Vapor Cloud Explosion Accidents Research Articles

A Database Extension for a Safety Evaluation of a Hydrogen Refueling Station with a Barrier Using a CFD Analysis and a Machine Learning Method

A methodology is proposed to extend datasets in a database suitable for use as a reference tool to support an evaluation of damage mitigation by a barrier wall in a hydrogen refueling station (HRS) during a vapor cloud explosion (VCE) accident. This is realized with a computational fluid dynamic (CFD) analysis and machine learning (ML) technology because measured data from hydrogen explosion tests with various installed barrier models usually require considerable amounts of time, a secured space, and precise measurements. A CFD sensitivity calculation was conducted using the radXiFoam v1.0 code and the established analysis methodology with an error range of approximately ±30% while changing the barrier height from that was used in an experiment conducted by the Stanford Research Institute (SRI) to investigate the effect of the barrier height on the reduction in peak overpressures from an explosion site to far fields in an open space. The radXiFoam code was developed based on the open-source CFD software OpenFOAM-v2112 to simulate a VCE accident in a humid air environment at a compressed gaseous or liquefied HRS. We attempted to extend the number of datasets in the VCE database through the use of the ML method on the basis of pressure data predicted by a CFD sensitivity calculation, also uncovering the possibility of utilizing the ML method to extend the VCE database. The data produced by the CFD sensitivity calculation and the ML method will be examined to confirm their validity and applicability to hypothetical VCE accident simulations if the related test data can be produced during experimental research. The database constructed using core data from the experiment and extended data from the CFD analysis and the ML method will be used to increase the credibility of radXiFoam analysis results for VCE accident scenarios at HRSs, ultimately contributing to safety assurances of HRSs in Republic of Korea.

Safety Issues of a Hydrogen Refueling Station and a Prediction for an Overpressure Reduction by a Barrier Using OpenFOAM Software for an SRI Explosion Test in an Open Space

Safety issues arising from a hydrogen explosion accident in Korea are discussed herein. In order to increase the safety of hydrogen refueling stations (HRSs), the Korea Gas Safety Corporation (KGS) decided to install a damage-mitigation wall, also referred to as a barrier, around the storage tanks at the HRSs after evaluating the consequences of hypothetical hydrogen explosion accidents based on the characteristics of each HRS. To propose a new regulation related to the barrier installation at the HRSs, which can ensure a proper separation distance between the HRS and its surrounding protected facilities in a complex city, KGS planned to test various barrier models under hypothetical hydrogen explosion accidents to develop a standard model of the barrier. A numerical simulation to investigate the effect of the recommended barrier during hypothetical hydrogen explosion accidents in the HRS will be performed before installing the barrier at the HRSs. A computational fluid dynamic (CFD) code based on the open-source software OpenFOAM will be developed for the numerical simulation of various accident scenarios. As the first step in the development of the CFD code, we conducted a hydrogen vapor cloud explosion test with a barrier in an open space, which was conducted by the Stanford Research Institute (SRI), using the modified XiFoam solver in OpenFOAM-v1912. A vapor cloud explosion (VCE) accident may occur due to the leakage of gaseous hydrogen or liquefied hydrogen owing to a failure of piping connected to the storage tank in an HRS. The analysis results using the modified XiFoam predicted the peak overpressure variation from the near field to the far field of the explosion site through the barrier with an error range of approximately ±30% if a proper analysis methodology including the proper mesh distribution in the grid model is chosen. In addition, we applied the proposed analysis methodology using the modified XiFoam to barrier shapes that varied from that used in the test to investigate its applicability to predict peak overpressure variations with various barrier shapes. Through the application analysis, we concluded that the proposed analysis methodology is sufficient for evaluating the safety effect of the barrier, which will be recommended through experimental research, during VCE accidents at the HRSs.

Numerical Simulation of Chemical Storage Tank Area Leakage and Explosion Accident Based on FLACS

The large amount of oil storage tank possesses significant risks of leakage, and once leakage occurs, the combustible gas is prone to fire and explosion accidents. When the combustible gas cloud is exposed to the ignition source, there are possibilities of triggering the domino effect with more serious consequences. As one important kind of protective layers, the combustible gas detectors continuously monitor the leakage of combustible gas, guaranteeing the safety performance of the site. Using the computational fluid dynamics software FLACS as a tool, the impact of the consequences of the raw material leakage with a vapor cloud explosion accident in a large chemical fiber manufacturer's storage tank area is studied, and the risk of domino effect in the tank area during the course of the accident is predicted. The study shows that FLACS can be applied to the simulation study of gas diffusion explosion phenomenon in complex operation and storage areas, with the great capability of the explosion risk quantitative assessment and the reliable prediction to the risk of domino effects.

Influencing factors of the chain effect of spherical gas cloud explosion

Flammable gases and liquids are widely used in industry and have serious leakage hazards. When a leaking gas cloud accidentally encounters an ignition source, it results in vapor cloud explosion accidents and multiple explosions. Pressure and flow field monitoring of a primary exploding spherical gas cloud and the secondary explosion of the gas cloud were conducted using the pressure acquisition system and schlieren system, and the impact of different influencing factors on exploding were analyzed. It was found that the larger the size of the primary exploding gas cloud, the smaller the distance between the primary exploding gas cloud and the secondary explosion gas cloud, and the larger the explosion intensity of the two gas clouds. Ignition on both sides of the primary exploding gas cloud was more likely to cause a blasting effect than was central ignition. The change in sparking ignition energy had no obvious effect on explosion propagation. When multiple gas clouds were exploding, the position of the primary exploding gas cloud had a considerable influence on the chain effect of exploding. If the primary exploding gas cloud was located in the middle of multiple gas clouds, interaction occurred between the primary exploding spherical gas cloud and the secondary explosion gas cloud because the angle formed by the secondary explosion gas cloud decreased, and the explosive intensity of the exploding gas cloud was higher. When the primary exploding gas cloud was on the side, the smaller the angle, the closer the lateral gas cloud was to the flame development path of the explosive gas cloud, which increased the likelihood of a blast and increased explosion intensity.

Assessment of Cascading Accidents of Frostbite, Fire, and Explosion Caused by Liquefied Natural Gas Leakage

Liquefied natural gas (LNG) leaks often lead to cascading accident disasters, including vapor cloud release, explosion, fire, and toxic gas release. The origin and evolution of each accidental disaster must be considered when assessing safety. This paper discusses the safety assessment project of an LNG gas storage station in Xuzhou, China. Multiple conceivable disasters due to the leakage of LNG storage tanks are simulated and analyzed using the computational fluid dynamic software FLACS. We studied different wind speeds interacting with the flammable vapor cloud area and creating frostbite in areas of low temperature. Diffusion simulations of vapor cloud explosion (VCE), thermal radiation, and the distribution of toxic substances were performed. The overpressure‐impulse criterion was used to calculate the influence range of VCE. Heat flux, heat dose, and heat flux‐heat dose criteria were used to calculate the safe distance for personnel in the event of fire. Based on the calculation results of the three latter criteria, this paper recommends using the heat flux criterion to evaluate fire accidents. The danger zone of each accident was compared. VCE accidents yielded the largest area.

Modeling and analysis of a catastrophic oil spill and vapor cloud explosion in a confined space upon oil pipeline leaking

Oil spill-induced vapor cloud explosions in a confined space can cause catastrophic consequences. In this work, investigation was conducted on the catastrophic pipeline leak, oil spill, and the resulting vapor cloud explosion accident occurring in China in 2013 by modeling analysis, field surveys, and numerical simulations. The total amount of the spilled oil was up to 2044.4 m3 due to improper disposal. The long residence time of the oil remaining in a confined space permitted the formation of explosive mixtures and caused the vapor cloud explosion. A numerical model was developed to estimate the consequence of the explosion based on volatilization testing results. The results show that the death-leading zone and the glass-breaking zone could be 18 m and 92 m, respectively, which are consistent with the field investigation. The severity of the explosion is related to the amount of the oil spill, properties of oil, and volatilization time. It is recommended that a comprehensive risk assessment be conducted to analyze the possible consequences upon oil spilling into a confined space. Prompt collection and ventilation measures should be taken immediately after the spill occurs to reduce the time for oil volatilization and prevent the mixture from reaching its explosive limit.

Modeling and analysis of vapour cloud explosions knock-on events by using a Petri-net approach

If flammable gas is mixed with air, and the mixture is ignited, it is possible to form a vapor cloud explosion (VCE) which may be very destructive, and easy to trigger a domino effect of accidents because of its large extent of impact. A VCE accident may induce secondary VCE accidents, then tertiary VCE accidents, and so on. This is called the cascading effect of VCE accidents, which requires an understanding of probabilities and propagation patterns to prevent and mitigate the potential damages. In this work, a methodology based on Petri-net is proposed to model the cascading effect of VCE accidents and perform probability analysis, taking the mutual influence between the accidents into account. The deficiency in probability analysis of VCE accidents is discussed. According to the limits of states and their changes which reflect characteristics of VCE propagation, a Petri-net approach is provided for modeling and analysis of VCE cascading effect, and the modeling approach and analysis process of VCE cascading effect are presented. The application and efficacy of the methodology are demonstrated via an example of VCE accidents occurring in a gasoline tank storage area. The results show that the developed methodology can effectively reveal the propagation patterns of VCEs cascading and calculate the respective probabilities of VCE accidents.

Lessons learned from analyzing a VCE accident at a chemical plant

On June 5, 2017, there was a Vapor Cloud Explosion (VCE) at JinYu Petrochemical Co. Ltd. During unloading of liquified natural gas, the gas leaked from the truck and formed a vapor cloud, then the vapor cloud met with the electrical sparks in the plant laboratory, and an explosion occurred. This incident caused significant casualties and property loss. The main causes of the accident are demonstrated by a fishbone diagram. The major causes include (a) defective design, (b) noncompliance with standard operation procedures (SOPs), (c) the presence of ignition sources, (d) ineffective enforcement of safety rules, (e) inadequate design of emergency facilities, and (f) delayed emergency response. The analysis reveals that process safety management (PSM) is a crucial factor in the success of chemical plants, especially for small and median-scale companies in developing countries. Dispersion phenomenon of liquefied gas is simulated by commercial Computational Fluid Dynamic (CFD) software. The simulation results approximately agree with the real incident. The simulation indicates that a visual and quantitative consequence analysis can provide general guidance for PSM. Finally, based on various PSM conditions (good, normal, weak, and bad), the probabilities of VCE generated from leakage are obtained by an event sequence diagram (ESD) and Monte Carlo methodology. By comparing the quantitative probability values in four different PSM situations, the results show that emergency management associated with effective PSM is crucial to avoid VCE incidents.

Real-time data-based risk assessment for hazard installations storing flammable gas

Large quantities of dangerous substances, especially explosive or flammable gases, are processed or stored in hazard installations. A risk-based warning/early-warning system for major hazard installations is very important for the prevention of major accidents. The real-time data-based risk and the risk factors are analyzed in this article, and a fuzzy logic based real-time risk assessment method is proposed. On the basis of fuzzy logic theory, the likelihood of an accident occurrence and the consequence of the accident can be assessed, and the risk value or risk level can be evaluated by utilizing a risk matrix. The method takes advantage of the real-time data acquired from the safety monitoring system so that the change in the risk can be determined as the accident develops. The risk assessment simulation of a vapor cloud explosion (VCE) accident caused by gas leaked from an liquefied petroleum gas tank is performed. It is shown that the risk of a VCE accident varies with the change of the monitored data. © 2008 American Institute of Chemical Engineers Process Saf Prog, 2008