Hazards from Process Infrastructure Systems
Douglas J Ferguson, PE – Consultant - DuET Process Safety & Fire Protection
Mary Kay O’Connor Process Safety Center -2007 International Symposium October 23-24, 2007
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What If What If ……??Process Infrastructure Systems
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Douglas Ferguson, PEDuPont Engineering TechnologyConsultant - Process Safety and Risk Analysis
Education: BSME - University of Texas – 1967PE License: 2004
Experience: 39 years DuPont experience, 17 years in PSM & Process Hazards Analysis. 6 years teaching - 5-Day PHA Leader Training course
Process Infrastructure Systems
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Process Infrastructure Systems
• PROCESS vs. INFRASTRUCTURE FACILITIES HAZARDS
• DEGREE OF ANALYSIS
• LOWER RISK, AND ACCEPTED AS “COMMON OR NORMAL” HAZARDS
• SAFETY BENEFIT FOR SERVICE FACILITIES USING IN-DEPTH CONSEQUENCE ANALYSIS
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Process Infrastructure Systems
COMMON OPERATIONS
• LPG Systems• Cryogenic Systems (N2, Argon, CO2)• Steam Generation (Boilers)• Compressed Gas Systems• Natural Gas (High / Low Pressure)
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Process Infrastructure SystemsPOTENTIAL HAZARDOUS INCIDENTS
• BLEVE/ Fireball• Vapor Cloud Explosion• Confined Space Explosion• Flash Fires/ Jet Fires• Asphyxiation• Cryogenic Temperatures• Overpressure/ Vessel Rupture
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Process Infrastructure Systems
POTENTIAL AREAS OF IMPACT
• Facility Siting Concerns
• “Knock-On” Effects on ProcessFacilities
• “Knock-On” Effects on Other ServiceFacilities
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Process Infrastructure Systems
LPG SYSTEMS
• Fire and flash fire
• Flammable vapor cloud- Unconfined- Confined/ Congested Areas
• BLEVE/ Fireball
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Process Infrastructure SystemsLPG SYSTEMS - BLEVE
Propane BLEVE Data
0
50
100
150
200
250
10 psi 5 psi 2 psi
Overpressure, psi
Dis
tanc
e, F
t
500 Gal
1000 Gal
2000 Gal
4000 Gal
6000 Gal
8000 Gal
10000 Gal
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Process Infrastructure SystemsLPG SYSTEMS – BLEVE Fireball
Propane Fireball - 12 Kw/m2
300
400
500
600
700
800
900
1000
500 1000 2000 4000 6000 8000 10000
Propane Tank Volume
Dis
tanc
e, F
t
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Process Infrastructure SystemsLPG SYSTEMS – Vapor Cloud
• Dispersion for various size leaks
• Model to ½ LFL• Determine if cloud reaches confined
or congested areas• Model area to determine explosion
overpressure/ impulse• No confinement – flash fire/ thermal
burns
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Process Infrastructure SystemsLPG SYSTEMS – Vapor Cloud
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Process Infrastructure SystemsLPG SYSTEMS – Vapor Cloud
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Process Infrastructure SystemsLPG – Falk Plant Milwaukee 12/6/2006 – 3 killed, 46 injured - http://www.jsonline.com/story/index.aspx?id=538906
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Process Infrastructure Systems
CRYOGENIC SYSTEMS
• Asphyxiation concerns- Tank failures/ large leaks- Leak into confined space
• Cryogenic burns to exposed skin
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Process Infrastructure SystemsCRYOGENIC SYSTEMS
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Process Infrastructure Systems
BOILERS – Steam Generation
• Fuel supply leaks – natural gasor propane
- Flash fires- Confined/ congested space
explosion• Fire chamber – fuel rich explosion• Steam drum (water side) BLEVE
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Process Infrastructure Systems
COMPRESSED GAS SYSTEMS
• Primarily vessel overpressure concerns- Compressor overpressure- Relief failure- Tank degradation
• Impact on personnel adjacent equipment- Shrapnel- Overpressures
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Process Infrastructure SystemsCOMPRESSED GAS SYSTEMS
2 .0 - D a ta E n try - T a rg e t In fo rm a t io n
T a rg e t D e sc r ip tio n
D ista n c e F ro m B la st
C e n te rD ista n c e
U n i ts
D ista n c e to 1 0 p si 3 4 .5
D ista n c e to 5 .0 p si 5 0 .7
D ista n c e to 2 .5 p si 7 7 .7
D ista n c e to 1 .5 p si 1 0 8 .9
D ista n c e to 1 .0 p si 1 4 5 .0
f t
C le a r
B a c k
H e lp
N e x t
1000 FT3 – 150 PSI Vessel
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Process Infrastructure Systems
HI/ LO PRESSURE NATURAL GAS
• Flammable gas cloud• High pressure (& may not be odorized)• Flash fire• Confined/ congested Areas (especially
low pressure gas)• Radiation
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Process Infrastructure SystemsNATURAL GAS SYSTEMS
20” Diam. – 850 psig
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Process Infrastructure SystemsNATURAL GAS SYSTEMS 1.5” Diam. – 55 psig – Low wind speed
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Process Infrastructure SystemsNATURAL GAS SYSTEMS 1.5” Diam. – 55 psig – high wind speed
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Process Infrastructure SystemsNATURAL GAS SYSTEMS
Natural gas leak inside building
Outputs
Expanded Volume of Burned Gasses (VE) = 61033 cu ft
Volume of Cloud Before Combustion (Vc) = 683.31 cu ft
Volume of Vapor in Flammable Cloud = 64.91 cu ft
Minimum Release to Create Damage = 2.666 lbs
H = 15 ft.
W = 50 ft.
L = 75 ft. Vb = 56250 cu ft
Enter building dimensions on this form.
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Process Infrastructure SystemsISP CONCEPTS
• Minimum Inventories• Storage/ Operation at Lowest Possible
Pressures• Vessel Design for Largest Credible
Overpressures • Locate to Minimize Facility Siting and
“Knock On” Effects • Piping - Minimize Flanges/ Welded
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Process Infrastructure SystemsSUMMARY
• Lower Risk, accepted as “common or normal” hazards
• Quantitative Consequence Analysis• Facility Siting Considerations• Apply ISP Principles and Concepts• Safer and More Robust Service Facilities
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