Fires and Explosions: What You Need to Know to Prevent Them

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1 Fires and Explosions: What You Need to Know to Prevent Them CSChE PSM Symposium Edmonton, Alberta 2007 Gerry Phillips, GC Phillips Consulting Ltd. Norman Nibber, Independent Risk Control

2 Objectives Understand Characteristics of Flammable Liquids & Vapours Effect of Temperature and Pressure on flammability Effect of Inert Substances on fires Ignition Hazards Practical knowledge required to prevent Process Fires

3 What is a Fire? Fire is a Chemical Reaction Fuel reacts with oxidizers Produces, heat, light, products of combustion CH4 + 2O2 => CO2 + 2H2O

4 Understand What Burns! What Burns Solids, Liquids or Vapours (Gases)? Only Vapours (Gases) Burn! Solids and Liquids have to be converted to vapours before they burn.

5 Conditions of a Fire It s not a simple triangle but a Fire Pyramid: Combustible Material, Oxygen, Heat or Source of Ignition and Free Radicals Ignition source needed until fire is selfsustaining: Very quick for vapors More time for Liquids & Solids Duration & temperature of ignition source are important

6 Compressor Building Fire Hazards

7 Flammability Parameters No single parameter defines flammability, but the major ones that influence it are: Flash Point Flammable Range Auto Ignition Temperature Minimum Ignition Energy

8 Flash Point Flash Point is the minimum temperature at which a liquid gives off vapor in sufficient concentration to form an ignitable mixture with air near the surface of the liquid Note that published values are for pure components, under laboratory conditions Example

9 Flammable Liquids Storage Cabinet

10 Use of Adsorbent Pads

11 Collecting Oil Leaks

12 Flammable Materials Classification

13 Compressed Liquefied Gases & Cryogenic Combustibles Compressed Liquefied Gases Flammable Gases stored above their normal boiling point but kept in liquid state by pressure. When released, liquid expands and vaporizes, creating large volumes of cold gas The cold gas behaves like a heavier-than-air gas Cryogenic Flammable Liquid Cryogenic liquids are generally below -101 C Behave like flammable liquids when spilled Liquid absorbs heat & vaporizes forming ignitable mixture Which is the worst fire hazard?

14 Location of Equipment

15 Excellent Fire Protection

16 Passive Protection?

17 Flammable Materials Classification

18 Nitrogen Pad on Storage Tank

19 Nitrogen Pad Supply Trapped leg

20 Methanol Storage Tank

21 Tanks Suck!

22 Flammable Materials Classification

23 What is the problem here?

24 Whoops! Lack of understanding of flash point

25 Storing Flammable Materials

26 Combustible Gases Lighter-than-Air Dissipate rapidly in the atmosphere Affect Smaller area than heavier-than-air gases Seldom accumulate to form ignitable mixture at grade - Unless Confirmed or Sub-cooled Heavier-than-Air Fall to grade level when released Dispersed by natural or forced ventilation When heated may behave as a lighter-than-air gas As the gas diffuses into the surrounding air, the density of the mixture approaches that of air. What has this to do with Preventing Process Fires?

27 What is the Hazard? Natural Gas Regulator Vents

28 Natural Gas Regulator

29 Autoignition Temperature AIT The minimum temperature required to initiate or cause selfsustained combustion of a solid, liquid, or gas independently of the heating or heated element. Before anything burns its AIT must be exceeded.

30 Wood Scaffold near Hot Pipe

31 Autoignition Temperatures Autoignition Material Temperature %LFL %UFL C..\..\..\RHA - F i-pentane cpentane Natural Gas Benzene Styrene

32 Effect of Molecular Weight on AIT In air at 101 kpa

33 Effects of Pressure on AIT

34 Oil Soaked Insulation

35 Flammability Relationships UR E AUTO IGNITION FLAMMABLE REGION RP RE SS MIST VA PO CONCENTRATION OF FUEL UFL LFL FLASH POINT AIT TEMPERATURE

36 NATURAL GAS, volume-percent Effect of Pressure on Flammability of Natural Gas in Air at 28oC Flammable mixtures Increasing Pressure: - Reduces LFL Somewhat - Increases UFL Considerably - Reduces Flash Point & AIT - Increases Maximum Attainable Pressure - Increase Rate of Pressure Rise Pressure, Atm.

37 Flammability of Ethylene in Nitrogen

38 Flammability of Pentane in Nitrogen Minimum Oxygen Concentration

39 Sources of Ignition Electrical Ignition Sources Hot Equipment or Piping Mechanical Heat Energy Chemical Heat Energy Heat of Compression

40 Explosion Proof Panel

41 Electrical Equipment Joint

42 Electrical Seal What is it?

43 Storage in an Electrical Room

44 Sources of Ignition Electrical Ignition Sources Hot Equipment or Piping Mechanical Heat Energy Chemical Heat Energy Heat of Compression

45 Providing the Match

46 Sources of Ignition Electrical Ignition Sources Hot Equipment or Piping Mechanical Heat Energy Chemical Heat Energy Heat of Compression

47 Belgian Pipeline Explosion

48 Sources of Ignition Electrical Ignition Sources Hot Equipment or Piping Mechanical Heat Energy Chemical Heat Energy Heat of Compression

49 Pyrophoric Catalyst Storage

50 Special Hazardous Chemicals Hydrogen Natural Gas Pyrophorics

51 Battery Room Explosion

52 Explosion Theory Objectives Be aware of conditions required for gas and dust explosions Understand the types of explosions and their effects Understand how various properties affect explosion potential. Be aware of methods to prevent and protect against explosions

53 Ignition Energies Material Min Ignition Energy Propane/Oxygen mj 0.02 Hydrogen/Air Hydrocarbon/Air Corn Starch

54 Ignition Energy Sources Energy Source Spark Plug Person with Rubber Soled Shoes Person with Rubber Soled Shoes on a Carpet Energy Potential (mj)

55 Effects of Stoichiometry on MIE

56 Classes of Explosions Loss of Containment Deflagration Detonation BLEVE UVCE

57 Effects of Material Properties on Gas/Vapour Explosions Flammable Range Minimum Ignition Energy Heat of Combustion Burning Velocity Rate of Pressure Rise

58 Maximum Flame Speed

59 Effects of Material Properties on Dust Explosions Minimum Explosible Concentration Particle Size vs. MIE Particle Size vs. Reaction Rate Moisture Content

60 Dust Explosion Pentagon Fuel Dispersion Oxygen Confinement Ignition

61 Minimum Ignition Energy vs. Particle Size Cellulose Acetate

62 Effects of Process Variables on Unvented Vessels Temperature Initial Pressure Turbulence

63 Effect of Temperature on Maximum Explosion Pressure for 5% Propane High Initial temperature lower Density

64 Effect of Temperature on Maximum Pressure Rise for 5% Propane High Initial temperature less energy needed to get to AIT

65 Effect of Initial Pressure on Maximum Explosion Pressure for 5% Propane

66 Rate of Explosion Pressure Rise vs. Turbulence Increase Turbulence increase convective heat transfer and reaction increase energy release rate

67 Explosion Prevention Ventilation Inert Gas Blanketing / Purging Grounding & Bonding Flame Arresters Control of electric equipment Plant Layout

68 Ventilation of Analyzer Room

69 Differential Pressure

70 Hydrocarbon Detection

71 What Could Have Caused this!

72 Small Bore Piping

73 A Failed Small Bore Fitting

74 Explosion Prevention Ventilation Inert Gas Blanketing / Purging Grounding & Bonding Flame Arresters Control of electric equipment Plant Layout

75

76

77 Ethanol Tank Fire

78 Explosion Prevention Ventilation Inert Gas Blanketing / Purging Grounding & Bonding Flame Arresters Control of electric equipment Plant Layout

79 Fire/Explosion Prevention?

80 Grounding Cables

81 Explosion Prevention Ventilation Inert Gas Blanketing / Purging Grounding & Bonding Flame Arresters Control of electric equipment Plant Layout

82 Flame Arresting Trash Container

83 Explosion Prevention Ventilation Inert Gas Blanketing / Purging Grounding & Bonding Flame Arresters Control of electric equipment Plant Layout

84 Loss of Electrical Integrity

85 Explosion Prevention Ventilation Inert Gas Blanketing / Purging Grounding & Bonding Flame Arresters Control of electric equipment Plant Layout

86 Furnaces CG Quench Demethanizer Caustic Wash Compressor Deethanizers Refrigeration C2 Splitter Compressors Offspec CG Dryers & Expander Chilling AC Reactors Expanders Control Building Waste Water Amine Coproducts Product Storage

87 Explosion Protection Venting Suppression Building Construction Building Location

88 What was lacking here? Designed Explosion Relief Panels

89 Reference Material

90 Knowledge Base

91 Books and Journals A High price has been paid for this information: people killed and billions of dollars worth of equipment destroyed. We get this information for the price of the book. It will be the best bargain ever made, if we use this information to prevent a similar incident Trevor Kletz from his book What went Wrong?

92 Fires and Explosions: What You Need to Know to Prevent Them CSChE PSM Symposium Edmonton, Alberta 2007 Gerry Phillips, GC Phillips Consulting Ltd. Norman Nibber, Independent Risk Control

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