Seminar for PETROVIETNAM 18th to 19th September 2012

Seminar on Depressurization and Safety of Process Plants

Segment Survivability Analysis Theory 1-3
Dr. Geir Berge
Petrell as Olav Tryggvasonsgt. 40 Trondheim Norway

Introduction to the subject

The purpose of a flaring system

Guide combustibles and other process inventories to a location where it can safely be released. Being one of the main safety barrier in case of accidental events. Being a part of the process operating system

Introduction to the subject

Flaring system
Segment

Segment

Segment

Segment

Introduction to the subject

Example process

Introduction to the subject

Flow diagram

Introduction to the subject P&ID for a vessel

Introduction to the subject

Means to protect process equipment

Blowdown strategy Sequential or parallel blowdown Emergency shutdown system Isolation and blowdown of segments Automatic or manual Flare capacity Sizing of segment Type of components to include Flow rate Relation to gas dispersion, explosion and fire Design of equipment Alternative material Wall thickness (vessel, pipe, etc.) Layout Distance between segments Avoid or reduce interaction between segments Fire wall or other sectionalization means Active fire protection Passive fire protection Avoid ignition of leakages Operational procedure Emergency preparedness plan Maintenance program

Introduction to the subject

Heat Exposure of Process Equipment

Introduction to the subject

Issues to be treated in a simulation

Heat transport Mixture of hydrocarbon components and water Phase changes Thermodynamic properties Solid material properties Fluid flow Stress analysis Scenario description

Introduction to the subject

Why do simulations
Cold blowdown
Low temperature issues Release rate Time to safe conditions Liquefied percentage of flow

When exposed to fire

Time to rupture Release rate Need for insulation Component behavior Time to safe condition

Introduction to the subject

When start using VessFire?

Pre-FEED

FEED-study

All possibilities, only experience available Almost all possibilities, main feature available, design basis still not fixed Less possibilities, main design starts to be set, design basis fixed. Changes are expensive, building process is going on.

Detail engineering Construction

Blowdown calculation procedure

Procedure for flare design

Find flare capacity based on radiation limitations on personnel and equipment. (gas dispersion limitations) Distribute capacity to each segment Identify credible scenario Perform blow down study on each segment based on given rate and scenario. Redistribute capacity if necessary.

Blowdown calculation procedure

Thermal radiation
ISO 23251

Jet fire test

1. kg/s propane gas

Photo: SINTEF NBL AS

0.3 kg/s propane gas

Photo: SINTEF NBL AS

Heat load

Potential heat load

900 800 700 600 500 400 300 200 100 0 200 400 600 800 1000 1200 1400 1600 1800 Temperature [C]
Radiation heat load [kW/m2]

Heat load

Flame emissivity
1,0 0,9 0,8 0,7

Emissivity

0,6 0,5 0,4 0,3 0,2 0,1 0,0 0,00

1 e
2,00 4,00 6,00 8,00 10,00 12,00 14,00 Flame thickness [cm] Extinction coefficient 0,2 [1/cm] 1,0 [1/cm]

Extinction coefficient s Beam length

16,00 18,00 20,00

Heat load

Effect of flame emissivity

900

Radiation heat flux [kW/m2]

800 700 600 500 400 300 200 100 0 200 400 600 800 1000 1200 1400 1600 1800 Temperature [C] Flame emissivity 1,00 0,80 0,60 0,40 0,30 0,20 0,15 0,04

Standards

ISO 23251 relation to API 521

This International Standard is based on the draft 5th edition of API RP 521, with the intent that the 6th edition of API RP 521 will be identical to this International Standard.

5.15.2 Fire relief loads

Under chapter 5.15.2.1 General The fire-sizing equations in Clause 5 assume typical in-plant conditions for facilities within the scope of this International Standard but can be understated for vessels in partially enclosed or enclosed areas, such as those in buildings or on-offshore platforms. For further information, see References [67] or [30]; these documents provide an alternative approach based on analytical methods and can be used to model fire-heat input for all types and sizes of fire. 5.15.2.3 More rigorous calculations As stated in the general introduction, two methods are presented If the user considers that the preceding assumptions in 5.15.2.2 are not appropriate, more rigorous absorption equations for specified. In such 5.15.2.2 Heat methods of calculations may be vessels cases, it can be necessary to obtain the required physical properties of the This is the traditional estimated containing fluid from actual data or approach from equations of state. It might be necessary to consider the effects of vessel mass and insulation. The pressure rate is based on an unsteady state. As the fire continues, the vesselrelieving5.15.2.3 More rigorous calculations wall temperature is a physical more correct approach This and the contained-gas temperature and pressure increase with time. The pressure-relief valve opens at the set pressure. With the loss of fluid on relief, the temperatures further increases at the relief pressure. If the fire is of sufficient duration, the temperature increases until vessel rupture occurs. Procedures are available for estimating the changes in average vessel-wall and contained-fluid temperatures that occur with time and the maximum relieving rate

The fire-sizing equations in Clause 5 assume typical in-plant conditions for facilities within the scope of this International Standard but can be understated for vessels in partially enclosed or enclosed areas, such as those in buildings or on-offshore platforms. For further information, see References [67] or [30]; these documents provide an alternative approach based on analytical methods and can be used to model fire-heat input for all types and sizes of fire.

Standards

Reference to a new approach

5.15.2.3 More rigorous calculations

5.15.2.3 More rigorous calculations If the user considers that the preceding assumptions in 5.15.2.2 are not appropriate, more rigorous methods of calculations may be specified. In such cases, it can be necessary to obtain the required physical properties of the containing fluid from actual data or estimated from equations of state. It might be necessary to consider the effects of vessel mass and insulation. The pressurerelieving rate is based on an unsteady state. As the fire continues, the vesselwall temperature and the contained-gas temperature and pressure increase with time. The pressure-relief valve opens at the set pressure. With the loss of fluid on relief, the temperatures further increases at the relief pressure. If the fire is of sufficient duration, the temperature increases until vessel rupture occurs. Procedures are available for estimating the changes in average vessel-wall and contained-fluid temperatures that occur with time and the maximum relieving rate at the set pressure [51], [52]. These procedures require successive iteration. For fire-insulated segments exposed to fire, it is recommended to assume the fire temperature outside the insulation layer and that the heat input to the fluid is calculated by conduction through the insulation layer and the vessel wall. The heat-transfer resistance from the wall to the fluid is very low compared to the insulation layers resistance and can be (is usually) neglected. A more rigorous method is described in Reference [141]. There are temperature differences between the liquid and gas phases. Tools are becoming available to perform non-equilibrium temperature calculations; for further information, see Reference [30].

Standards

New procedures for design of pressurised systems

Guidance for the Design and Analysis of Fire Response of Pressurized Systems, Statoil, Hydro, Scandpower Guidelines For The Design And Protection Of Pressure Systems To Withstand Severe Fires, The Institute of Petroleum, London

Heat load; New approach

Heat load principle

Peak load Background load

Heat load; New approach

Calculation of heat load and exposure time

2 scenario applies: 1. 2. For the time period t mleak > 2 kg/s use 350/100 For the time period t mleak > 0.1 kg/s use 250/0

Each scenario shall run independently, meaning the initial temperature for each scenario is the operational temperature.
mleak is based on the hole size giving the longest leak duration. The segment is not exposed for heat during calculation of t and t.

Heat load

Calculation of fire duration

Exposure time for the two scenarios (previous slide) shall be based on the segment that gives the longest exposure.

Unexposed segment has been used when exposure time should be found
Include time for detection and activation.

Heat load

Leak duration
Duration of leak rates > 2 kg/s for the IP-segment 18 16 14 12

Time [min]

10 8 6 4 2 0 10 15 20 25 30 35 Diameter [mm]

Heat load

Heat load model

1400 1200 1000 800 600 400
5W/m2K. Curve for resulting flame temperature when applying default settings of heat transfer coefficients in VessFire. Curve for radiation only. Flame emissivity equal 1.

Flame temperatur [C]

100W/m2K. Frequently used heat transfer coefficient for jet fire.

30W/m2K. Frequently used heat transfer coefficient for pool fire.

200 0 0 50 100 150 200 250 300 350 400 450 500 Exposed heat flux [kW/m2] Heat tranf. [W/m2K] 0 Heat tranf. 5 Heat tranf. 30 Heat tranf. 100

Heat load

Exposure from jet fire

Fire scenario and its key parameters

Standard jet fire test

0.3 kg/s propane gas Photo: SINTEF NBL AS

Heat load

Axial and radial temperature

From Principles of Combustion Kenneth K. Kuo (Mao et al.)

N-pentane liquid spry

Heat flux variation on a steel plate exposed to fire

Ref. A test method for Jet Fire Exposure, R. Wighus & L. Shirvill, 6th International Symposium on Loss Prevention and Safety Promotion in Process Industries, 1996

Heat load

Jet fire exposure

Heat load

Pool fire

Heat load

Pool fire simulation

Steel behaviour in fire

Stress-strain relation at normal conditions

Steel behaviour in fire

Stress-strain relation at elevated temperature

Steel behaviour in fire

Steel behaviour in fire

Creep

Acceptance criteria

Acceptance criteria
The API recommended practice: Pressure reduction to: half the operational pressure within 15 minutes.

API 521 5th edition 2007

5.15.1.2.2 A characteristic of a vessel with an unwetted internal wall is that heat flow from the wall to the contained fluid is low as a result of the resistance of the contained fluid or any internal insulating material. Heat input from an open fire to the bare outside surface of an unwetted or internally insulated vessel can, in time, be sufficient to heat the vessel wall to a temperature high enough to rupture the vessel. Figures 1 and 2 indicate how quickly an unwetted bare vessel wall can be heated to rupture conditions. Figure 1 illustrates the rise in temperature that occurs with time in the unwetted plates of various thicknesses exposed to open fire. For example, an unwetted steel plate 25 mm (1 in) thick takes about 12 min to reach 593 "C (1100"F) and 17 min to reach 704 "C (1 300 "F) when the plate is exposed to an open fire. Recent calculations indicate that the heat flux of the fire is in the range of approximately 80 kW/m2 to 100 kW/m2 (25 200 Btu/ft2h to 31 500 Btu/ft2h).

704C 593C

120 (17.38) 60 (8.69)

5.20 Vapour depressuring 5.20.1 General EXAMPLE If a pool fire exposes the unwetted wall of a large [25,4 mm (1 in) wall thickness] vessel fabricated from ASTM A 515 Grade 70 carbon steel, it will take about 15 min to heat the vessel walls to around 649 "C (1 200 OF), as shown in Figure 1. At this temperature, rupture due to overheating is imminent as the material's allowable stress [120 MPa (17 500 psi) at ambient temperature] approaches its rupture stress, as given in Figure 2. In contrast, if the vessel is depressurized within the 15 min heat-up time to, say, 50 % of the initial pressure (i.e., half the initial internal stress), then the time to rupture would increase to about 2 h to 3 h (see Figure 2). If vapour depressuring is required for both fire and process reasons, the larger requirement should govern the size of the depressuring facilities.

A vapour-depressuring system should have adequate capacity to permit reduction of the vessel stress to a level at which stress rupture is not of immediate concern. For pool-fire exposure and with heat input calculated from Equations (6) or (7), this generally involves reducing the equipment pressure from initial conditions to a level equivalent to 50 % of the vessels design pressure within approximately 15 min. This criterion is based on the vesselwall temperature versus stress to rupture and applies generally to carbon steel vessels with a wall thickness of approximately 25,4 mm (1 in) or more. Vessels with thinner walls generally require a somewhat faster depressuring rate. The required depressuring rate depends on the metallurgy of the vessel, the thickness and initial temperature of the vessel wall and the rate of heat input.

Fire experiment
Small fire 0.3 kg/s propane

1400

Flame temperature
18 1200

1000

17 800

[C]

600

400

18 17 200

0 0 10 5 15 [min] 10 20 15 25

1200 15 16

13 12 1000

14

800

[C] 600

400

Steel temperature

200

0 0 10 5 15 [min] 10 20 15 25

Acceptance criteria

Time History of Internal Pressure and Average Temperature of Vessel Shell

3 000 2 500

1400 1200 1000 800

2 000 1 500

600 1 000 500 0 0 2 4 6 8 Time [min] Pressure in vessel Max. average steel temperature 10 12 14 400 200 0

Temperature [C]

Pressure [kPa]

API 521 Requirements

Acceptance criteria

Time History of Internal Pressure and Average Temperature of Vessel Shell

3 000 2 500

1400 1200 1000

2 000 1 500

API 521 Requirements

800 600

1 000 500 0 0 10 20 30 40 50 60 70 Time [min] Pressure in vessel Max. average steel temperature

400 200 0

Temperature [C]

Pressure [kPa]

Acceptance criteria
Time History of Yield Stress, Applied Stress and Average Temperature of Vessel Shell

100 90 80

1400 1200 1000 800 600 400 200 0 70,0

70 60 50 40 30 20 10 0 0,0 10,0 20,0 30,0 40,0 50,0 60,0 Time [min] UTS Calculated stress of shell Max. average steel temperature

Temperature [C]

Stress [N/mm2]

Acceptance criteria

How much time is needed?

Emergency preparedness plan: Rescue injured personnel Evacuate personnel to safe haven Abandon installation Avoid escalation Reduce damage Extinguish fire

Acceptance criteria

Common acceptance criteria

Maximum remaining total hydrocarbon: 4000 kg Maximum remaining hydrocarbon gas: 1000 kg Maximum pressure in pipe: 20 bar g Maximum pressure in vessel: 4.5 bar g Minimum time to rupture: 3 minute.

Theoretical basis

Physical phenomena during depressurisation

Theoretical basis

Definition of a segment
Orifice

Blowdown valve (BDV) Blowdown line Vessel

Theoretical basis

Wall thickness versus diameter

Wall thickness

10

Diameter

Theoretical basis

BDV and flow orifice

Location has to be set Opening time Orifice
Contraction factor Back pressure

Theoretical basis

PSV profiles
PSV does not function as protection to fire

Theoretical basis

Vessel
Multiple vessels in a segment Liquid height Water height Inventory composition
Composition at inflow

Adding insulation (3 layers) Pool fire or jet fire

Theoretical basis

Pipes
Diameter, wall thickness, length Liquid and gas Heat exposure principle Mill tolerance Corrosion allowance

Theoretical basis

Exposure of pipe

Theoretical basis

Longitudinal vertical

Longitudinal horizontal

1 Circumferential
0 Up

Vessel Vessel

Theoretical basis

Specification of applied material

Weakening curve UTS stress from standard, certificate or class description Stress factor Database operation

Theoretical basis

Theoretical basis

Theoretical basis

Theoretical basis

Variation in reduction factor

Calculation results Temperature development of vessel shell

0 sec. after exposure

30 sec. after exposure

300 sec. after exposure

1200 sec. after exposure

1591 sec. after exposure . Fire extinguish after 1500 sec.

1766 sec. after exposure

Calculation results

Inside and outside temperature plot after 300 sec. of start exposure

Calculation results
Gas filled pipe without insulation
700 600 500 01>6-PS-23-062-CS71<Str 1400 1200

400 300 200 100 0 0 10 20 30 40 50 60 70 Time [min.] UTS Calculated stress Steel temperature

800 600 400 200 0

Temperature [C]

1000

Stress [MPa]

Calculation results
04>12-PS-23-051-CS71<Str 700 600 500

Liquid filled pipe without insulation

1400 1200

400 300 200 100 0 0 10 20 30 40 50 60 70 Time [min.] UTS Calculated stress Steel temperature

800 600 400 200 0

Temperature [C]

1000

Stress [MPa]

Calculation results
00>1-PL-25-195-CC11<Str 500 450 400

Gas filled pipe with insulation

800 700

300 250 200 150 100 50 0 0 10 20 30 40 50 60 70 Time [min.] UTS Calculated stress Steel temperature

500 400 300 200 100 0

Temperature [C]

Stress [MPa]

350

600

Petrell as Olav Tryggvasonsgt. 40 NO-7011 Trondheim Phone: (+47) 73 80 55 00 Fax: (+47) 73 80 55 01 E-mail: petrell.petrell.no www.petrell.no www.vessfire.com

Petrell AS Olav Tryggvasons gate 40 NO-7011 Trondheim Norway Phone: (+47) 73805500 Fax: (+47) 73805501 post@petrell.no www.petrell.no