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Lessons Learned from a Catastrophic BLEVE Accident in China

Lessons Learned from a Catastrophic BLEVE Accident in China

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第四届ccps中国过程安全会议

作者： Wang Yu Yi Liu China University of petroleum Center for SafetyEnvironmental & Energy Conservation Technology China University of petroleum

On July 16, 2015, a sphere vessel made a fire which contained liquefied petroleum gas about 900m3 at Shandong Star Science and Technology Petrochemical Co., Ltd. in Rizhao of China. The fireball exploded two liquefied hydrocarbon tanks and destroyed two other vessels. The explosion injured two firemen and caused at least 28.12 million yuan of direct losses. This paper summarizes the lessons drawn from this incident both of causal and consequential aspects. Emphasizing human factor and fire hazard were identified as the accident cause by the government of China. After analyzing the operating conditions and the aftermath, this incident has been recognized as a Boiling Liquid Expanding Vapor Explosion(BLEVE) under a fire hazard. Simultaneously, additional safety-related problems, such as safety culture, management of the corporation, and state supervision are discussed.

关键词： Explode BLEVE Management Case study Lessons

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An integrated method for process monitoring and fault mode identification based on PCA and SVDD

An integrated method for process monitoring and fault mode i...

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第四届ccps中国过程安全会议

作者： Xi Ma Jinqiu Hu Laibin Zhang Jing Luo Department of Mechanical & Storage and Transportation Engineering China University of Petroleum-Beijing

Due to equipment degradation and process disturbance, it is impossible to avoid abnormal situation and malfunction in petrochemical process. Especially for complex process, in most cases, the changes of different measured variables seem similar among different fault modes. Operators tend to make inappropriate decisions when they are not able to recognize the exact alarm reasons, thus leading to that the process runs in abnormal situation until root causes are found. PCA(Principal Component Analysis) is used to monitor the variable correlation varying with working condition, which can be treated as the indicator of the current situation. PCA is then combined with SVDD(Support Vector Data Description) to optimize the control limits of monitored statistics. Thus, PCA-SVDD models are respectively established for normal situation and different fault modes to achieve process monitoring and fault mode recognition. PCA-SVDD is proposed and tested on several fault modes in TEP(Tennessee Eastman Process). It is illustrated that PCA-SVDD is able to detect incipient fault and recognize the fault mode in real time.

关键词： process monitoring fault mode recognition fault diagnosis PCA SVDD

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nalysis of the contribution to PM2.5 by VOCs in petrochemical plants emissions

nalysis of the contribution to PM2.5 by VOCs in petrochemica...

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第四届ccps中国过程安全会议

作者： Anqi Liu Dongfeng Zhao Shi Li Zhao LIU Chemical College of Chemical Engineering China University of PetroleumQingdao CNPC Safety and Environmental Protection Technology Institute

In recent years, with the speeding up of urbanization and industrialization process, PM problems have become a matter of urgent concern. And the significance of PM particles is also becoming increasingly important. The way that PM particles formed from volatile organic compounds in atmospheric pollutants was studied. The petrochemical plants' production processes that may produce volatile organic compounds and its form and principle were summarized. On this basis, the conclusion that the petrochemical enterprises emissions of volatile organic compounds have certain contribution to the formation of PM particles, and among them, the equipment leak is the most important emission source of volatile organic compounds became clear. At last, VOCs reduction measures were put forward directly, and the reasonable basis for the petrochemical industry PM emissions control were provided. The final goal is to improve atmospheric environment quality, and ultimately reduce PM impact on human health.

关键词： PM2.5 VOCs petrochemical plants control measures

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Domino effect Modelling Considerations for Quantitative Risk Assessment of Offshore installations

Domino effect Modelling Considerations for Quantitative Risk...

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第四届ccps中国过程安全会议

作者： Brian Bain David Worthington Cynthia Spitzenberger Andreas Falck DNV GL

Quantitative Risk Analysis(QRA) remains one of the main tools available to understand risks of activities on offshore installations. The modelling requirements involved with undertaking a QRA are more difficult than most people, even those working within safety engineering, appreciate. Hydrocarbon leaks may lead to domino effects and yet these are often neglected in the analysis because of the additional computational burden. This paper describes a novel process to analyze the risks in a more detailed and structured way than is normally used. It takes account of the consequences of the accident as they exhibit domino effects in which failure of structural elements and other hydrocarbon containing equipment lead to additional inventories contributing to the fire. This has been done in an attempt to calculate risk levels more accurately and in turn provide the industry with a more powerful tool to understand and ultimately manage the risks on an offshore platform. Much of the methodology presented has been utilized in a new software tool which depicts the timeline of the development of the accident in a three-dimensional graphical form with representation of mustering actions which enables insight by a range of stakeholders in a way not possible with conventional approaches.

关键词： Risk Assessment Fires Explosions Gas Dispersion

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A Case Study of Major Accident at a Waste Water Disposal Facility in Korea

A Case Study of Major Accident at a Waste Water Disposal Fac...

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第四届ccps中国过程安全会议

作者： Ji-Pyo Yim Hyung-Sub Lee Dong-Wook Lee Korea Occupational Safety and Health Agency

This is the case of major(industrial) accident happened in one of the process safety management sites in Korea. ‘Major Accident(MA)' is defined in the article 49-2 of the Korea Occupational Safety and Health Act. According to the article, MA is a serious accident caused by fire, explosion, or emission, which is also specified in ILO convention No.174 in the same way. On average, ten cases of MA have been occurred each year in Korea over the past decade. In particular, the year of 2015 had a unique pattern, showing the increases in the accidents in suplimentary facilities and ones caused by subcontractors, rather than ones in manufacturing process itself. The Waste Water Disposal Facility(Pond) accident was a typical example. There was an explosion at the waste water disposal facility(pond) within a PVC Resin manufacturing site at Ulsan, Korea. The explosion resulted in six fatalities and a shutdown of the whole plant with complete destruction of the pond. After this accident, the importance of the safety protocols in a utility(subsidiary) facility of chemical plant were significantly emphasized, which led to the safety inspection and training in all waste water disposal facilities.

关键词： Major Industrial Accidents Explosion Water Waste Disposal Plant

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Two-Phase Flow Emergency Relief System Design for Runaway Reactions:Its Criticality,Complexity,and Practicality

Two-Phase Flow Emergency Relief System Design for Runaway Re...

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第四届ccps中国过程安全会议

作者： Guibing Zhao Cain Wang Dekra Insight

The preferred option to avoid the exothermic runaway reaction hazard is often through inherently safer design. However, this may not be reasonably practical in many situations and for a variety of valid reasons. Under such conditions an appropriately designed emergency relief system（ERS） is often the most commonly accepted and selected measure to protect people, the community, and business from the consequences of an exothermic runaway. Proper design of the ERS is therefore crucial for the effective mitigation of runaway reaction hazards since such a relatively passive protection system functions independently of the main control system, and is expected to provide adequate protection even if all other systems fail. However, designing an adequate ERS for two phase relief is complex and requires extensive knowledge, experience, and data/information in both thermodynamics and reaction kinetics. This is because the engineering design method is quite different for different reaction systems. This paper discusses a number of key issues in practical design of an appropriate ERS for different reaction systems through multiple case studies based on our extensive experience, which includes:（1） Fill ratio issue for tempered reaction system;（2） An issue on gas generation rate test;（3） How to use design method of tempered hybrid reaction system.

关键词： Runaway Reaction Emergency Relief System Design Reaction kinetics

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A Study on Risk Assessment of Hazardous Materials from Industrial Chemical Process in Korea

A Study on Risk Assessment of Hazardous Materials from Indus...

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第四届ccps中国过程安全会议

作者： Ha-Na Jang JaKon Koo Min-Jae Jeong Yong-Chil Seo Dept.of Environmental Engineering Yonsei University

Hazardous materials cause serious adverse effect to human health and public environment with increasing a consumption of chemical materials in industry and a usage of energy by fuel combustion. Those are emitted from diverse anthropogenic emission sources such as large coalfired power plants, waste incinerators, and industrial chemical process to air, water, and land environment as primary pollutants. Those primary pollutants become more serious problem by translating to secondary pollutants, or by transporting between nation border as global pollutants, or concentration to eco-system. In addition, large amounts of hazardous materials are exposed by careless management and explosion accidents in diverse industrial process. Therefore, it would be necessary to develop management system of hazardous materials from industrial process by enactment of related regulations. In this research, various case studies are reviewed to specify development of risk assessment for hazardous materials with focusing industrial chemical facilities in Korea.

关键词： Hazardous material Environmental risk assessment Process safety management

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A comprehensive and practical methodology to assess combustible dust hazards under NFPA 652

A comprehensive and practical methodology to assess combusti...

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第四届ccps中国过程安全会议

作者： Cain Wang Vahid Ebadat DEKRA Insight (Shanghai)-Chilworth technology DEKRA Insight-Chilworth technology

In recent years, Chinese manufacturing companies face more and more safety challenges from risks of combustible dust. After several serious explosions, Chinese government has launched a series of regulations and standards to demand enterprises to control risks of combustible dust. According to Chilworth's communication and cooperation with Chinese enterprises, it is clear that many companies are eager to find a systematic solution to control the hazards as well as to comply with the current codes and regulations, but unfortunately most of the companies do not understand where to start and which methodology should be used to control the risks. This paper introduces a comprehensive practical and systematic methodology to assess combustible hazards under NFPA 652. It not only discusses the procedure of a dust hazard analysis(DHA), critical factors in each step with case studies, but also explains the most common questions about combustible dust from local enterprises.(1) How to select typical samples for DHA(2) How to choose appropriate tests you really need for DHA(3) How to conduct a DHA based on NFPA 652(4) Common safety tools and technologies related to DHA(5) Suggestions for DHA under current Chinese regulations and standards This paper is aimed to help Chinese enterprises to have a clear picture of the most updated hazardous management of combustible dust.

关键词： DHA combustible dust hazard analysis

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Assessment of Fire and Explosion Hazards in Drying Processes——The Role of Experimental Test Data and Thermal Explosion Theory

Assessment of Fire and Explosion Hazards in Drying Processes...

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第四届ccps中国过程安全会议

作者： Guibing Zhao Cain Wang Dekra Insight

Fires and explosions resulting from exothermic decomposition or oxidation of products during drying process are not uncommon. Amongst the 13 different types of ignition sources that can generally be identified(EN1127-1:2007), self-heating(or self-ignition) of combustible powders is a very credible ignition source during drying processes. Self-heating can occur where high temperatures could be present, including in solid accumulations, deposits on internal walls of process equipment, solid chunks agglomerated around spray nozzles, fluidized powder bed, and in product storage. This self-heating causes smoldering material that initiates fire in bulk storage, or fall down into dust cloud or bulk material to initiate a dust explosion and/or fire. To identify fire and explosion hazard, proper tests should be performed to find out the onset temperature for self-heating and critical atmosphere temperature that could lead to self-heating. This paper presents a number of experimental methods to quantify fire and explosion hazards in different actual operating conditions in industrial drying process. These methods include screening tests such as aerated, layer, and bulk powder tests, as well as calorimetry, Dewar, and Basket tests. Since not all testing methods are applicable to all situations, understanding the theories behind these tests are critical for the selection of proper tests that will represent plant conditions. Thermal explosion theories including Semenov Theory and Frank-Kamenetskii Theory and how these theories related to the testing methods are presented.

关键词： Drying process self-heating fire and explosion hazard thermal explosion tests

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Gas Detector Coverage Calculation Using Scenario Coverage of Gaussian Dispersion Models

Gas Detector Coverage Calculation Using Scenario Coverage of...

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第四届ccps中国过程安全会议

作者： Edward M.Marszal Kenexis

In the past few years, the use of quantitative risk analysis tools to determine the required number of location of gas detectors has gotten more attention in the literature and also in real world project execution. While there is great interest in these performance based methods, often referred to as fire and gas mapping, there is little information available on how these types of studies are performed. This paper will provide a discussion of how gas detector coverage, as defined in the ISA 84.00.07 technical report Guidance on the Evaluation of Fire and Gas System Effectiveness is calculated. Specifically, the paper will address the definition of scenario coverage and how it is more accurate and effective than more common, but less sophisticated geographic coverage, because it takes into consideration the actual leak sources and nature of the leak scenarios. The paper will begin with a discussion of the creation of Gaussian dispersion models from a sufficient set of leak sources and leak conditions. These modeling results will then be manipulated to consider multiple release orientations and their relative frequency, along with consideration of wind directions by modifying the relative directional release frequency based on wind direction frequency. Next a discussion of integration of the risk is presented, discussing accumulation release frequency at all geographic positions based release scenarios present in those locations. Coverage calculation is then described as the determination of which scenarios are detectable given the detector locations relative to locations of released gas clouds. Resulting the calculation of coverage as a fraction of detected scenario frequency over total scenario frequency. The paper will then go on to provide an example of how results are typically presented both graphically and in a tabular format. The paper will give an overview of the entire process using a case study of a well bay in an offshore oil production platform.

关键词： Gas Detector Coverage Calculation Using Scenario Coverage of Gaussian Dispersion Models Gaussian

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