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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