 wheels (40.6 cm diameter) was used than when the medium (22.9 cm), small (20.3 cm), and handled (17.8 cm) handwheels were used. Although the main effect of heights was found to be statistically significant, post-hoc analyses between the heights found them to be, essentially, equal. In addition, the vertical and horizontal wheel orientations were not found to be different. The results are applicable to all industries where handwheels are used and applicable to valve manufacturers for designing operational torque specifications below the values found in this study.     

Application of risk based inspection in refinery and processing piping

In refineries and processing plants, the enormous amount of piping is more complex in distribution than other types of equipment. In general, compared with other types of equipment in these industries, more difficulty in inspection planning is encountered.

However, under-inspection or over-inspection can occur due to the lack of jurisdictional requirements on the inspection interval and method for piping, or the inspection interval being based only on piping service classifications in the existing regulations, such as API 570. This can result in unacceptable risks, along with costly loss of resources.

To lessen the piping risk level, more and more companies have adopted and applied risk based inspection (RBI) methodology, leading to risk reduction and cost benefits since the last decade. This study applied RBI methodology to optimize the inspection strategy of the piping in a refinery and petrochemical plants in Taiwan. Two actual case studies were corroborated better with quantitative RBI methodology than without the methodology in terms of risk and cost reductions.