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  • 2002 11 What Has Your Steam Up

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    Harshad Solanki
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    This document describes a process safety incident where hot asphalt was added to a trailer that still contained water from a recent cleaning. The water rapidly vaporized upon contact with the hot asphalt, expanding 1600 times in volume and causing significant damage to the trailer. Such incidents commonly occur when a hot material is introduced to a vessel containing a lower boiling material like water or oil. Proper cleaning and verification that no trapped water remains is critical when transferring hot liquids above 212°F to prevent dangerous pressure buildups from vaporization.

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    This document describes a process safety incident where hot asphalt was added to a trailer that still contained water from a recent cleaning. The water rapidly vaporized upon contact with the hot asphalt, expanding 1600 times in volume and causing significant damage to the trailer. Such incidents commonly occur when a hot material is introduced to a vessel containing a lower boiling material like water or oil. Proper cleaning and verification that no trapped water remains is critical when transferring hot liquids above 212°F to prevent dangerous pressure buildups from vaporization.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    6 views1 page

    2002 11 What Has Your Steam Up

    Uploaded by

    Harshad Solanki
    This document describes a process safety incident where hot asphalt was added to a trailer that still contained water from a recent cleaning. The water rapidly vaporized upon contact with the hot asphalt, expanding 1600 times in volume and causing significant damage to the trailer. Such incidents commonly occur when a hot material is introduced to a vessel containing a lower boiling material like water or oil. Proper cleaning and verification that no trapped water remains is critical when transferring hot liquids above 212°F to prevent dangerous pressure buildups from vaporization.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
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    CCPS

    An AIChE Industry Technology Alliance

    Process Safety Beacon


    Messages for Manufacturing Personnel
    November 2002

    Sponsored by Monsanto Company

    WHAT HAS YOUR STEAM UP


    The Incident:
    At first glance, this appears to be a traffic incident but take a closer look! You are looking at a process safety event. The photos graphically explain what happens when HOT asphalt is added into a trailer that has been recently cleaned with water. Unfortunately, the excess water is not removed from the trailer before adding the asphalt - the water rapidly turns to steam and expands in volume about 1600 times. The result significant damage. In this case its a tanker, but it could just as easily have happened to a vessel or piping system. No injuries occurred.

    Common Causes of failures like this:


    This type of event has happened MANY times, often involving heat transfer fluids, mineral oils or other heavy organic materials (like the asphalt above). The event begins when a HOT material is added to a vessel or piping which contains materials with a boiling point under the temperature of the hot material. In general, the larger the difference between the temperature of the hot material and the boiling point of the lower boiling material, the more significant the damage. As heat is transferred from the hotter material, vaporization of the lower boiling material occurs and the pressure that results can cause lots of damage!

    What Can I do?


    During ANY material transfer, if the liquid being transferred is hotter than 212F/100C take steps to make certain there is no water in the downstream equipment. Water removal is often difficult in complex piping systems: Low point drains MUST be opened, piping must be carefully examined for traps and flanges may need to be opened in MANY locations. Shipping containers are frequently cleaned with water; any shipping container must be assumed to contain water unless steps have been taken to remove it. Proceed slowly when starting up processes following shutdowns, especially with fluids that are very hot.

    HOT liquids have many hazards! Dont forget they can lead to significant pressure buildup if added to vessels containing water or other materials with boiling points lower than the temperature of the hot fluid.
    AIChE 2002. All rights reserved. Reproduction for non-commercial, educational purposes is encouraged. However, reproduction for the purpose of resale by anyone other than CCPS is strictly prohibited. http://www.aiche.org/ccps/safetybeacon.htm Contact us at ccps@aiche.org or 212-591-7319.

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