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Pressure Vessel & Boiler: High Consequences & Hazards

Boilers and pressure vessels can fail due to overpressure, overheating, or material defects, leading to explosions. Common causes of failure include inadequate design or maintenance, corrosion, opening a closed system, or equipment malfunctions that result in overpressure or excessive temperatures inside the vessel. Failures can cause injuries, fires, hazardous material releases, and property damage due to the rapid release of steam or other contents into the atmosphere. Proper design, material selection, operation, and maintenance are needed to prevent failures and their consequences.

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Makhrus Shofi
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63 views

Pressure Vessel & Boiler: High Consequences & Hazards

Boilers and pressure vessels can fail due to overpressure, overheating, or material defects, leading to explosions. Common causes of failure include inadequate design or maintenance, corrosion, opening a closed system, or equipment malfunctions that result in overpressure or excessive temperatures inside the vessel. Failures can cause injuries, fires, hazardous material releases, and property damage due to the rapid release of steam or other contents into the atmosphere. Proper design, material selection, operation, and maintenance are needed to prevent failures and their consequences.

Uploaded by

Makhrus Shofi
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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PRESSURE VESSEL & BOILER

High Consequences & Hazards

Sidik Mastrilianto, ST, MKKK


Boiler

A boiler is a closed vessel in which water or other fluid is heated. The


heated or vaporized fluid exits the boiler for use in various processes or
heating applications, including boiler-based power generation, cooking,
and sanitation.
Boiler

Causes of boiler explosions

"The principal causes of explosions, in fact the only


causes, are deficiency of strength in the shell or other
parts of the boilers, over-pressure and over-heating.
Deficiency of strength in steam boilers may be due to
original defects, bad workmanship, deterioration from
use or mismanagement."
Boiler

Causes of boiler explosions

"Cause-Boiler explosions are always due to the fact that


some part of the boiler is, for some reason, too weak to
withstand the pressure to which it is subjected. This
may be due to one of two causes: Either the boiler is not
strong enough to safely carry its proper working
pressure, or else the pressure has been allowed to rise
above the usual point by the sticking of the safety
valves, or some similar cause"
Boiler

Causes of boiler explosions


Boiler explosions are common in sinking ships once the
superheated boiler touches cold sea water, as the sudden cooling
of the superheated metal causes it to crack (JT Effect)

Boiler explosions are of a particular danger in fire tube boilers


because the top of the firebox must be covered with some
amount of water at all times; or the heat of the fire can weaken
the crown sheet or crown stays to the point of failure, even at
normal working pressure. Locomotive-type boilers use in traction
engines, portable engines, skid engines used for mining or
logging, stationary engines for sawmills and factories, for heating,
and as package boilers providing steam for other processes.
In all applications, maintaining the proper water level is
essential for safe operation.
Boiler

Principle of failure

Many shell-type boilers carry a large bath of liquid water


which is heated beyond the boiling point of water at
atmospheric pressure. During normal operation, the
liquid water remains in the bottom of the boiler due to
gravity, steam bubbles rise through the liquid water and
collect at the top for use.
Boiler

Principle of failure
If this boiler opens up to the atmosphere as a result of a
break from over pressure or other such failure the
contents are allowed to expand suddenly into the
atmosphere. The rapid release of steam and water can
provide a very potent blast, and cause great damage to
surrounding property or personnel. Since the water in
the boiler is at a higher temperature and pressure
(enthalpy) than boiling water would be at atmospheric
pressure, some of this liquid will flash into vapor as the
pressure drops by the rapid formation of steam bubbles
throughout the water.
Boiler

Principle of failure
The energy of this expanding steam and water is now performing
work just as it would have done in the engine, with a force that can
peel back the material around the break, severely distorting the
shape of the plate which was formerly held in place by stays, or
self-supported by its original cylindrical shape.

The action of the rapidly expanding steam bubbles will also


perform work by throwing large "slugs" of water inside the boiler. A
fast-moving mass of water carries a great deal of energy (from the
expanding steam), and in collision with the shell of the boiler
results in a violent destructive effect. This can greatly enlarge the
original rupture, or tear the shell in two.
Boiler

Principle of failure
Many plumbers and steamfitters are aware of the phenomenon
called "water hammer". A few ounce "slug" of water passing
through a steam line and striking a 90 degree elbow can instantly
fracture a fitting that is otherwise capable of handling several times
the normal static pressure. It can then be understood that a few
hundred, or even a few thousand pounds of water moving at the
same velocity inside a boiler shell can easily blow out a tube sheet,
collapse a firebox, even toss the entire boiler a surprising distance
through reaction as the water exits the boiler, like the recoil of a
heavy cannon firing a ball.
Boiler

Principle of failure
A steam locomotive operating at 350 psi (2.4 MPa) would have a
temperature of about 225 °C, and a specific enthalpy of 963.7
kJ/kg. Since standard pressure saturated water has a specific
enthalpy of just 418.91 kJ/kg, the difference between the two
specific enthalpies, 544.8 kJ/kg, is the total energy expended in the
explosion.

So in the case of a large locomotive which can hold as much as


10,000 kg of water at a high pressure and temperature state, this
explosion would have an energy release equal to about 1160 kg of
TNT.
Boiler

Firebox Explosion
Typically occur after a burner flameout. Oil fumes, natural gas,
propane, coal, or any other fuel can build up inside the combustion
chamber. This is especially of concern when the vessel is hot; the
fuels will rapidly volatize due to the temperature. Once the lower
explosive limit (LEL) is reached, any source of ignition will cause an
explosion of the vapors.

A fuel explosion within the confines of the firebox may damage


the pressurized boiler tubes and interior shell, potentially
triggering structural failure, steam or water leakage, and/or a
secondary boiler shell failure and steam explosion.
Boiler

Firebox Explosion
A common form of minor firebox "explosion" is known as
"drumming" and can occur with any type of fuel. Instead of the
normal "roar" of the fire, a rhythmic series of "thumps" and flashes
of fire below the grate and through the firedoor indicate that the
combustion of the fuel is proceeding through a rapid series of
detonations, caused by an inappropriate air/fuel mixture with
regard to the level of draft available. Usually causes no damage in
locomotive type boilers, but can cause cracks in masonry boiler
settings if allowed to continue.
Pressure Vessel

A pressure vessel is a closed container designed to hold


gases or liquids at a pressure substantially different
from the ambient pressure.
Pressure Vessel

High Consequences of Pressure Vessel in


Production Facility:
1.Injury to Fatality
2.Fire or Explosion
3.Hazardous Material Pollution / Spill

Beginning with Injury, we can see that the hazards of fire/explosion and
hazardous material pollution become conditions for injury since they can
lead to injury as well as being hazards in their own right.
Pressure Vessel

Common Causes of PV failure:


1.Vessel Overflow
2.Opening a closed system
3.Equipment Failure
4.Vent / Flare System Discharge
5.BLEVE (external heat)
Pressure Vessel

1.Vessel Overflow
1.Inflow Exceed outflow
2.Liquid discharge blocked

2. Opening a closed system


1.Valve Operation failure
2.Leak due to corrosion, erosion or
Maintenance
Pressure Vessel

3. Equipment Failure
1.Over Pressure
2.Excessive Temperature
3.Hit by Object
4.Material defect
5.Sudden failure of a Mechanical seal
Pressure Vessel

4. Vent or Flare System Discharge


1.Inadequate Scrubber Size
2.Scrubber inflow exceed outflow
Pressure Vessel

Loss of Containment Potential Hazards / Causes


Causes:
• Inadequate mechanical design Preventive Safeguards
• Incorrect material selection
• Corrosion – Internal & external
• External stresses – vibration Event

• Pressure and temperature excursions


• Incorrect operation
• Inadequate maintenance and Protective Safeguards

inspection
Consequences

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