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    © All Rights Reserved
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    48 views92 pages

    Perrys Process Safety Section

    Uploaded by

    Roy Mustang
    perrys safety

    Copyright:

    © All Rights Reserved
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    of 92
    Section 26 Stanley M. Englund, MS, Ch.E., Fellow American Institute of Chemical Engineers: Process Consultant, The Dow Chemical Company retired). (Seton Edo, Section 20; Intro- ‘duction; Hacard Analyt; Storage and Hanan of Hazardous Motors, Reactive Chemicals Combustion on Flammability Hazamts, Masards of Vacuun, Hazan of Inert aves) Frank T. Bodurtha, S¢.D., £1. Yond Nemore and Co, Be, (rtived) Comsalant,. Frank T. Bodurta, Ine. (Gas Explosions, Unconfined Vapor Cloud Explains [UVCBs) onl Boiling Liga Esponlng Vopor Explovions [BLEVES) Laurence G. Britton, Ph.D., esearch Scent, Union Carbide Conporaion. (Blane Artery Daniel A. Crowl, Ph.D., Profesor of Chenical Enginering, Chemeal Engineering Department, Michigan Technologia! University, Member, American Institute of Chemical Enginerrs, American Chemical Soeety, (Can Dispersion) Stanley Grossal, Presiden, Prices Softy & Design, Ine Fellas, American Insitute of (Chemical Enginvers, Member, Aserican Chemie Society, Membr, The Combustion Insti Member, Explosion Protection Systems Commit of NFBA, (Emergency Rolf Decce Etat Callection and Handling) W.G. High, C.Eng,, B.Sc, FLMech-E,, Burgoyne Consultants Lad, W: York, England (Guidlines for Eiaring Damage) Trevor A. Kletz, D.Se.,_ Senior Visiting Research Fallow, Department of Chemical Eng neering, Loughborough Unieraty U.K, Fellow, American Institute of Chemical Engineers, Hoya Academy of Engincers (U.K), Institution of Chenteal Engineers (U.K), nd Roy Sot. ty of Chemstry (UK). Innere Safer Design) Robert W. Ormsby, M.S., ChE, Monage of Safty, Chemscals Group, Air Product and Chemeas, Ines Air Products Corp. Felli, Averican Institute of Chere Engineers (Risk Analysis) John E. Owens, BEE, Elecirostatics Consultant, Gondus, Ine: Member, Institute of letical and Electonics Engineers, Elecrstatcs Society of America (Static Electret Corl A. Schioppa, B.S. Chi., Poco EngiseringAsocate, Mlsigan Dison Engh tering” The Dow Chomical Company, Member, AICHE and COPS: (Piet Ravi and Pr colores) Richard Siwek, M.S.,_ Explosion Protection Manage, Corporate Unit Safety and Enos ronment, Ciba-Geigy Lid. Bas, Suitzerlnd. (Dust Explosions) " Robert E. White, Ph.D... Principal Eugicer, Chemistry end Chemical Enginering Dit. sion, Sothest Research nail, (Plane Arrests) David Winegardner, Ph.D., Encincering Asoote, Michigan Dien Engineering, The Dow Chemical Company Member, AICHE and CPS. (Pressure Rl Syston) John L. Woodward, Ph.D, Prisca, DNV Techies ne (Discharge Nats from Pune tured Lines and Vee) Process Safety Copyright © 1999 by The MeGiaw-Hll Companies, Ine. All ight reserved. Use of| this product subject othe tems a its eens azoemen. Click har view 26-2 PROCESS SAFETY PROCESS SAFETY INTRODUCTION INHERENTLY SAFER DESIGN AND OTHER PRINCIPLES Into: What Pres Sule? Inherent Suerand More Cherny Dein Tiesto Subse tin of it Pals Stapleton ‘iting Herre Ae ‘olermoe Tow ten ie Kal Conan Siioare Desig ines Sue and More Use Piel ate Irsttuton Mery ns Trepeston of Equipe aintnane. (Con of nt tnd Proce Maisie PCE SAFEY ANAS gat cute Race Feehan ioc Soest et Soren pa te Seria en toa ih eee aos netic sete ciate orp serene ee Seu Sere oceainattnt Senet Sebi etc fc ciel argent JERE Sciatica ehh ee fanaa (emer tn ina seed peam pi Reticle att SUE SCnISA hag to i Pca eek Tol Falsre ene SEER aap te Qeeral Respoase " = Spee oer Sone Soe SAFETY DEVICES Pres Rl Systems. Tateducon eke Sc Terni (Caer Strands and Cine ete Deg eens Sing Pres Reef Seis ergy He Deve oct Calin an Handing Tata ‘pea Equip ERtpenent Seca Gite wd Guise Singand Design of pet Maat irnter ac Seton trator Keorout Duo Tok Plane Anetere Geno Conca Delagaton Aree tonto snd Otic Ari ‘Ares feta Suds. Set reste pe and lets sug so Harding of Hrsdons Mater Tatedusion ‘Tot and Te Haan Denge of Tai, png and imps [Xi Gully Reglatoy ss HAZARDOUS MATERIALS AND CONDITIONS Reactive Chemie ‘arta Reve Ch ‘Sta role sete ai Renive Chemo fing Sources of Rene Chews Bata eb Co conbuten Taveducton, wate? Combustible Dass os iene Cais od Tamaya a eee Bamingn Oster Onde Ap Farland Ona eee robted Vp i snd Being igi Hes rtee tae tae ta epi! pom i = “os Preventive Explosin Protection ™ ecto ene Expos Suppreston Compuron Sf pe Poet Desig esac suse Hecsey Tonoducon Delton cent Changin (Ghoge asa Ekta ods ‘Ghee of ardour Dichargs wth agi owe teehee Fenonnel and Chahine Nonooaiting Errore oaneniie Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view ae 2628 aa 8 coe ost a eso, rae ‘hn a comet as ete thor Roop did as Sere gas, ceil Sr ese tae Ga ieee Sopa Cee oe ert cio che ‘Sr Se: ry ei Oa tagger Ng tener Coven ‘Sans PROCESS SAFETY. arco Parte Mlcting Gas Dipeion ‘Bape Consus Base Flange 2 ENC Dierson Bt Diag Rae fos Panel Le sed Ve Discharge iw Hoss Conca Phas Flow Bela ‘ncp Metbol HEM iit os iis THEM for fwePhase ipe Blase ‘Asura Oops Medio HEM SEM fr Te Mate Once Dc Discharge Coote and Cw Ds Blown Mode, " Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view Pay PROCESS SAFETY INTRODUCTION In recent years there has been an increased emphasis on process ‘cys os mumbo rns cents Mists aacs pr {o the worldwide stention io fsnesn the emia industry brooght tn by sever drumati accidents molvng gus releases, major exlo- ‘Son, and ensronmenta incidents Pie swareness of Shee ond ‘ler ancients las provided ding force for inusty to impeove {safety record. Local and national goveranents are taking a ard {ook at tafty in industry ata who and the chemical inst in particular Tere has been an inecesig amount of goverment fey. Slason “The Chemica Process Industries constitutes ne ofthe safest ofthe nanufaeturing sectors, buts single major accident or distr ean do Irreparable damage to company’s reputation and possibly fect the nde induty Sheridan “OSHA EPA and Pocse Sampling hem Pe Soper 18 pp. 381 Oe re he em {ndsty gets bl press thai avi are very nllceable age chemical works ae stking features on the landscape Chemie las ae oer nosy and garish it and many ofthe efMuents case Ihsances which are well elow the eal and safety bmits, Ha irdous chemicals are transpertd in bulk in highly vile container ‘chiles, ang to the publics image of the industry shar dous and ‘Enngerous (Benson and Ponton, “Process Miniatursation A Route to Teal Environmental Acceptability” Irsttuton of Chomial Engle teers 0253-81824). For many reasons, the public often ascites the chemical Indust wi ensronmentl and safety problems sod, tunforunatel somes the negative tae ha goes with the probe Tem desered es wal tothe future oft chemical dase hat cess safety have high prin in the desig and operation of Rremieal poss fites oe Environmental presses onthe proces indus wil prove to be te mos seat change forthe nex 50 years. Not ony wll ew Jrocestes dhnge, bet mature induatres wi have to develop ew roves technology to survive (Benson et lop). lzards from combustion we rmaway reaction playa leading role in many chemical proves acidents. Keowee of thse eats sent for ont of proces zara Tis important that ssf cone tanment he sided. For example: "Much of the damage anos of Men chem acdent results from the akon release of mater high presses which mayo sno lk rm re, Clef res nd yrs 2 he fale of proces equipment and pipelines ca form tse clouds that cane agent prope ner ares * Vapor cloud explosons can res i clouds of fammable vapor in sir ae formed Tet imporeant to undertand hw is and gases flow though holes in equipment and how resuing vapor oF cloudsaredspened ina zeroes "Understanding how sudden pressure releases an oecurisimpor- tant, They can happen, for empl, from rpturedigh-pressore tank, runawayreatton,fammable vapor lous, o pressure devel- ped rom extemal Sire. ‘The proper desig of presare rele systems ‘En reduce the psa of lines from united overpressure. * Static elect is aens hidden case nacident INHERENTLY SAFER DESIGN INTRODUCTION: WHAT IS PROCESS SAFETY? Process safety ders from the tradional approach to scent p= ‘eatin ina numberof ways (Lees, Lass Prenton i the Proce Tutsi, ded, Bullet Heipeann, 1096, . 3): 6-4 + 1 inportant to undarstand he race nature ofthe cena inven scheme iy owt of content da to nachanil ile or misopeaion a aro hr rc accents, Te pcan, One Ihundred Lanse Lees Ary ror Revie of Bropery Danae dees th Higdon Choma yn aM Pe Senta, Chg ee of contment the aing Catt of proper loss ith cemkal process nse ‘Govern ropatons equre bard andi ane as pat of proces softy managemen TSM) programs These are pr Othe Proerseclety progr of any chic proses aioe Process sly cludes many subjects ht could wat be inched in {sins cre ole space, Thefelowing dese the og ‘oaon ef Section 35 “inherently Sefer Design thor than addon equipment to con tel heard rw protec pe other conveyer to deg wera plas which can wiatand human rot aad ‘xqpment fale witha serous ffs on sty the emsonment, ripe and eso Tas pre concer a is ate ‘Procas Safty Analisis par rested svalyav ol apeocese or pel ire thesis of erro, pocehcs eek ing potential damage res, and poof reviews and wails ca SAESpRl o management insets rats ina poet Ieeonastsof the fig ‘Harard Asay Esha Goins for Eating Da Prject Reviews and Pree Safety Deven Presse rl deers, Same arester, and snd for handling eluent (rom contre reese provide com trol of acidetal undeicle events Spee equipment shoud be Considered for highly tone chomicd sei, Ele ater Se conadred "renie ale Stems Energency Rebel Device EflentCollction and Handing Flame Artes Store net alg of Hazards Mates ‘asatdous Materials and Conditions The chenscal nd phys ications tha can rm when operating wh sare tera ‘Rosle derstand so these mates be handed suey. Th ‘covers the allows ace Chemis © 1 Vapor Cloud Explosions (UVCEs) and Boiling Lig "Bvaporating Vapor Byplsions [BLEVES) Hazards of Vicuure sands of ier Cases Gas Dipeasion Discharge Rates from Punctured Lines and Vessels AND OTHER PRINCIPLES. «+ There it mone cancer with cident ha aie out ofthe teh log «+ There is move emaphasis on foreicng hinds and taking ation before accident occur * ‘ Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view INHERENTLY SAFER DESIGN AND OTHER PRINCIPLES + There s nore emphass ona sjstemate Father than alan ctor approach, particulary on tematic methods of dentine a Srv al of exttating he prot that they wil oss, ae thee There is concern with accidents that cause damage to plants and loa of prof but do nt injure anyone, aswel x Use al do cause injry hdtonal practi an tans a ook t moe ene roca fey be ape in any indus, the tor and the gph in Bon partly weed nt presse eet ena see the sre a ns prevention ‘Athough process satya old a process enpacring i A not besame gro aa et th esac tl he 98 schon anew fenration of plans, ager than ei nes and oper Tngati prin an prea wad a ‘tion res and epson They mae te indy rahe ac ‘Ent prevention afeded the aut aon of aetemaee and techincal Study every aber aspoct of plan design st operation Sine then thes pein pct ry rr tnd calber of engineers speciality in the fel have grown py. INHERENTLY SAFER AND MORE USER-FRIENDLY DESIGN ormany years the usual procedure in plan desi wast iden the hava by one ofthe sptematic techniques described later or by ating unt an secdent occurred, and then sl on protective equ ‘nent cont foe cedonts or potest people Eom thi ona. {quencet. This protective equipment soften complex and expensive fd requires regular testing and maintenance Te oe intereres wth the smooth eperation ofthe plant a is somedines bypassed. ral: tly the indy eae to eden tn heer pol, one lod dctign wserfiondly plans which ean withstand man eror and rqlpment fre wiiout serous elects on ase and output and slicleny). When we handle ammable,exlosve, tox, or oeosve ‘naterals we ca tolerate only very low fare rats of people and fsulpmest™rates while may be Iposse oF inpracicable to ‘chieve consistent for long periods of te “The ost effecting use edly plant 0 ao when pou, lage imentories of lardous mates proces ot orage. "What you dont have can leak” This sounds obvious, but pth espa abr gana re era thought wat gen to ways of educing bnentores. The Inds in ed's punt aid aceped whatever mentor the Oe pare” cnt theyll keep wer onl Fiebre ‘weakened Hat confidence andthe disaster ten year late at Bhopal. Tn almost destroyed Pants inch we avid 4 van. by redcing Inventor or avoiding hazardous reactions, ate usally edie | : “The pine ways of designing inherent safer plants and other ways of mang plants sersency are sumimaraed ss flows, wth aang Klis a infor Sey“ Uae randy proach, Intensification This vohes using so litle hazardous materia that i does not mater tal Teds out For example, at Bhopal ‘methl Bocjante (MTC), the material tat leaked sad killed ver 2000 peopl. was an intermediate for which wax convenient but not nent to sore, Within a fe years many companies had reduced thetrstoes of MIC and cher haradousintereodats. ‘As another example. a one Sime trogherin (NG) was mafic tare in bateh reactors containing about 4 ton ofr materi and roduc. If thereto got to hot there was «devastating explosion immiom pas, NCE mateinwsmal conte Oe Ingabout a Llogram, Th seventy of an explnon hasbeen reduced thousandfld, not by addingon protective devices, which might fal or bre neglcted but by redesign he process. The key change wast ter mang, achieved not by a beter rer which mug fal, but by Sng one reactant acid) shough a devi ke a laboratory water pumps that Hsueh nthe other eactant (gern) through aide firm. the acd ow stops, che gyerin wo stops, not through the intervention of «flow controle, which might Tal. but a an 26-5 aie of a ppl a Fete oa ad asic age Tati ed to oy er dg sega aie Ht iC a alee coogi ters ara Pape ene oath hacer at Lalande imi ih lege ptr lc SEA ls eh td Tea cae ieee th CSE fetta a Sten Sd chases! ela seein et. AST pa etna ‘tines nec igs te ah Fate Ne grein pdt ole yer andes re Seve en ellie eae cata inno Ee of ares_Unson ce ey eine Barre js me dt i ied oe sh bey Tur pe nf hn ts thet sale Sess mi: > Hiren ected tn ih SECTS i i a ogc + Rita dcp ed ae rod a rage tek i af han se ie ane ti wa +i cd nh eer ethene dm ae ana in Scenes haps ante oe ag tt orn ENTS a pong il nl axing pre crops eed ance ach ~etoals oa Wal acgttick afte de qe cela Sieplpmetne tte STRHENEiSg lin saa TERR Papa te ae ESE pio isha hag pees wh tin le to Mey ha nla in Ges, By ie ie is imposnble to aod he basa Sal shat an be done to a om cemplex spent to cont “Knockeon Effects Plants should be dengue so ut done ack dent ese doo pcs recon domino es Ts ‘si bed, fo osmpl Providing frebreak, shout 15 m wid, between scons, Uke free ns Fret to rset he spread of fire Sing eine wach bbl to lea otoor so hates of Namable iss and vapors are dispersed by natural venslaton Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view 26-6 PROCESS SAFETY Trdoors, few tens of gran ate sulicent fo an explosion that an dlstoy the balding. Outlors, afew tons are nocestary for serious ‘damage. A roof ort equipment suchas compressor acceptable, Ibutwals should be avoided. flak of tae gues ae lable to occu may e safer to locate the plant indoors, less eas el pers ‘eloe they reach the publ or employee on oer als) + Constructing songe tanks 20 tat the root-vall weld wil fil ‘afore the Base wal wel, hs preventing spilieof the contents. fn gener equipment designers ahold conser the way in which ti ‘ow ikl tof an when psn oes he pment ‘Avoiding Incorrect Assembly "Pants should be designed so that ncormet esrb ifn or impossible. Por example, compressor ‘aherstould be designed so that tet and ex valves fannot be inter chan ‘Status Clear Itshosld hepossbeto se at. glance feqnipment hasbeen atenbled or nstlled incoreey or whether avave un the wepetpees ng enue i ce at Seas CT pe a ir da ae wt apie sender essere hs Se SRE = Figure-cight plates {spectacle plates) are friendlier than slip Seca ce ect ae ie iatieP RSE peer tenac ohh ieee ce ly wba pa Shot neces to search for thems, as wth sp plates. Siege "ther pet ee sits oun ts fern pe Serge serena Face Soca AA etc ae en ieee elie a apa ‘he ee a te aoturuly Sey iar ee Sef ute ae gy SORTE re eet Spal Tae hae tin WER ae ae SELES edn ha gt obec eel aes pet Sepa as mere ie See ot SOUPRTE ME ig eile ee he So eee STE Sag EN Be aes To tht ny pe da in oe sn Ca era RT a a a wh Sm atc oh Taga ote on Sige ny pa Peck terre ee et rg ieee pseu ove iekibc ied See nen Goes tial nid ee STE Prete aie cei atta mpi teh ‘oko ete pda BRS apg et ee a Sed IES oat Ee” Eh li emi en) ‘errors are much easier to detect and correct than in others, Using the Spano wes eit ieee op eo canbe are epi Psat shea Same Sant afta dh SMa cnc gp Eee ney el DexgringIarety Safer and Move User Pat ‘The following scons ae needed for he esgn of iorety ser tnd ere coer pes 1. "Designers ned To be made avace dat tne is scope for imprning the neralines of he pans iy des "hee ay ofthe hinge pro ged ee tonsteratn of alkraties caring he cary stages design tans iceman noma Tro tie gn et tbe concpmal or basing anaes stag when the process Bin ‘Bonen, aid snaher a the flowthet sige For theatre su itard snd operably (HAZOP) study qutstons nay be table bt ‘wth one siference. Ina nomma HIAZDP om ne cag or “Samplers of trpperatir” is beingdssated tis sumed hat {hin undcahle and ways of preventing tare sought. Ina HAZOP ff a flowaet son be aked more of temperate” ol Be eter Forthe concep study, dllret quests age needed 3 Many companies wil sty that they do consider slerativs daring the Cary og of plant eign. Hlowover, wa is ahing ‘any Compenics sa formd stoma, strutured procedure of he TiAZoP be “Tachi the ore detailed inprovements aged hee, he mesay toad few questions thow asked during aoa HAZOP forecample, what pes of ves, sake, an eth teused? amen atom « INCIDENT INVESTIGATION AND HUMAN ERROR Aithongh most companies investigate wcidents (and many investigate During maintenance, as the maintenance workers may be temptel to improve the plant a wel epat They may suggest Srwcatons ft cholate pat bast was do lenge has been authorized Men odin cheap nn anni rnecessury. Many scemingy trivial modifications have had tage resale, When the maifetion i temporary. Twenty-eight pple were lille bythe temporary modiiaion at Piboroug, one of te mest, faons of allme Lees Loss Prevention in the Process Industries, 2 ed, Butlersorth- Heinemann, 1096 p-2) When one mosieaton leads to snot (Klotz, Plat/Operations Progres 8, 1988, p18), snd then another PROCESS SAFETY ANALYSIS HAZARD ANALYSIS. crt 4. es gc espese Brn, Sana Osean a Aeoatr Adisrtn NOAA area Sects hg reer ae feces di ent en rf Ai eine come ecm sine bse re cue ire Be rt rth ee ha Spel tiers ENE gay i rt aeach SITS EES Geeta ese aie teas fain oes tarverie ecg fe er ores ctor anita Nita Tete feason Sent anny Tl ey ad. Sot isehaigne eect a rece Hen Cele nea oe a, ‘it Meet Ala, Quy, Me” Hab FEN Sod So siigiceyie er ee toad Lins car tare ereaaeicc ial ict en tea eed Tete to Soo and shoot (gle), 22-26 Ape 1885. PHAST ite foepacia as enial eRe BR oe ere eet see as {G54 a ded go cio poes ay mare, Rina Pee een sot ia os Introduction The meaning af hazard i often confused with ik Hazards defined ae the inerent potential of a mater or acti to Jharm people, property, or the environment Hazard doesnot hase 8 probability component “There ge ferences in erinology on the meaning of ik nthe publted erste tht ca fe to confusion. Rsk has tn ened Ferns wae CFORA. 18H py) th ein fhe ban tol rs defn ar"A mas of conosco injry interme ait the pent keto ad matteo fs oy i Tips probity of something exces ‘Betintion of Term "Following ae some defaitons tht re ef understating be omnes of ras ad bk COR, 1980, pp. 3 accepible rok Tho werge rt of sk considered tlerBle for “Gecident A specific combination of events or crcunstances hat leads toa undeatableconsermen. “acne Rasard The potential fr ijory or darsage to ose a 3 sen ofan nsantancous or shor duration xpos the es of "Sonic hazard Tho poet da mic hesard The potenti for ijn or danas to acura reno prolonged capstan unesine concion, Cent Connquenes A precede erty Gagrant to iosite the eames and consequences of parti wesar. They ae not ih ed sae, eon fr amp ons, plying al case ‘Chemical Tader [CED “he CEI provides « medio of ating the ree penta of arte eh hed to pope om fate chen live edo pe on “The direct undesirable esl of n cident, ay messredn health wl safety efectos of property or ness Cont or measure of the expected eed of a ede outcome fee For expe, an amor clos rm 1s les ners iy dss D weuher condone anda -adh wind tvehing rt ortho reton may inte 50 people ‘onequence analysis Onc hazars have boon stblhed svat at fr aaling ther consequence eae of vapor dau, hemes ng eps esto Tink frequent or probably domino eee An incident which stats in one plece of equip sent a alles oer near tems, sch se west omen {rons material by thermal Bat or fagment wnpck Thc ed ‘oeraation of consequences or frequeny of ocaence. This lo Kim asad , cent Anocerreaeivohingeqpmient performance ot human scllonor anorectal ovem iat cots ton ope neem saris wi an nse, eters case or com trbuting cause of he nent or respnse oan aang event [rent sequence Aspect eplaned sequone of vet co pest ent tat ett ea os Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view somnt r_Sils to nly tn te congue of cote ful apr ano lye be us ot "ure mode and fect nage (MEN) Khar ent sere ohh il not fare er of somone or trot i awed conto oh ve ripe SSG etsy ly xed tre Ast fr mpeg gel ombinns o “it nd Hplvion nder (REI) the isso nthe sealed blah ees Te at aie leer prdtd on TEE AgbF ano ann endopertyess Tae ia fal uel ern Sd tn pee Sesion ods rope pees at te Tacthet "Toca cnanet utl engy et plots Raabe od us camps farina opr col rnd fe, ebebliay "Wiel ocinene of ora me suffi deoef ble he luo change om 01 se Ung ihre rea repent ping met sh Erk etnue he mgnyee en qn A ain ila Se ua con for eo rch Se kamen (RY) Te yea ol anh mest! sats of heaped ion anor cone wae ag luc Sis day 2 Seeunat we te Senn te et rg Sas En wera ‘Sta Ne tocignenrequatan cuter cect he dm sae et ubsheuancacyuneuiceae acted tial then ee se eng Te meen ont fishnets is ml Cot kw 8.90 eA Pre Si Oe 0 seb re ae tone aes Tr natcaa ee nda pao TABLE 26-1. Process Hazard Anclysis Methods Listed In the OSHA Process Safety Management Rule Chek 1 Win heat 1 Hadad operat study (HAZ08) 1 Fle mold fc any MEAD 1 Rite sna FA {LAntppreprat gaan medal sooner: Bowl, 198, pp. 0-94 PROCESS SAFETY ANALYSIS. 26-9 pl commen, ngueing dwn antl ad Sefoqunces lc alte cli sng nd human ato Con Serine occa ated ben eke ioa rel oreo hells PiRtoemenr tosis Rely oth ko PHA anon od gh ey SESS it and Ra Assent ok, Rae en ee one ak aes eee eats he ne Sai Qualitative Tools for Hazard Analysis SHEL (Safety, Health, Encironmental, and Lose Prevention eviews) these reviews ae performed dung design. The purpose the reviews stove an ouders evaluation of te proces a ay ‘ut fom safety, industrial yee, environmental. and loss prevet- tion points of view. eis often desta to combine these review Improve the effcency ofthe ne of ime for the reviewers ‘Gheeklits Checklists ae single means of appving experienc to sign situation to engare tit ee features tppearng inthe Ist Ste ot overlooked: Chects tend to be general snd tay not be Spores sei ton They ay not handle adel ‘Renoel design oF uso process ‘Whatif "At each proces stp, what questions are formulated aud answered to vane the efers of component lanes. prace= Aral errors This technique elles on te experience level ofthe ques “ral (EMEA) | This is a systematic, Teilure Mode and Effect Anal study ofthe cases of falies and thet effets All eutses or mendes of flute ae considered foreach element ofa sytem, and then al pose sible outcomes or aflects are esol: Tis thei uoally wa in Combination with faut ue analysis, a quanstatve technique: FMEA ‘combed prices, aay cared ot hy epee ik Seats ‘Cause-Conse ‘These diagrams dlustate the cases and comsehurnes of pares sear Ty aro wide ‘sed because even for simple systems dplsyng al cases and ont Somes ade Ysera as An, he she ‘mployed ty experienced rc anayts. ‘Reactice’ Chemicals eviews The process chemistry is revwedforesdenceofexotherm,thock sensi ad ether iste ‘ity wth empbass on poste exsthermic reacSone Ts especialy important to consider presure elect" Pressure blows up people ‘ok terperstre! Tit porpse of thi ew to prevent oie pected and unconted chemical reactons, Reviewers should be edgeable prope nthe Feld of reactive chemicals and include people fom lose prevention, mankfaturng and research ‘Thduatrlal igglene Revieics "These reviews evaluate the poten sisof «proces fo ean har ode health of people Tis the sence ‘fhe siiipatlon, eengitio,evaatlon, an control of heath har rds the environment. 1etsually deals with chon, not act, lu atid hot “Tosi the ably to ease bilo injury. Teac a property fa mateis even sak gar. and water Its related to dose apa the Alegre of faardssucated with a material The amount ofa dose is bathtime ard duration dependent Dose i funtion of exposure (Concenration) and duration and 9 sometimes expressed as Sse {oneentraton? edo, where an vary rom 1 to “dust yyene deals wih harards cased by chemicals, radiation, sau noise. Routes of expaure are trough the eye, by inhalsion,hy {gestion and through he skin. An lads bygone gues ased on ‘Spon fran hour day Ashour work and tobe wed rage {nthe conta of health harads et to be sed sae ine Tetween se and dangerous conditions Types of contol used include * inrecring chs ontunnent, cea, ae stoma ‘Allinstratve, soc a se of emote areas and job rotation 1 Protective equipment Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view 26-10 PROCESS SAFETY Fociltics Reviecs There are many Kinds of lies retews she uence an preetng pcs ay pens, ‘They nde prstarcup ree toe tee pat opens). new at seis ie plat Ha stared but tl tr ees of es Jig pit (fey technnlogy, und operations suds am reviews), mmigement reeset strc tes al hats tates transport ree. TAZOP (hoor ton. 1982 Ls 1950, CRORA, 1982p. 419- 428)TiAZ0 stands for hard a operably stig” TH ase of fora bsardwevfaton and eliinaton procedure designed $5 Mel hazards to peopl, pots plans El the erm hina ni te naga of degen and people wo pert pans or equipment oy ean ‘dently potentid’ Huard Te elleet, HAZOP mudies make. the ‘Ssumpln thats za or porting problem can as when tes devin from the desig or opering intention, Corectvesctons an then be made before real sciden ours. “Some ules hive shown hats HAZOP sty wl rel in ecom- tmendaton hat are 4 percent salty snl 60 percent per ‘Migcrelted HAZOP fr more an asl oo a ood HAZOP San olen imped prt of he poe hich an ean geter rol. "The primary sal in perorming & HAZOP say isto ident. not anajal or quik i ars a pres Te ond pti oa Sid's bil of ences ad recommendatons fr prevention of the Dbl, pot an ana of te ecurence, frequney, veal ees, Tid the deft tin. HAAOP started toate profes a a llecvenee bec SA he enn nt wo dere a dey esting 2 changes may come too ate pousbly requiring redesign ofthe Pre Tuer maybe los of operahiy an design decon daa wed togenerat the eng. TKZDE t's oral procedure that offers a get potential to Anpove the safety reality and operability of pres plats by ree et ad etiintng pret problems athe Sse tage Ts tevin dv Kg wee nb ped ange {hata dag intention how de prt proces sexpected to opera) emnbedeined sas = ‘Sontinuous or bth process bag designed or operated ating proceires Sent pote Mectaniel efpment design + Gita istrunet tems + Develpment fps cnt compote nde ‘Those mud mak us of te combined experience and tang ofa {up of mowiedgeble people n asta seting Some bey cn tenon defines how the part or proces i expected to Fe Guide words—slmple words wed to quay the neni in order to gue and simulate cesive inking and sever Gov. Tons Tale 9-2 denies common wed gid node * Deciatons—depareres Irom the inten dacovered by 5) tena apleaion guide words Candi reat at deans might occu + Ganeuencerresls of dation thy ce TABLE 26-2 + Aetions—provention, mitigation, and control prev exes SNe eee ee ca —Coaliol actions ng provide alarms to ndste dings get tnt of contol efine contol actos t et hacksnt contol ‘The TAZOP aay snot complete ual reponse to alone has been documented. nial HAZOF panning showk establish the mane ‘geet flow op proce that vil be sed “The pide words can be used on broaly based intentions (sce ‘Table 252, but when Intentons ate exprested in fine deta sme yesticons or sobicatons are nectar for chemical presence mica None Reve flow Iss flow More temperstre lsc Composton change Sentiog Conoaberosion Te grees prs pl pci HAZ gudowod it wth PTAZOP atuties may be made om batch as wel continuous resi Fer contin proves, the working document al ito shel piping und instrument gre (PDs). Bateh procerses have another dimension: ome Time i ually not ig soot otha coninsos proc thls operating woe ccort ig startup and shutdown, when te wil be inporant andi wl cml tiatch proces For batch procesne. te working des {eta comi nol cy oft ow shee or PSUs bu he oper ‘Singprocedtres One methad to ncrporate fourth neni too de wore soit wth ine sch ss Shove dese in tea THAZOP studies vo «team, a leat ome of whom have had ceperience inthe plan Jeg tobe sed. The ean tombe ‘ppt expere to achieve the ins of HAZOP. There ae four ‘tral sim to whch any HIAZOP sy sos headend Tr Ken sy deviations a pos rom the wy te design is expected to wore thee case, and probles sociated with these oP Beside whether at cand entity way the prob 7 Decide whether action required, nd ientiy way the lem canbe sobed “ ovens “LT eases in which a decison cannot be eas ioroniniely sod decide what information atone reqred. “nse tat equine ston are fw hong Tie tou leer it hy to Une suces of « HAADP sy aod should have adequnte ting forthe jo. Proper planning x impor dite sues eer stays cin er tod one wo keep the nsetingy on ac) whose nating dire [Simmer ansehen” Heer ote he Foundries ofthe study and ensires tat he dengn intention slaty nertood. The leader applies pide words snd eocorages the eh to dacs caves, emertenee, and poate remedial scone for Sich sviion, Prolonged cussing of how a problem ny be Sshed shold be vid Some people flew that it may be an advantage forthe eam leader oo to ave animate owfedge of the lant or proces by sted n onder to maintain nesta Healy be team leader shold Some Guide Words Used in Conjunction with Process Parameters Gs Wend Messing Noo Nowe ‘Ganglats epton of design iti No paral neon bah ad elie aaa Moves ‘Grattan of ay elvan (Quant and ecvant pineal properties oh aoa, bea 7 ‘ssa prunes paver Lowef Guta eres shove Sevwel os alle ieee A ig and opertingiatecins ae schieed wells some ado ctvty foteh pale docete Stee ented av adicnel se cat _ Other Cop ato Noparotnenton eaters meting que dill happens sooner Raion TR Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view ‘TABLE 26-3. Guide Words Associated with Time Giaewent Messing Retin nied More aine Sto i oscar won should Lert Sep acu re pres t's Sih Won ime Flow orate cv onan wen thud ot ‘onc Koon, 1 be accompanied y ere ocd cing the lee ofl Tinea latig esl a rots etal fr ll co Ingots muchof te meting as hacsary ocr the ent of hee onl reoomentent onputs ts we salable to al information capt. Tn sme cast be faator aye tempter tol or oer reple ing the secretary. For example, Prima Tech fers avery sel tom: ule prog to din HAZOP sues (HAZOP-PC. 1908) Otter xtc Smpstor sor IAZOP ar is commen wale “fans ipa, Les an tee treating ember, cxcacng the sca and ener il pray rae tam ce segs eae oe ‘including the laser an seb, re azar aude par ih en estimate at cc ine oo Conway an eo qulpnent may sure rang of bot 30 itso an ‘itm tea although sh ime may wary wily Te sho be ee lon tt th tne setae HAZOP tes ny nota be {Sitond tie forthe fgets a whe, purr taxed ary ough in the design, and may actualy sve ne onthe project. I “hay make design of parts of the proces more ellleat, seduce the ) FATALITIES, W 16,268 Eumplef asecetl ak F-N cane. ACRE COPS 188, p44 For al isk measures it is posable to estimate the risk level ofthe current proces a well asthe ak levels fom incorporation of various sKredcton alternatives, Management can then use tis information an important inptin the inal sk eson-making process GUIDELINES FOR ESTIMATING DAMAGE [Nomenclature Popa aap Bean Tape aoa Sherer naree an Buch ogy ab " Crete pont Nata fgnntnte ac enuecean? ‘i pt ca So ee may aitigeae aracare ‘cst dpe eal duse ‘Sessa Set Mak pe ot te of ee hl cere ekg hornet Nit Unita pretre in Ita seed pel a) One pi abeTex I) Poor oe + udemee Pete Domne pe Rode St ae Fe EE ware Fr Noted ted sth at os a Sor? : = he tages Be i thet what tet th Eline nme wa Ye ime Y Betaper Kise om wa ofl taree Copyright © 1999 by The MeGiaw-Hll Companies, Ine. All ight reserved. Use of| this product subject othe tems a its eens azoemen. Click har view 26-18 PROCESS SAFETY senelatre [Conled Galion 5 Ealompasin, Yio apc hens of ws GC. 3 Stand ty te ely Y Poort tn ese eet Sitesi 7 Were ene 1 etatsane <,_Eirment at +4 _Denoter i pa fom eae 9 the enone abit se (Genena Rerenens_Babet Cot "Espn Haan ato, ‘Saal Seo Easing Be Sonn Paling, Ne Yor, 19 Knng and Cty, Epa ks re, Sprig Ne ae lien Asaf Ma More effin’ geile ‘eleont 1 Major Lazard Pim, UKAEA SRDVBSEIRATT, Noveier 1985. 1s Tou retin the Prien Id, utero, Cae, 198 fae and Bi Sta ote A ese of Peed agi ou Conner Flr Moder sad Anca Pjecie Hsu: fur of fsrd Mrs Eola ASCE i hs eB of Sa Fe ‘aces Maral on eporton Eager Ptr no S94, Ptr Shee “lt 1c Vt Gol Bren Prope Sify Seer wl 18) Ho yp. SE-S poses nthe Pes Tas ‘Ses Major tia Monograph Ses 1 Chom E(U R10 “The avalbilty of enegy from an explosion canbe approximately cl Cate a ct cases Bat he ethal sed depend tpn te nurs fie explosion. ner Heal Cas-Filled Vessels The energy svalable forester nal work following the rapid danteration of the vessel calculated ty asuing cat hea win he veel expands ably 0 thnospherie presure. aells-()" e-Gov ‘Soe Nomeneltrs tebe for dino of ers he eae of Hack walled HP wea he ssn energy i the ves sel shel can contribute othe salable nen but for sel blow Shoot 20 MN [20 ng 8 nepipe nd e hegre Ta Moller ear forthe gusta I adiabatic energy can Be a ‘ed eth s the prefered eet, bat sn many cases the ele Suntebert baat ol "The malbleencry is dsipted in sever] ways, eg the stain cou foe ate racer he raga tlc SF gents la wre erin, tery el ne {ent hea nergy inva conn, t- Fo damage etinaton p= psc the eng dsnon can be imped to m Fifpto eee sow be a0 fagrent nec eachiy 0% other dpuave mechan Blast Characteristics Accurte calculation of the magnitude of wetter eran lal el ne aoe a z Ss mt fini eat wn pte ts eee Ee a Bigatti wh sre te he deep a fo enti rn a en seni hn er ae nee Fh de re nw fo mt ‘ifepa hie seen sad et se oon trol lang scores pina oa seep ete get te ke PE MIE ALT Oise See ee eS IT Beate Keo alae ey am eo fe tng al 2 we Fg 2.7 5g Senecio ioe dines ES ieee a ptt cle gh. Seed i eng he el sheet p ee oer Se REST apse ess Soa ch tne ute eb penny ert ope he pad tn ft woo eae eer ea pen tating ew hiro poe Sete aoe eal Hess ile BC dp te (Pa at nd mem Cts a Nn ok Sor fs Tara eT a Meee it pnw Nia ao trrane burda sy Serine ea oy euros Cael ele ab ce gin cule seo Geese infbena several Tngments a a consequence ofan explosion or metal falure ipa pe Contry nic Sey iN eee det Reach pelea lagers Eos engh Spt dene tats go part en ey ‘be nw mpage bu wc cn! ied uy a he peace tape eect nn eed at Rea ios inal aad gad tea Tig pe Ses 5815995 oe a wth ‘ep agp li pe na ene Sa SATS ay spn nce nen gett eptingga otted inp alsne a Sag ees potent he ol org: crag (ei of ss Cette eaten os ested np unfree oe SME i Nene 1p, he Sen ites, 5 (5) 6, 269. ncidetoveprmre ve, wal due, sure ban. (The Ite ae fo Kingery ad Fail Memo apr 153 BA Bric fa Ry aM Fs TB NANA AP Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view ePScams eae ee SAG me i ag ia Set ae = walle) Jooinlt-le 8)" as (26) wet sure at expanding gis contact surface Sotnd welt ambient condition, Sound veloc in gas prio vest! fre “The sale of, may he approximted using pysel property data for the spc gs athe tempera and prsrure af te war of the pation, Equation (88.5) must be soked sing 2 tialand error thethod. Most fragments never achieve the wevosmsa velo and their veloty cane assessed using the corelaions of Baum Di ‘pve Pale of Presure Vessel: Preliminary Design Guidelines GG Fragen Vy andthe Eta ofthe ud Zane Pre pp. sure ase Tocmalgy, Tea ASME, wo 110 May Tee-17e, Baum, apres Gar Pressured Gyindnel Prete Ness he Velocy of Roseting Fragment Los Pre Proc Tn woh, Jananty 1981 pp 13-88 Baum, Welty ofa Sine Sal Mae Byte Son Vase] Contalnng Hig Pressre Ga J tose tren Pres nds, 41989 pp 291-268 "Ths Baa copltond or sever vate! lee mo re he qs (26-7 to O66), End-Cap Released from a Cylindrical Vesel Pressurized with fan Inert Ideal Cas % » Yin gpe 57) where Fic a dimensiones initial fragment acceleration given by PAR , ia (268) ejected area of fragment agent mass Reveel dius Rocket Fragment from s Cylindrical Ve fm Inert Ideal Cas ° sel Pressurized with Sicaus eee x x whore L = length of vessel and F is calulated using the area of the fen end. Fer mace preise res, a coretion factor 0 allow for Ue vessel opening une should be made (Baum, 1991) (269) Rocket Fragment from a Cylindrical Missile Pressurized witha Liguid st a Temperature Such That Rupture Initates Flash Eeporstion Mnoa(22)" w (5:10) PROCESS SAFETY ANALYSIS 26-19 Range of experimental dats zB Water, Tux 990°C, 15 er To £ 155, NIL=1.0, Bs J/RS28 “The vessel is completly il of iguana Ns the length ofthe vessel Forming the rocket fragient, wh inte data Whole Vestel Driven by an Inert Ideal Gas Escaping through hats y ping throw zon) ange of experimental das eo) voc Eecsaye 1a sctites Large, 5 Je Fragment Ejected from Cylindrical Vesel Pres- sized i : fan Inert Ideal Gas % 2m (26-12) ange rn Becton 14pm i958 Ind gn oot Ep etin 65a = Sng gn te fom nel el Sobre) ooeletall” viene cre Range of experimental dats (26.18) oc conn ya 14r<03R MOIR Fragments Generated by Disintegration of Cyndie! Venel Pressurized with an nea Ideal Ga v 0.58 P= (26-18) Espernuntl data show no strong dependence on P,/P or LR. ical Vessel sat on Rupture Hemigpherical Fragment Relensed from Pressurized with « Liquid at a Temperature Initiates Flash Evaporation Moone! ( (26.15) z wm Range of experimental data Water 7. 250°C, 4955-2 z ited dat, vessel fll of water Fragments Generated by Complete Shattering of Spherical ‘Vestel Pressurized by an Inert Ideal Gas es Seas ‘asl led with Reatv Ga Mises Mott of a Sere eer SNL canes ee (26:14) Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view 26-20 PROCESS SAFETY potent of such indents, the pak explo or recon pressure Eisen be ealelated, nd if ths pak pres F hen nsered pee 55 a rile py an el de a Aragmebt heard termined. Where the expected peak explosion [reno ingest exes ofthe sessel dice preset Tracer oncrelae fe burt preaare allow for the ees in ee gee drt ero cry rah elo fore athe figment of removed fom he path of Ue expning ‘sel contents Where the gas pressure inthe vessel ng api. sted amie {he gas may reach amuchhusher pressure than ic estin {nntpresture ofthe veel Phiseet smart he se on a elf vale. I, therefore eanerathe to assume thatthe gus ‘aches the presi calculated on the assumption of complete reat= tn. The rection assumed to go to completion before the conta ing vessel fall. However there ate reactons where it simpler to Calla the erg: vay usin thermody wet Suncom energy lewd in a explson canbe assed om the ctuange i the ficinhole free enegy (All = “AE + TAS), bt if ‘he reuied datas ok aval my be necessary tows the Gibbs free energy (AF = AH ~ TAS), which-espcily in he caso of reac tion ith ite ona ral chang, eg ys endton— is snl to the Helmbols energy. it may sometimes be: more Convenient to calelatethe batch energy avait [= +86 MU nar = AV; al (Cron, “Caeasting the Energy Of Exponion ‘aag'liermodynatie Avalabliy" J Lowe Peo Process Tad 5,00 2.1982, p. 100), which fran del ps becomes ofc) “The energy tion been bt wane energy and agent netic nergy was seed i paragraph ne ‘ersele Completely filled with an Inest High-Pressure Liqe wid "A typi amp ithe pressiretting of sls th al “he energy valet cause Gamage ithe sm of he id com ream Stergy an the san energy in the veel shel Te odo ‘ean of th energy on vst falure generally crates Dying fg trots rey ay sitions bls eee “The aero energy wp to aot 150 MN? (22.000 pig canbe eat fra i=, where Byte gid ble com TEMES Geel peed We heigl wine At igherpessre, ths oop equation becomes too consenative and tor ls toc ein she Md compreton cnr {Se epiced.Tchobc strain ewng br nec tovcl gn Shines, can boestnated fone enn 26-16) cs whew F x % Energy arb U=U;+ Uy “Gay 2 sl action of aval to provide Kinetic energy to ths fngments Tere are ow dat sralsble but in five incense. Iyzed by High (nplib des no action se geste han 0.15 "Fe gent hut vloly ca be aseaed om 0150 = 80V) Distznce Traveled by Fragments Theres no method valle to esinte the dtr rele by an iegulenyshaped, powsbly {hnhlng subsonle fragnent projected xan unk gle cat {crathe approach esse et al th gents re prfoted at Sturge of othe bert and tignore he srreipune ete rag and or The ange then en by Ae Vlg whore = sraitasonal acelestion "This too comenatve to prove anything mare than an opper ound. Some Tinted gustarce ts gen by Solly and Gromer (Methodology for Pediting Domi Eifecs fom Presse Vee! Frgmontaton” Fr: asa Ident and ih nl tamanPacors an aman kay Proen Sfey. Orda a 3 Ja 192. "5 sponsored by ALGAE and HSE) wre the ange, esl wth AateT than 20mm (079 62.50, wth the angen meters and at the vessel burst pressure a bas, Other sources are Baker {tsplotn Hears an Evaluation, Elser, 198, p, $92) and temic Propulsion Information Agency lands Of Chemical Rockets and Propellant HandBok, vo 1 RTIS, Vr May 1973 race Srking Vela rally sens ragment Striking Velocity ti oneal poste tosses the Fement vel bajo, age of Incidence, and agment atte atthe moment of king target consequent the cone Walvis le tha the agit ke the get ght ang, inti asian ete ge pct, avo oo Theil wot ‘Damage Potential of Fragments In designing protection fr fexgment pact. ther are wo re made ob cree el ‘soma Shor apna, hal ean es “onerfraton nthe rep ofthe mpace Overall response nc thetendingand shear senesn teal tage cement, Le, wl the ole taret element fal regu of whether clement spe {ted or pevfted? Tova Faure The pentation operation of mos intial targets canol be assed ning theo ans method aad ‘are it made tong one of he many empinea equtions In {Sing the eqns is Sonal tat the paramere mpc “custom xtra the condone of the aa get. he penetra of ramen depend on es Rt ergy den sity (ED, gen by xep=1 0? Ba ‘where A i the fragment erst-scctional area, The KED is useil ompantive measure ofa fragments penetrability when comparing like wih Ue. Several equations are gen in the follong ston, (2515) Ballistics Research Laborntry (BRE) Equation for Ste! Targets B= bac ie! (26.19) svhere dis the fragment diameter. the sel target pate thickness snl Fi the cae perforation energy in Stunts ag, ‘then Spi to fragments between Ih and 138 hy. apacting tre ets Lin fo 25 ren (in) hick plate wth elt from 10 so, fo ms Nelson (Procedures forthe Design of Inpact Protection of Offshore Miser and ESV UKAEA fed 180) found a age sat terin the rene, ft most were thin =30 pers Stanford Research Institute (SRI) Equation for Steel Targets (26:20) steam Ba oe te tn ree Sa ogee ie ane teeter Be einen ba, See Sette, tN itl elke Se Mae, es rs ri a ae gett ae Schnt aegton yang et seiseta ehateps raging SUPT cote waht eel See seer aca ee Pe ah Some an i Rew Sy aoe scat Wee theta eon ‘wave parameter which can filly describe the damage potental of the Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view bast Some rgts espnd more songy ta the peak aden ne posure und ober tote impus fp ofthe blat."The bas po Famer are eal se og the conernive sump that Ba itches we age normal ots sures at nora een "tne presure exerted by the Bast wave on the urge depends nortan he th ag ce es ‘en the age il eaperiene the reece aceon Bie presse Prat fhe tage suc ado toe st he Use ret wl experience the cident o doo Hat presto Pr The releted Et pps oping et ta {ordeal yes be hgh seg Uns the incident presre, For ‘tnt targets where she nie preset ont TFINin? (5 path rls premre noe more han 25 times the indent presse ‘of Equipment The respons of inet to Haste sts condi cf lets boo e Space of be ‘spent a singe enthy and the other's the fa ofthe oh SEP Tene ihe Ripert of te equipment an peat CSnsderation for snl umecured emg™eg empl drugs ner years Mv ange lf ch fren Pat or etal he equprent or contin irate ac "he lat parameter afc uly based onthe consent ssump- to that the sre he target nora os rfc, hal re ‘al reflectonprameers hay be oad “The respon of target ra function ofthe rt ofthe last wave duntion td he nat peril of baton oe target 17). Ne therof there preter Con be only defined. Caletng te pee espns of ee target exn generar te don on approcnaely Rocuacy i ot pated wns he bl perce sre net wel dafined A pide tote damage potent of fSedermed pate expt la gen in Tle 3 (yan igh, “The' blast Elect of Explosions” Lose Peeention and Safety Promavion in the Process Industries. European Fed of Chem. Ey 537 Event, France, September 1088, abe 2), Neckar dat seal ‘he (Table 26-6) Walker. "Estimating Production and Repalr Eton in Bastelamaged Petroleum Refneres” Stanford Research Inst [eee Tas 2) si ie pn enero ato as (63)-This ages atthe Walher dat wll conservative for ‘he much sheer dation at rom acide nde explosions ‘last incident overpresute af 35 3N/n (Spa vate used to define the reson yond which the damage used wl be minor apd ‘ot lead igniicart volvement of plant sod equipment beyond the S54N/a? boundary ‘of People ‘the goats hazard people fom lat is gener fom the fecelerton mechanism afer prople have been Elin off thie fee and they become mises This occurs asin het ewerpresire of aboot 27 KNim™ (40 pi) for long. posite TABLE 26-5 Damage Effects Theo, Presi mt ee Dang it Tapa pa ners wldbom, yt a pa age ce ee cet, ssbethdspenitaasoe et Ts "feel Panceoms sat thie ed 9 er a a ae Sirsa thats See age mane et Ss pedir at a oe sep Se dara es canes 1a age ner phoning a Am ames ga ben “8 probly lec ae lana 20 pine 8% pba css wal ies ole a8 ne pereuee 20 “ PROCESS SAFETY ANALYSIS. 26-21 duration nuclear weapon blasts. People have mare blast resistance Bi, or equpment and can sive nee overpreary of 180 KN ins 20 pa) (Bowen, Fleteher, snd Richmond, DASA 2115, ‘Washington, D.C., October 1968), even for long-duration bass [PROJECT REVIEW AND AUDIT PROCESSES Gnas, ResraeNces Cee for Chel Prss Suey (COPS), Cie IeyolasardEelutn Pesce Second Elton ith Worked Ecampiy, AICHE. Seon 1008 CCS, eid for Tea! Manage hema Proce Soe. ABCA 60 COPS, Cer Aung Pret Saft Menagemon yon, AIGA, 18 Introduetion view and alt proceses are used nthe che cal process indstry to evaluate, examine, and verify the design of [roses equipment, operating procedires, and management tems Tiese process sssire complance wath company standards an guidlines well ak goverament regulations. Reviews and audits an Sema i re pres nd pene gy, one nd Industral gene protection, Gualiy assurance, manenance cess and on os "Todtinganh tween a review and an aut, some deiitions wil be provided. A revew i rial examination or exauation of hy ation, procethire conion, event. or equipment item. Reviews hn take ahany forma and be identiid ss projet renews, design revi, ley reviews, pre-sarcup eviews an s0on The allowing ‘Excontn ofthe revew process val ea with projet reviews aso Sted with capa project and focus on the areata pres sale) "An abt femal metho examination snd verietion of penton, procedure, condition, even or series of transactions, The ‘enfeation clement ofan abd makes it dint from a review. A reject review wl recommend design, procera maltenance ad Tiahigemont practices to muninins hoards and seduce tak wide ‘meeting company standards and gowerment regulations. An aude srl wry tha the desig, the procedures, and the management sy tems are actually in place and ae being malted and wsed as Intended. Inf uncommon or an wt donee nents ofthe review proces are Being folowed. “The following sections wil deseibe the projet review and and processes separate, alvessing the wy, when, and haw foreach pees Project Review Process The scope of capitl projets can be lang, vosng the construction of new plans with new technologies ss products, or sal svoling mor changes to exiting faces i lle ep ny vane ca ed te a amine te process desig, operating procedures, and process con- ‘oleae fr press ls conan fo mn ‘andar nd gueline, tnd complance wih goverment regulations, Some Prt fh von press 5) ‘uipment or process anges tht could introduce harards, (2) en “tthe design bass of conta and salty ystems, (evaluate oper= king procedures for necessary revisions, (4 evauate the appiction ‘trea telnclogy and any subsequent azar (5) review the ae ‘quay of maintenance and safe inspections, and (6 evaluate the cone SEqutnees of proces deviations and determin they are sccepable (Cs 198045), “The projet review process should be integrated with the develop- ment of the projet from the conceptal sage fo the start-up Sage (CCPS, 1989, p46}, Fagwe 26-10 depts the various stages of cap fal projet. The sic and complet project wl determine Drolet progress through af diese tages and nthe same manner, Uotermie the nimber and typeof eviews that are needed. The ear Jiri projen hat «review em be ed okey required anaes, the ls coal the change ul bet nplement. For exsmpl, reviews heldat the research stage of a projet can be benef in cooing te {rest havardoustechnslgy and conrbute to at inherently fer process design that needs ewer addon sulety stems ‘As the project progresses, more information i aval therefore, the review ecg used Can be iret at each tage ofthe prop ct The use of various harard evaluation elinigues, suchas cheese Ses, late rankings, wht wes, and ra and oper F Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view eat Se rs sage among Teg Ksuea AqeOUINA UO AAR SNTRATDN OIG G-9E HOV Anpropeation Tequests <_— Projet Authorization << ~ PROCESS SAFETY ANALYSIS 26-23, Process, Design, and Review ee eee Equipment concepts paste Detsied Procurement ‘Commissioning Engineering Engineering Enginering ‘and Construction “ectinicelFensibity Process Develop Construction Instatation neck sonoma Feselaty Flow Design ‘Specitontone snd ‘nie enw ity studies, is documented in Guidlines for Hazon Eealuation Proc. fares Second Eaton with Worked Beales (CCS, 1002). The nee to use more quanétatve techniques for hazard evaluation may Beenie during these vic, and become a action Nem for the projet team ject review process inwalvesmuple eps that should be dined i management aidlnes (CPS, 183 pp. 37-61). The Steps nude 1) review plc, (2) review scheduling (9) review the nie, review team representation, (5) reve dcmentation, (6) review fllowsap, (7) review fallow-up veeaton, and (8) review roeedres change management. These steps define haw a review, Whether i be a ally resem evironmetial review, presdar-op Yeview or whatever, conducted and how closure of review action items achiewe Reclewe Po sie foal el pt {bc The number and types of review should be stated ina mavage se Pein se en by outside firms. Eee eer ag igen cients, ah ictal ent oat ae pe eon eh ge Steet ate me eel ey fois tay tr cpa fg we Bee Ero ieee ‘Reolew Team The project review ould he conducted by a func: cee te operate pect dieri wn ois he matey ome Gin cane ai pe od eta elge Oy go ean ee seca eee ee es ein Sa coef ee alt a er Rote to Seto “Review Techniques The review techniques sed st the various he phases of pital project. (CCES, 189 by penne of AICHE) stages of projet shold bleed be on the amount of process informatie ao deal avalail: gue 2611 depicts sone peal Tevow technics at the varus wage of acpi poet A dead econ eng the Qpe so emoeat ot plas fliretion Tequedfor each ew otha eu be found im Cates for idan Beatson Praca Second Eaton wth Worked Exe ‘les (CCS, 105) The procs information required for the revi ‘Roald be defined nd documented nto review gudeines Up. Aiea acne proces ron eta emg seal ice ‘evies Documentation The project rvew em ade asthe imate respons for documenting the resus of the projet Teton Ths esponsly ay be deleped oa teu seo see {ary to record Ge evi mites and ie a summary repr wth iikdation tema The aton toms cold sires econ to com nyo nds sacar od gnermentreptons, eve tam Tecommenvlatons based on expevener and knowledge. and further {Sue rsa at cul not i esd dung the Sw see “The summary rpor shoul ave asad frmst and contd con- taina don pred pe omer antago ever team morbers i iinet ling of pojec eam mebers presen, esting Hons crchekit topes reviewed bythe teat, a a is of cone Send nn tn pee lop fe hi forthe surmary repr sold be eb ad inclu the review eum, peje foun aed any penmnal oti the profet bum ike Elna sesponsbilder for any af the aon ems Alo dncide onthe dstfouon Is any appropiate management enon tel whether they be project tosh Speraees, rameter, mae $e cin nes, Pe un front ine fag. th lice begin. Review Follow-up An inporant clement (maybe the most Amporant ofthe eve process the fll to wan ems Te frgest review wil ell oa let a poten concores and tin Free, bt thot fllownp. de ante wll never be raced snd implemented. A persn() Chol be asigued to cach acon er, ey athe Une athe projet rove The porsct) ssid Joni ive s omtnaon of owed, eee and ether ‘doa proper jin allowing upon the ation tems (ECPS, 1008p 55)" Fhetol action tom i should not be ssgned to one pero, $iceltiayovenhel one india Depending onthe muber of ‘ton ems generated, pring the ation tot maybe lp Seda responsi te Foe ea can ase "Pogees on the non hems should be dacamened in pero ogres reports tothe review toa leader of aers sig a Fingiona sponsblty If noone i arigned thereon of tracking thi roges, omplton of the ston lt wl reba be ‘Pluto over pony nd ot be done Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view 26-24 PROCESS SAFETY conceptual! Enginearing Equipment Construction Changes mae to the proces res of tbe pj resew may require & sunlar review belore inplementaion, especally he logs pitane ‘Rte Fllowup Verification Inabon to someoncking the followup though progress reports, responslty should be ‘Sogned oly at eh pecs lags we actual made he RAPHE Verte Ske dae Be een tae ep Protes pre's pvt: Rem abo be prt oft poe ten Ina respons or aged wo «arcane iesRinflas pletion epeestnatne esau of he mace Prats lscompltcone npbimenan steed ‘On ve soos he Tookton pret seve cose of acini ap efcontentn bees sin ean and pe ‘Ssmmenbors fn ich sea anagomen acu al ea ne Bathe ch danas Review Procedure Change Management The project review perspec sung apedrocta ines orcs, pico sadd podls cng cigs ‘mechani or ggg change nd gn pon ego ‘Bag snd inp mong wr veces Snes ‘tt Brocla Au chia reid ca be foal on pots icy pros fc mssagencat ener {Sh eat sens 102 ecston tle ul soy roc sya pos fey mangement acy but tall be Feopnzed tthe proces ean be ap tothe ober areata wel "Proceer safely audits are intended to provide management with incesed surance al sprang fasts nd posts lane ‘een dso comerated opened and matned rh ht he Sty anf hath of mpc catanry cumin atl ds Sven beg pope pve’ (CCP, 18.315) Bry manne oe penne ae Eichten ppp asin pe to manage rg (COPS, a8 10) Pr at pre bd nthe ing eas bc wed te cy the inpencsaon af copment bsatperang and nanannee procedures contr se and ‘nagement sytem to meet the previo sted nents Preiminary Hazard Analysts of project Heard and opereity Cchecit rview Prostartupsntty review Haar evasion var poet stags: (COPS, 1955, by ermaion of AICHE) “The hey step im the sbi process are etre according to sue sa vie sd oats n B31 ‘These acotcs are desert etal in Guanes for Aaditng Fron Sefty Monet Syrtems (CCSE, 1885} ae wil be on Bey usd nace ‘PreauditProcene "Prot he acta onsite wat some prelimi sary aste the take pla, These aves inc slong the {Elis toe aude scheduling th aul slot the au team ‘nd pinning he sot The seleson eres may edom sed tm potential haar of the fen o the vate fe fics fom *Tbisines tandpoin Abdi schedling must acount for the sal ‘lio key fac personnel ands teas member person foods of he fy Qe shoul be ia normal operon, and te iced ime required to bain background information tha may rie hae te ian ea nae ian ‘embers should posses the techni tulnng tad experence to Understand the fais boing wed. They sould be owe sie im the suiting procs in the appropriate elas od ‘andarde ha el sph to he ate Tey shold set mparal {nd ebjetve dot tt Sings Th att pan shld defi the Si scope ha parts a te ay be covered wha op no wld eee) deel an at pctel that step yp gue {Dhow te ait petormed,ensy any prioty tp for Ge: Sein dap lone ines ‘Site ud Proces” An opening meting ey iy pe sonnel is bela which the abt tao covert the objectives nd ‘gpoach forthe san the acy personel provide sn overview iF he ste operations inch ste ney eles eel a seer The rvs al pres should tht low Be base te that nade {i} undemeanig management stems, 2) evaluating management ‘ystems (3) arg at ifort) eating wn rae Tint sept au fading (ECS. 199,17). ‘in anderanding the management stems pice fo contd aod dct the prt salty othe uty an beat ron ea ing einer und administrative standards, gudsines and proce. tres ht sould waa in he backrouinfomaton upp Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view Pro-audit coe Aut dose 1 “Gaon aos da = toakgouad Armen apa ai is dorand ranageTenTSTsOR ‘ona ron Sa STS PROCESS SAFETY ANALYSIS 26-25 Post-Ausit Fo. 26-12. ‘Type stepsinthe proce ty management sd proces (CSF, 108, by prion of ACRE oto the on-site sud. Informal prosdurs and guidelines used by Reality uy only be dscovered i ntersion vth sta an ‘teat and operons anagement Th understanding af the fra ind informal management ses i serial ep nthe ao ho ict proce step eae the proces tft management tome to dtermine if they ar adequate to achieve te dened ren, Sel the rectal rene hs atone igh sabete tn the anitors part. Tis step sets the stage forthe resto the aa. iting te sudhor nord gaerng an acannon on ‘Gathering at dita can be sesorplied through oberon documents ed inewcws, The date Sbsied i used to very oe ‘aide ta tbe pros ee maogementater se inglenaled {nd fenconng us deine Dts gathering can be ae by the we tau sanplsy wheres represented to dw aconclason, and by sing selevdaaton qestonaies. the se dat con hove be eeuate, reslig ih se Sings (se; concen both pose snd tego). The su Team hal cond that eee dats tas Been elected to support exch Sd in Aion ts may eed ob tre ellen ‘decides From the dts oteaton dd bo eam comers Thr poem te Sone re wad any sures acy personel, Repoing sesso should be be it the cd ofeach at day to infor acy personnel ofthe Rn tng erp ny misundentandings of he dl sn bep erect te st team necnary. The om ste au shuld end wih» wel flannel ext or con meng between the ut ears and ay Rng of te and tan shoul be presented st Tir mectn oy for eatin of any abies and detente al dipeston oe Bd Inge (written sud epor, for local stention ony et) Poet Proce The yay pce ctf peso sehr tater opment ae plas ar Art aaa inane oa Seren eng ec ad cetyl poe! SiashaSationa ln Resear ae [ined una dstsbuton st provide! iy the laeliy personel, Te aps ey t pl h el e Seema a * Mae ee a a eg Sa Pere Bs es a a et Copyright © 1999 by The MeGiaw-Hll Companies, Ine. All ight reserved. Use of| this product subject othe tems a its eens azoemen. Click har view 26-26 PROCESS SAFETY SAFETY DEVICES PRESSURE RELIEF SYSTEMS [Nomenclature &. Tiga he pac BP ‘Cc orchoed) Mit Not ton presse ide Seale ae ofthe Pie poe sae Seen owcieane ee em Tne Pie wdc storan PECs oti fg ti ae espa oe eee See caBe dcten eE te gapct reeks : RES cate t on f Mowteogh j ee Innens $97 Ren Where espasin lc TP eso apoio, Bll. Steam des emerge protected ocean? Sar eaten fle ste Ta Inve Al ces ng eal ang cen cdma lees a ct nar a ie ere So ep che as omer erty gee aa sichnegy geneccleme meee te et eruenatres cs gen ney oem Ie cone it dor cr Saeed Reece mares, pelts Se Naas he ‘Tejardless of the number of nes of defense and depressutog systems Sp Sete seein sendy Se ams myth ied li ie ss ares rn Sa ‘eewidceh che Ene ae este sien sere Sy ea ce ae He espe rnnion hs Hen eee erie ieee! lie tbe’ eth spoon penny Oo eee Ti ae pe et ae ah dare cette in oslo it to aye eta wots pou ae BEE go cis Cer tas ll fe tes dd 8 score oat aad h Cine ho iach cr ket ctl pple te fens nen begin required fora device to cose, spe " ae i ane pe toe pn ing eit iw, sully epresed as & percentage ofthe ileental se i swe wring pra (MVD) sum alowed pressure atthe op ofthe veel ane normal operating cc alec aa te PeAccumulation Tie p sure above the MAW ofthe pro- So RNtane Remnant ESN se er tn ot Coe okey rs 8 sect ta oP tae ny Hod Re heey reat Sham artiulay ets Aaa gett eam on Mana emergency Heb Stra Dengn Using DIERS Tochol pli the eer ed ry sana se ‘Metventng [NFPA Sand API Standard 2000 provide guidance for desig of verges préeton inviting rig nk tt pert st nest Sinner presen pare, NEPA) focuser farabiity issuer le AP 2000 adteses oth presse and aco ei ‘hon The ASME ode (Secon {und Vil) nd APURD 30 af the nay eferenees for pressure rl device sng requirements Deciersf emengeney presi malin ates sho i iar wh wing aan coe rt, a ty Sandan and gules. APICRP 590. Sing Solotion, ond Intaltion of Presure Relucing Devices in Rofl Past Sng sn Slecton, 50h, Js 19, and Pa fsalaton Sed, November 988 Armor {leur nso, Washington D.C ‘APU NP 221 190, Cutde for Presure-Relecingand Depresurig syed, Ameo Hele atte Westin BE APLSTD Si 1008 Vong Ampere nu Ln Besse Stor age Tan, Nonrefgeted etd Refieraed. Amencan Fete Ins, ingen, DB Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view APURP 2001, 1954, Fire Froteton in Referis American Pete Tou site, Washington, B.C ASME. 1982, Bele and Presmie Vesel Coe, Section 1, Power Bolles, and Section, VI, Pressure Vessels American SoGiety of “Mechanical Engeers, New York ASME. 1988" Performance Test Code PTC-25, Safety and Rel Vals. American Soest of Mechanical ngnoers, New York {CGEST988Engnering. Deng for Proves Soy, Amecan Taste of Chemie Engineers, New York DIENS. 1992. Emergency fie? System Design Using DIERS Tednaogy, DIBRS Pret Manual afer taste of Chemie Engineer: Nev York ‘ional Bowl of Boller and Presnie Vessel Inapectors. 1988 Presure Reliving Detoe Cerication (el Book), Nefnal Board of Boller and Pressure Vessel Columb, Ohio. ‘NFPA $0. 1980, Fammabte and Combustible Liquids Code ‘National Fie Protection Association, Quine Mass. Telief Design Scenarios ‘The mort ificut pact of designing an sdeuate emergency presrie reli system i determining the emer: ey events eres design scenario for which to design The A Sey ass prmanly heesse the identeton of erie design scenaroe usualy involes highly sobjeetve judgments, wkd ate afteninfuenoed by economic stuatons. Unforantey there exis to univerally accepted Int of credible design scenarios Relief tins be deg rte afer ta eae the most severe venting requirements (wor eredble scenario) Great judged primary hy the mimber and te ne frame of asathe faves regured to generate the postulated emergency Guia independent ester haan ies ok eo Sideredwhen judging refi Atlure resulting fom another fal tre is an effec rather an an independent causative Tato. A Sige een for asessingeechty a urction of he mim Feand tie franes of independent ease events ‘hy sage alae scribe [Mb sao res are not dle 1 Tio event in sequence are ered. 1 Three or mae evens in sequen are not rede ‘The fmt step in sconara selection i to dently al the credible veces gh peeing dens og tT hap bet accomplaved by identijing ll the possible soures of Fenland sash lle 367 nse wom asin regu and vacuum sours, PiFire ‘The main consequence offre exposure i eat np casing ‘hermaexpansonvaporation, of thennlly Induced decompostion resulta presure s. An adiional result of ire enposure isthe Dorit of werheating the wal of he equipment in he vapor pace Ine the wal not cooled bythe bq. Im his ese, the vessel wal thay al du tothe hightemperature eventhough the rit sytem i Spoaing, Culdches for eating the hal fp om fie are {bund in APL recommended practices, NFPA 30 (or bulk. rage tanks), OSHA THUD 108, and corporate engineering standard Tn determining the eat np rom Bre exposure: NEPA allows cre for ‘pation of water spc toa vessel, APT allows no sch resi. reature vessels (cluding heat exchangers and air cole) in a TABLE 26-7 Common Sources of Pressure and Vacuum Hes Relecd oe 5 Oikos ren 2 Aine Sh ne “E Repe ud enresrs 1 Heist ‘ene anfoldirereonnectons Ua ies tum ate ce) Pipl Changes ‘hoon og, Clin water eed pense” i Mijorsndlnaton SAFETY DEVICES 26-27 ant handing Sammable ida sujet opel expose to Extra fie. Avese or grup avec wich Lake apne oa pal Ire moa be poet bf apecsre rll deve, Altona po. Ton oredce the device lel ad can be ped by suaton, ‘ter spay, or remote-control Geprering eves. Hane yout Nou uotder spacing rajuremekos sus those st ork by NEPA, APL Indl Rsk Insurers, or Factory Muted mk Tiled acest fr fire Aging personnel snd ene. Ser Sees ofeqpnens octal adden yeah thereat be SELES i las pence fe Required rele load, ering ee rational Flares number of scenarios of ations ope hl les nay ret athe generation of oerpresue conan * Blocked ul,” Opraton or maltenance ems (especialy flowing pant tare an Hock he tt of god crap Sam gt aplwal pos cpp lignes Openings manual cle, Mami! wakes which se normally ial ec el le tae stream or resulting facuur conditons. Oller effects tay tnude the development of erica! love ashing of liquids, or the generation sissy demic ° Gola water are The hs of enlng water cone of he mmo ‘common cheantred cases of erpeseaon. Too ‘ampere eal eonsgnenes fs eer ete cone ‘Tinga incom meendcme and th okng Smprtsor sas and he of tens Dern sce sl be onldewed forthe crentdopeodng on wheter the aoe lets 9 ‘Sige pce af eyupmnt 6 proces unl ors plate ee ate ie es pve sh Son al ator ts and vessel agar. As with codify wate lore, power falure Go hare ane cascading efica on Ser equpmen and eos titi pt Tnsmen afr The consequences ofthe oes of inr- inet sr shld be erased tn connote ae de of ovonvel abe ata Teche not be used hatin conect "lee ilecron he coal ees sone ees Thermal expansion, Equipment and pipelines which are igud- fuller normal perng onions are eto sae csp Minis tpentare neaes Commo Sous hea ta ‘ean gh reste du fo iconal expansion inca sot Ton, ea of hey bested cing, hedge are hat ander item aie pees equpment 2 Vanuh Vac onion proces equipment cen deve due toa wide variety of ations indadiag ” Tastrament alfunton Baan of emi Id with ening Shutting off purge steam wind prestorng with noncondens able vapors iEtreme cod ambien tempertures suki in suatnopherc vapor pss “iter alton tyes that ae een stean-pargd Ujvantm onion cane ten ether epee! ast be Ahoiged fr tarun condngo aacuun rl ser mast be ep ile dares th lead Equipment Failure Most equpent Fares tht ca ea vorpretsure situations involve de rupture or brea of internal tubes Std heat exchanger undoes vents an the fae of he td I naga er eet ne pce ‘STinteral fuer Churaieratin ofthe pes a tale and to {an of he reef sem ae to he doaon ofthe dine SNARES presen guane ndetermg these ropureent itluing ena fr lng when al te pare ly SSevinthang the far of nl ves nd repannpor {Sitch both the al open dalled postions Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view 26-28 PROCESS SAFETY any, enon gop ed epee a ee a iy bape een re Sees pl le 6 a: Sere ge ee nat en Berean acento chorea ectaah Fee fa bol He nt nnn af ornare ary be ly na ge REIL AES Naa ea Sel Mecordgctyoth tele feay Dy eS ae guages Sinn, ct ane prc Bee pee ies pee ee se TTS YN Ppt Eats sins hy pe ins un erie nme eer eee see ate fe Soy Sg th adit ede igher abe et Sento rhc eA te eel cer Gs ea ae ke Sas Scbegee Se Weg ee ce le rere Falk Opt al ae pnt shea es opie od co ye ‘Coser ae espn a SEEWpos wr inloete dence acne feel ea ee oe ting eal ey rapes Sores Roca eaten et Sool Pa a anil nde hes Siggy SOT Reece cp Seeger sat eB SE ela de eee ens TABLE 26-8 summery of Device Characteristics Nea Redongdevies _| “Siri sabes | combine | Rupe ds Fadaiewenomalbalingpan | + * = “Tote de t : - Comore fide * : + ‘Feingad nner = : t Wo poe andl : 3 ‘Open qa aly t 2 “ees adage sadn § pct of st pens ad de toe ae wie F Disha Arup dis device deseo uncon by Pe tein te 9) en St haa ey meat ole See ee See oe a Re re ae Neer eee eee THE Se eapare a one as eet eee eee atte ae peter nec ae ronan ornare "The burst tolerances of rupture disks are typically about “3 percent coh lene Rl Yt for asin moh See eer eat sea hob stn etn ne gas Bae ah ese one nega ae em Phra asl ul thc ess Renta a te ttn lee fe bile wal CL eae een ann ‘Weather protection are drains as ne2ced Tallpipe systern I vatvo —§ |-— Vent ine Salety head -— sssombly — Inet aioing ® AG, 26-13 Typical presize ef stem coniguaion (a) rp dk tom) pesie Ehret Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view cae al STEM (spd) aouusnns scnew —} sea — BoNNeT — ‘SEATING SuAEACE: ADIUSTINGAING oor nome ~ 10, 26-14 Type onvotion press saab a ne t 110, 26-15 typical npr dk asebly Siring of Pressre Relief Sytem ct point design i deteeiing wheter ora thee tem sped nse ps ropa low oe funy csc Inga navn resco, bt ca ay oc nomesee wemn staves wip spargers vessel experienc hgh ea spot ‘ates or stems contsining Kao fsming agent sc atx In 8, the Desgn Institute or Energy ei! Stems (DIERS sr formed to develop tnethods for Se design of enenency sel ‘prem to handle mnaway reetons Tie DIERS from eons of Soin 2 cpus wth mc he Aran insttte of Cheneal Enver Of pata intrest wer the pre then owen trope for eog wen ecu an the pre iy of various sing method for too phe vaporiuid Baking flow situations. The tort sigifeae Storal and experimental Ending ofthe DIERS progtnfsthe ease wth wich two phase ‘apor gid fw can octur during an emergency reli sation and {Srepuement ora ch rg yo on es) to ‘The DIERS methodology importa ssa meus of addressing st: ations, such as twosphase flow, Hot covered adequately by ASME and SAFETY DEVICES 26-29 API methods. The DIERS Project Manual (DIERS, 192) the best ‘source of detailed information on these method, ‘Required Relief Rate The rived rebel rte the venting ie requited to remanethe volute belng generated within the protected ‘equipment when the eupment te highest alowed presse net volume generation rite specic volume of vent stream “The required reli rate constant oaly both the numerator ane enor Ey, 3-2) arco. coon win he protected equipment (temperature composition, etc) or he compo- tion andlor qualty of Ge vent steam are changing, Wea the required reel rates define above represents the tnsartancos Teuired ele rae. For steady-state design senaro, the reid rel rate, once determined, provides the epetyinfrmaton tha require to propery sie the webet device td asodited piping, For ‘tlsions at are ansent in nature fe the veang of «ese ed to fe) the required reli rat wl be continual changin ‘Sis espe td In te satin the dai stone “sr inthe protected eripment a or low the mas alowed ‘cumulation during the entre venting period, These case wil require the simultaneous soltion of the splcable material and ‘cneay balan ron the protected eqns ‘Conant Flow ino Protected Eupment Bor the steady-state 10): where r= voli ‘mete wapor fo rateNlamett iid Bw eae Tecnico dnl sapor ow bathe Moderate vlumeti apo liquid ras (<< 10} 1. ‘The liquid may inhibi the mass transfer rates needed to condense the vapors sparging may teretore, be lest sfiectve. Suen vapor condensation if ess concern Tow volumetrevaporfiqui tis < 1 The mitre aes ike aiid and he vapor condenstion ie dependent on et xing This il reir» ilfrent ‘ype of sarge desig. Siring and Design of Equipment ‘The information inthe fl. lowing sections that peran to the sng and design of Bowe cums fextch tanks) ind lone separators are for normal ide ‘por sytem ow veo nd nonfoamy or unstable foams) The re aol applicable to highwcosty (oewtonlan and nonnewtonia) liquids ator systems wich eat srface-active foaming behavior 20 information i ela at the present tne a fo the separation ecleney for these types of equpment Quench tanks can usually Ina high-cost bide wr wel a able foams. “Horisontal Blusdouon Drum, (See Fi 26110) The Swo main cries used n sizing horipnalboweown drums or atch tanks ae ‘Solow To The dameter must be suficent to effect good vaporquld "The total volume must be suffient to hold the estimated mount of ig earyoner from the reactor Fo &foany discharge, Copyright © 1999 by The McGraw-Hill Companies, Ine. All ight reseed. Use of| this product subject othe tems a its eens azoemen. Click har view 26-36 PROCESS SAFETY the holding volume should be greater than the reactr quid volume (tobe dseused further). One design method for sizing s horaoatal ‘lowdown drum i presented in APPRPS2] 1997), Tas ay require 2 tialand-eror design procedure to arive at an optimum drum se. “Another procedre, which has been teed inthe dnt by many companies, may be used to sie horontalblowelown deus sore ‘ireland ia olor Th Calnlte the allowable vapor veleity Us (26.2) P= vapor density Hy? eS Capac oat Values of pete in theese iterate have ringed from 0157 to 040, AK value of 0 hat rested in coment aed blow hum dns, sl to separ gud ropes 309 net ard inge "E™ calculate the vapor flow aea A, “T whore A. =vapor ow ae, Qe eeu ae 3. Assume A occupies half ofthe drum ae, so thatthe drum diameter (26:29) zx De Noms 4, Beton he dun wl ocd by id ¥ sed ‘ciate oe wephing lume ofthe rut s Te Berm tag rons, hich apy diam hl tet pninumal mt ns wn nae fe Fipmienatisa mye ar hss bees gran 5 pcagbth es,ct he dm ngh v. “Tsar were Yd aga ame Yeo du kh 6, dum gh unt iene dane aaa tee MeonePa us eS a als Se cone Peta me SS Recewet Elt cnee the dein diameter 258) ae 2n.s0) 50b* J.-E (26-36) where W-= vapor dow rate, Ih D=

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