Emergency Relief System Design Using Diers Technology: The Design Institute for Emergency Relief Systems (Diers) Project Manual

by H. G. Fisher; H. S. Forrest; Stanley S. Grossel; J. E. Huff; A. R. Muller; J. A. Noronha; D. A. Shaw; B. J. Tilley

• ISBN13: 9780470938300
• ISBN10: 0470938307
• Format: eBook
• Copyright: 2010-09-01
• Publisher: Wiley-AIChE

Summary

OSHA (29 CFR 1910.119) has recognized AIChE/DIERS two-phase flow publications as examples of "good engineering practice" for process safety management of highly hazardous materials. The prediction of when two-phase flow venting will occur, and the applicability of various sizing methods for two-phase vapor-liquid flashing flow, is of particular interest when designing emergency relief systems to handle runaway reactions. This comprehensive sourcebook brings together a wealth of information on methods that can be used to safely size emergency relief systems for two-phase vapor-liquid flow for flashing or frozen, viscous or nonviscous fluids. Design methodologies are illustrated by selected sample problems. Written by industrial experts in the safety field, this book will be invaluable to those charged with operating, designing, or managing today's and tomorrow's chemical process industry facilities.

Table of Contents

Preface

Introduction

Overview

Design Institute for Emergency Relief Systems (DIERS)

A Strategy for Major Accidental Release Prevention

A Strategy for Emergency Relief System Design

An Approach to Emergency Relief System Design Assessment

Two-Phase Vapor-Liquid Flow

Two-Phase Vapor-Liquid Flow Onset and Disengagement

Two-Phase Vapor-Liquid Hydrodynamics

DIERS Bench-Scale Apparatus

Runaway Reaction Emergency Relief System Design Computer Program

References

DIERS Committees

DIERS Sponsors

DIERS Contractors

Vapor Disengagement Dynamics

Overview

Vapor Disengagement Dynamics

Design Considerations

Detailed Discussion

Open Literature References

Project Manual

References

The Coupling Equation and Flow Models

Best Estimate Procedure to Calculate Two-Phase Vapor-Liquid Flow Onset/Disengagement

Fluid Behavior in Venting Vessels

Energy and Material Balance Derivations for Emergency Pressure Relief of Vessels

Internal Energy and Venting Calculations

Pressure Relief System Flow

Introduction

Scope

Organization

Special Terminology

Recommended Design Methods

Newtonian Flow

Complex Fluids

Useful Approximations

Technology Base

General Flow Equations

Nozzle Flow Models

Sharp Reductions

Pressure Recovery/Expansions/Equilibrations

Pipe Flow

Application to Pressure Relief System Elements

Networks

Complex Fluids

Nomenclature

Acknowledgments

References

Thermophysical Property Requirements

Equilibrium Flash Calculations

Model Parameters for Pipe Entrance Sections

Computer Routines in SAFIRE Program

Example Problems

Generalized Correlations and Design Charts

DIERS Phase III Large-Scale Integral Tests

Summary

Introduction

Program Objectives

Program Description

Test Configurations

Test Results

Tests T1 to T8

Tests V32-W1 to V32-W8

Tests T9, T10, T11, T14, and T15

Tests T12 and T13

Tests T20

Tests T17 and T18

Tests T21, T22, T23, and T24

ICRE Tests 32-6 to 32-11

ICRE Tests 2000-1 to 2000-5

ICRE Tests 32-14, 32-15, and 32-18

Acknowledgments

References

Test Configurations

Experimental Results and Model Comparisons

Kinetics Model for Styrene Polymerizations

High Viscosity Flashing Two-Phase Flow

Introduction

General Discussion of High Viscosity Flow in Relief Systems

Why High Viscosity Systems Require Special Consideration

Necessity for Conservatism

Summary of DIERS High Viscosity Relief Flow Tests

Project Overview

Styrene Reactive Tests

Small-Scale Rubber Cement Bottom-Vented tests

Large-Scale Rubber Cement Tests

Large-Scale Polystyrene-Ethylbenzene Bottom-Vented Tests

Recommended Design Practices

Theory and Scaling for Highly Viscous Systems

General Equations for Newtonian Fluids

Approximate Momentum Balances for Scaling Power-Law and Newtonian Fluids

Scaling Using Integrated Approximate Momentum Balance for Newtonian Fluids

Scaling Using Approximate Momentum Balance for Power-Law Fluids

Unanswered Questions about High Viscosity Flow

Uncertainties

References

Simplified Theory and Sample Problems

Containment, Disposal, and Mechanical Design

Introduction

Blowdown in Drum Design

Types of Knock-Out (Blowdown) Drums and Catchtanks

Sizing of Blowdown Drums

Disposal of Vapors from Blowdown Drums

Direct Discharge to the Atmosphere

Discharge through a Scrubber

Discharge through a Vent Condenser

Discharge to a Flare Stack or Incinerator

Mechanical Design

Vent Piping Considerations

Catchtank Mechanical Design and Safety Considerations

Reaction Forces-General

Reaction Forces Equations

Reaction Forces on Safety Valve Nozzles/Piping

Reaction Forces from Rupture Disk Discharge

Transient Effects of Reaction Forces, Rupture Disk Discharge

Thrust Restraint Design

Other Blowdown Load Considerations

References

DIERS Bench-Scale Apparatus

Background

DIERS Requirements for a Bench-Scale Apparatus

Limitations of Previous Test Equipment

How the Test Methodology Fits into the Overall Process Safety Design

Requests

Worst Credible Incident Scenario

Screening Tests

DIERS Venting Tests and Analysis

Recommendations

Description of the DIERS Bench-Scale Apparatus

Schematic Description of Apparatus

Apparatus Control and Data Recording

Test Cell Configurations

Emergency Relief System (ERS) Sizing Using the DIERS Bench-Scale Apparatus

Emergency Relief System (ERS) Overview

Functions of the Bench-Scale Apparatus

Onset/Disengagement Behavior Testing

Flow Rate Calculation/Viscosity Characterization

Characterization of Runaway Reaction Behavior

ERS Design-Analytical Methods/FAI Nomograph

ERS Design-Area: Charge Scaling (Top Vent Test/Top ERS Device)

ERS Design-Area: Charge Scaling/Scaling Equation Method (Bottom Vent Test/Top or Bottom ERS Devices)

Limitations on Area: Charge Scaling for ERS Design

References

Experimental ERS Sizing-Some Do and Do Not Recommendations

SAFIRE Computer Program for Emergency Relief Sizing

Background

History

Overview

Program Description

Overall Architecture

Pure-Component Physical Properties

Mixture handling Rules

Flash Calculations

Chemical Reactions

Vent Flow Calculations

Vessel Hydrodynamics

External Heat Fluxes

Mass and Energy Balances

Data Input

Sample Problem

Experience with Program

References

Input Data Forms

Sample Input/Output

Index

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