vessel design slides
TRANSCRIPT
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Where We Go Wrong In Vessel Design
Dick Hawrelak
Presented to ES-317Y in 1999 at UWO
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Introduction 30% of large property damage losses are
caused by failures in tanks, process drums and marine vessels.
Average Trended Loss was $40.5MM for tanks alone.
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1984 U.S. National OSHA Record
6486 accidents. 516 injuries. 90 deaths.
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OSHA Record Includes Power Boilers Water Boilers and Steel
Tanks Cast Iron Boilers Pressure Vessels (poorest
record)
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Pressure Vessel Record 1310 / 6486 accidents 437 / 516 injuries 73 / 90 deaths
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Press Vessel Components Shell Head Attachements Piping Safety Valves Misc
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PV Failure Causes Operator error or poor maintenance
– 149 / 933 Faulty Design – 144 / 933 Corrosion or erosion – 132 / 933 Pressure control failure – 41 / 933 Other – 420 / 933
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PV Failure Types Cracked – 403 / 1087 Other - 298 / 1087 Leakage – 163 / 1087 Rupture – 158 / 1087 Explosion – 22 / 1087 Collapsed Inward – 15 / 1087
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Obtain Data & Analyze Search OSHA records On Internet -
Google Extract records Create Excel Database Sort and Filter data Analyze Data
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Personal Experiences Based on 33 Years of Chemical
Plant Design at Dow.
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Incomplete Mass Balances
Normal mass balance. Start-up, shut down or upset. Recycle conditions. Off-loading situations unplanned.
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Residence or Hold-up Time
Inventory logistics not well defined. Flammable or toxic inventories too
high.
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Containment
Dyke dimensions do not meet codes.
Drainage does not follow NFPA 15. Catastrophic failure overwhelms
dyke walls.
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Materials Of Construction
Not suitable for corrosive fluid at high temperature.
Not suitable for low temperature excursions.
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Quantum Explosion - 7 June 89
A-515-70 grade CS brittle failure of heat exchanger shell.
Start-up, inlet flange leak, isolated exchanger and depressured to flare.
30 minutes to failure. Two fatalities, seven serious burns, major damage to ethylene plant.
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Nozzles Level control nozzles in wrong
location. Nozzles too small creating
impingement on far wall. PSV nozzles not suitable for thrust.
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Visit U.S. EPA CEPP Web Site
Chemical Emergency Preparedness and Prevention Office web site at www.epa.gov/ceppo/acc-his.html
Check Rupture Hazard of Pressure Vessels.
Check Catastrophic Failure of Storage Tanks.
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Ammonia Storage Tank Modification Oil and Gas Journal, Dec 26, 1998 Pressure storage in spheres Removes bottom unloading lines. Converts to overhead siphon system. Excellent article on 4 process design
options.
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Typical Pressure Vessel
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KO Pot Design
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Internals Impingement details not well
designed. Pump-out sumps act as dirt trap. KO Pot internals not designed
properly.
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Design Pressure Design Pressure not suitable for
upset conditions.
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Reactive Chemicals P&IDs must be examined for
reactive chemical possibilities.
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Low Pressure API Tanks Very easy to bulge or suck-in
resulting in loss of containment. PSV, pad de-pad settings very
close. Floating roof explosion at Suncor
in Sarnia. Roof hangs up on pump-out, air sucked into vapor phase, lightning ignites flammable vapor.
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Breathing. Pumping and temperature change
breathing not allowed for in combination.
High breathing losses a cost and an environmental problem - Benzene tank.
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Vapor Recovery Options Not well understood. See BLOSS program for design
options.
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Flammable Storage Area
EO storage bunkers located 1 mile from ISBL.
3 independent means of checking quantity to prevent overfilling (dual LC, weigh scale & flow rate x time).
Refrigeration to prevent polymerization, chart temperature.
Dump contents to pond if runaway reaction takes place.
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EO Storage
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Toxic Storage
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Possible Exam Questions What are three independent methods
for preventing overfilling of a storage vessel.
If a storage product can generate heat by polymerization at ambient temperatures, what safety measures should be considered?
What are the main problems with fixed roof, low pressure API type storage vessels?
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Exam Questions Cont’d
What is one of the main problems with an API, floating roof storage tank in flammable service?
What are the safety measures that should be taken for a large chlorine storage sphere to prevent a toxic gas release?
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Summary This short list is indicative of some
of the problems caused by poor engineering discipline in vessel design.
Recommend you obtain a copy of the Chemical Plant Design programs and follow the procedures built into the vessel design spreadsheets.