On the non-monotonic wind influence on flammable gas cloud from CFD simulations for hazardous area classification

Hazardous areas are defined as a result of a variety of variables as storage temperature, pressure, leak orifice size, physical properties of flammable substance, and wind characteristics. The potential formation of an explosive atmosphere must be accurately assessed to ensure process safety. Therefore, computational fluid dynamics (CFD) arises as an important tool for accurate predictions as recommended by the international standard IEC 60079-10-1 (2015). This study aims to analyze the influence of wind velocity magnitude and direction on the hazardous area classification. The authors evaluated the extent and volume for methane, propane, and hydrogen leakages from a CFD model. For each flammable gas, the wind velocity magnitude and direction were regularly varied. The outcomes show that the behavior of the plume size as the wind varies mainly depends on the gas concentration. Counter-flow wind directions lead to zero relative velocity closer to the release point, which concentrates the gas, and wind in the release direction promotes a higher dilution of the gas cloud increasing the hazardous extent while decreases the volume. As a consequence, the wind also influences the zone type, which was accurately predicted from CFD simulations and significant differences were found when compared to the standard analyses. These differences are, to some extent, related to the consideration of wind velocity effects on the gas jet release.     

Ventilation theory and dispersion modelling applied to hazardous area classification

Critical formulae given in the current Explosive Atmospheres Hazardous Area Classification Standard IEC 60079-10-1 (2008) [BS EN 60079-10-1, 2009] to determine the expected gas cloud volume which is used to determine area classification do not have any scientific justification. The standard does allow the alternative use of Computational Fluid Dynamics (CFD) methods, which serve to compound the concern with these formulae: the predicted volume of the gas cloud from CFD models being several orders of magnitude smaller than that given by the formulae in question. To resolve such major discrepancies, replacement of the current formulae with a scientifically validated approach is proposed. Integral models of dispersion and ventilation have been used routinely for many years in the analysis of major hazards in the chemical industry. This paper presents an adaptation of these models to determine the expected volume of a gas cloud arising from a release of gas from a pressurised source. A very simple integral jet model is presented for outdoor dispersion, extended to the case of indoor dispersion, from which the volume of the gas cloud is derived. The single free parameter, an entrainment coefficient, is fixed by comparison with data on a free jet, and then predictions of the model are compared with CFD calculations (which themselves have been validated against experimental data) for dispersion within an enclosed volume. The results of this simple integral model are seen to agree very well with the CFD predictions. The methodology presented here is therefore proposed as a scientifically validated approach to Hazardous Area Classification.     

Laminar jet modelling for hazardous area classification

A previous article dealt with turbulent jet flow modelling with the aim at developing a method for estimating the size of explosive clouds following a high Reynolds number release, within hazardous area classification scheme. The results have demonstrated that the standard EN 60079-10 (2009) largely overestimates the real size of clouds resulting from a piping or a vessel leak. On the other hand, laminar jets are possible also at moderately high Reynolds numbers; furthermore, a reduced momentum, typical of laminar jets, is often assumed in QRA studies, as a conservative assumption, due to the expected lower air entrainment and to the corresponding larger size of the flammable cloud volume. These considerations have suggested the suitability to extend the previous analysis also to laminar regime, taking into account the effect of density and viscosity differences between air and flammable gas.     

Turbulent jet modelling for hazardous area classification

Hazardous area classification, as per EN 60079-10, is based on the explosive gas volume of the clouds in which the average gas concentration is related to the Low Explosion Limit (LEL). The higher Reynolds number, the less this approach is valid, because of the development of a concentration gradient due to the momentum driven flow. The resulting areas and volumes may be overestimated by two or three orders of magnitude, which is often critical in equipment design and selection. This paper proposes and technically justifies an overview of turbulent jet flow modelling, with the aim at developing a more realistic calculation method of the hazardous areas, within the ATEX approach.     

Emissions of volatile hydrocarbons from floating roof tanks and their local dispersion: Considerations for normal operation and in case of damage

This work investigates the release and dispersion of volatile organic hydrocarbons, which may escape from external floating roof tanks (EFRT) during normal operation or in case of damage. The dispersion will be described using CFD simulations in close range of the EFRT where hazardous areas are assigned. The aim of this work is to investigate which events can lead to emissions in dangerous quantities and to estimate the corresponding likelihood with regard to explosion protection. An emission in hazardous amount is present if the lower explosion limit has been exceeded and if the extent of this emission is not too low. It is discussed in particular whether the used zoning of potentially explosive areas is conservative or over-conservative.     

Comparison of explosion parameters for Methane–Air mixture in different cylindrical flameproof enclosures

Flameproof enclosures having internal electrical components are generally used in classified hazardous areas such as underground coalmines, refineries and places where explosive gas atmosphere may be formed. Flameproof enclosure can withstand the pressure developed during an internal explosion of an explosive mixture due to electrical arc, spark or hot surface of internal electrical components. The internal electrical component of a flameproof enclosure can form ignition source and also work as an obstacle in the explosion wave propagation. The ignition source position and obstacle in a flameproof enclosure have significant effect on explosion pressure development and rate of explosion pressure rise. To study this effect three cylindrical flameproof enclosures with different diameters and heights are chosen to perform the experiment. The explosive mixture used for the experiment is stoichiometric composition of methane in air at normal atmospheric pressure and temperature.It is observed that the development of maximum explosion pressure (P_max) and maximum rate of explosion pressure rise (dp/dt)_ex in a cylindrical flameproof enclosure are influenced by the position of ignition source, presence of internal metal or non-metal obstacles (component). The severity index, K_G is also calculated for the cylindrical enclosures and found that it is influenced by position of ignition source as well as blockage ratios (BR) of the obstacles in the enclosures.     

Analysis of gas dispersion and ventilation within a comprehensive CAD model of an offshore platform via computational fluid dynamics

Maintaining an adequate air flow with a desired air quality that is free from hazardous gases is among the most important actions taken toward the improvement of safety in any process plant. Due to the increased focus on the consequences of existing hazardous material on safety, health, and the environment, air quality and sufficient ventilation within a plant has been increasingly considered in the design stage. This paper investigates and analyzes methane and hydrogen sulfite dispersion and the effect of air ventilation within a CAD model of an offshore platform using computation fluids dynamics (CFD). In addition, this method and its principals could be utilized in any other hazardous environment. Simulations of possible hazardous events along with solutions for preventing or reducing their probability are presented to better assess the data. These investigations are performed by considering hypothetical hazardous scenarios which consist of gas leakages from pipes and process equipment under different conditions. After drafting a precise and highly detailed CAD model of the plant and performing CFD simulations on this model, the results of gas behaviors, dispersion, distribution, accumulation, and its possible hazards are investigated and analyzed. The larger amount of details of the actual plant model in CFD simulation are obtained by using a combination of different methods and software. These include PDMS for 3-D drawing of the plan, Rinoceros for geometrical integration of the process equipment and facilities, and Sharc Harpoon which meshes the model. Moreover, the probability of inducing ignitable or toxic concentration of gases within the atmosphere and air ventilation of the unit is considered by these investigations.     

A new simple methodology for evaluation of explosion risk in underground coal mines

The key objective of this paper is the presentation of a new risk assessment tool for underground coal mines based on a simplified semi-quantitative estimation and assessment method.In order to determine the risk of explosion of any work process or activity in underground coal mines it is necessary to assess the risk. The proposed method is based on a Risk Index obtained as a product of three factors: frequency of each individual scenario P_ucm, associated severity consequences C_ucm and exposure time to explosive atmospheres E_ucm. The influence of exposure time is usually not taken into account up to now. Moreover, the exposure to explosive atmospheres may affect factors of hazardous event probability as much as its consequences. There are many definitions of exposure to explosive atmospheres but in the case of underground coal mines the exposure is defined as frequency risk of firedamp and coal dust. The risk estimation and risk assessment are based on the developed of a risk matrix.The proposed methodology allows not only the estimation of the explosion risk but also gives an approach to decide if the proposal investment is well-justified or not in order to improve safety.     

Charge-separating processes by spraying water under high pressure

Spraying water under high pressure generates charge-separating processes. While cleaning tanks and vessels in which an explosive atmosphere is present, an explosion may occur in the event of a resulting discharge. Water forms electrical double layers at the phase boundaries. Mechanical separation processes dissolve the water into many drops. This leads to charge separation and the charging of the sprayed water. The mechanical separation processes include water exiting from the nozzle, hydrodynamic instability in the jet and impact with an obstacle. Given that water has many charge carriers, the charge is stronger than with solvents. Whether the charges and the resulting discharges are potentially capable of igniting an explosive atmosphere must be investigated. The aim of this research is to define the quantity and polarity of the electrostatic charges of sprayed water under high pressure. Different measurement techniques and methods are used to enable mutual validation and to generate verified measurement results of the electric field and the potential. Water of different electrical conductivity is sprayed in free space and into a grounded conductive 1 m³ vessel. Design changes to the vessel allow centric or oblique spraying. The result is intended to extend the scope of application of the German regulation TRGS 727 and the international IEC TS 60079-32-1, which refer to ignition hazards due to electrostatic charging. This project is funded by the DGUV (German Social Accident Insurance) and partners from industry.     

Concentration model for gas releases in buildings and the mitigation effect

In case of accidents involving releases of hazardous materials, calculating the gas dispersion is essential for assessing risks. In general, the leaked chemical is assumed to be instantly dispersed to the atmosphere if the leak occurs in the outdoor location. However, a different approach should be made for the incidents when sources are located inside a building. For the indoor release, the gas will be diluted prior to the release to the atmosphere and the gas release from a building to the atmosphere demands the application of another model before the dispersion calculation. The indoor release model calculates average indoor concentration and volumetric flowrate to the exterior. The model is fast and reasonably accurate compared to rigorous but time-consuming computational fluid dynamics (CFD) models. The model results were compared with experimental data, and CFD simulation results both with simple geometry to demonstrate validation and assess the performance of the indoor release model. Lastly, the behavior and effect of mitigation of indoor release were demonstrated by using the model results.     

Ignitability assessment of shredder dusts of refrigerator and the prevention of the dust explosion

Explosibility of polyurethane dusts produced in the recycling process of refrigerator and the ways to prevent the dust explosion were studied. In recent years, cyclopentane is often used as the foaming agent and this produces explosive atmosphere in the shredding process. The minimum explosive concentration of polyurethane dust, influence of coexisting cyclopentane gas on the explosibility, effect of relative humidity on the minimum explosive concentration of polyurethane dusts, the minimum ignition energy, influence of cyclopentane mixture on the explosion severity, etc. were investigated.The minimum explosive dust concentration decreased with the increase of cyclopentane concentration and increased with the increase of relative humidity. The minimum ignition energy was about 11 mJ. The ignition energy decreased with the increase of the cyclopentane gas concentration. The cyclopentane gas concentration up to about 5300 ppm did not influence too much on the explosion index (K_st) and maximum explosion pressure. From these, it would be a good way to increase the relative humidity and to regulate the cyclopentane concentration in the shredding process to prevent the dust explosion hazard.     

Thermal hazard analysis of triacetone triperoxide (TATP) by DSC and GC/MS

Thermal degradation of triacetone triperoxide (TATP) was studied using differential scanning calorimetry (DSC) and gas chromatography/mass spectrometry (GC/MS). TATP, a potential explosive material, is powerful organic peroxide (OP) that can be synthesized by available chemicals, such as acetone and hydrogen peroxide in the laboratory or industries. The thermokinetic parameters, such as exothermic onset temperature (T₀) and heat of decomposition (ΔH_d), were determined by DSC tests. The gas products from thermal degradation of TATP were identified using GC/MS technique.In this study, H₂O₂ was mixed with propanone (acetone) and H₂SO₄ catalysis that produced TATP. The T₀ of TATP was determined to be 40 °C and E_a was calculated to be 65 kJ/mol. A thermal decomposition peak of H₂O₂ was analyzed by DSC and two thermal decomposition peaks of H₂O₂/propanone were determined. Therefore, H₂O₂/propanone mixture was applied to mix acid that was discovered a thermal decomposition peak (as TATP) in this study. According to risk assessment and analysis methodologies, risk assessment of TATP for the environmental and human safety issue was evaluated as 2-level of hazard probability rating (P) and 6-level of severity of consequences ratings (S). Therefore, the result of risk assessment is 12-point and was evaluated as “Undesirable” that should be enforced the effect of control method to reduce the risk.     

CFD方法对突发性化学事故中危险物质泄漏范围的确定

简要分析了目前国内主要用于预测易燃易爆(有毒)物质发生泄漏事故后浓度扩散范围的计算方法。并介绍了国际上比较成熟的计算流体力学相关软件的数学模型及特点和边界条件的设置。针对液氨发生泄漏后氨气在一定大气环境条件下扩散的过程和特征,建立了相应的数学模型并设置了边界条件,通过数值计算得到氨气在水平方向风速环境下在三维空间内浓度分布规律。通过分析氨气扩散后爆炸浓度下限范围,探讨了如何设置警戒区的方法。最后分析了将计算流体力学方法应用于确定易燃易爆(有毒)物质泄漏后浓度范围的前景与不足。     

Dust Emission and Efficiency of Local Exhaust Ventilation During Cast Iron Grinding

A method of determining dust emission and efficiency of its removal by means of local exhaust ventilation from machinery has been described. It complies with Standard No. EN 1093-3:1996 (European Committee for Standardization, 1996) and consists in determining air pollution concentra-tions in the measurement duct used for air removal from the chamber incorporating devices to be tested. The air volume stream that is pumped is measured at the same time.

Test results are presented for dust emission and the efficiency of local exhaust ventilation for cast iron grinding by means of manual power tools and a bench-sander. It has been found that application of local exhaust ventilation contributes to a significant reduction of dust emission with efficiency greater than 90%.     

A case study: An explosion in a milk spray dryer,CAPSA, NW Spain

European Standard EN 14491 (2006): “Dust explosion venting protective systems”, based on German Standard VDI 3673 (2002): “Pressure venting of dust explosions”, Verein Deustcher Ingenieure, specifies the basic design requirements for the selection of dust explosion venting protection systems.In this study an investigation into the efficiency of venting surfaces in accordance with Standard EN 14491 has been undertaken to check the validation of the same. Thus, the application of the standard to an actual case of an explosion in a milk spray dryer has been studied, taking into consideration the explosive characteristics of products treated in this type of installation and their venting requirements.The results obtained indicate that, in specific situations – such as the effects of turbulence, particularly in the cone, or dust layer self-ignition – the European Standard could underestimate the venting surface requirements needed to alleviate possible excess internal pressure in order to avoid injury or structural damage to spray dryers.     

Consequence analysis of an open fire incident in a pesticide storage plant

This paper deals with the consequence assessment of an open fire incident in a Pesticides Storage Facility. Consequences are mainly caused by the atmospheric dispersion of toxic substances produced during the fire and transported downwind to considerable distance. An integrated methodology, based on Computational fluid Dynamics (CFD) techniques and the dimensionless buoyancy flux number, F/U³L, a parameter that can be associated with the flow characteristics, taking advantage of the dynamic similarity of the flow domain, is presented and used for the simulation of the plume dispersion.Rise to the present study gave a real incident, which happened in northern Greece in the beginning of 2004 and constituted the basis for the development of the accident scenarios eventually studied. Owing to the uncertainty in the estimation of source term strength and specifically of the magnitude of the heat released during the incident together with the variation in wind velocity, a parameterization of these two quantities has been applied. Four typical accident scenarios have been designed and studied.It is concluded that the proposed methodology allows for the calculation of the ground level concentration of any non-reactive substance dispersed in the atmosphere and constitutes a complementary approach in the consequence analysis of accidents in agrochemical (pesticides) plants.     

室内丙烷连续泄漏扩散浓度变化的数值模拟

探究室内气体燃料泄漏后的扩散特性及危害范围的影响,采用CFD软件FLUENT对室内丙烷连续泄漏扩散浓度变化过程进行数值模拟,研究丙烷的浓度场分布和爆炸浓度范围的变化规律。结果表明:水平射流运动和重力对气体的扩散有显著的影响;墙壁对气体的扩散有阻碍作用,在近壁面处形成高浓度区域;爆炸危险区随泄漏时间的增加而先增大后减小。