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Root Cause Analysis of a Cryogenic Refrigeration System Explosion

机译:低温制冷系统爆炸的根本原因分析

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Emergency response personnel who responded to a smoke alarm at a manufacturing facility were injured when a cryogenic refrigeration system overheated and then exploded. The refrigeration system was a skid-mounted package unit that relied upon liquid nitrogen as the cryogen, a heat transfer oil as the secondary refrigerant, and electrical resistance heaters as a heat source to provide split-range control over the heat transfer oil temperature. The incident investigation revealed that the event was not the result of a simple single cause. Detailed root cause investigation and failure analysis was performed to identify the underlying causes.rnThe explosion was caused by the thermal expansion of trapped liquid. It was determined that several elements of good engineering practice that are considered to be basic safety measures in chemical processing plants were not considered by the equipment designers. The following deficiencies were noted:rn1. The freezing point of the heat transfer oil was lower than the approach temperature of the nitrogen vapor in the cryogenic heat exchanger. If oil circulation stopped for any reason, the oil could freeze.rn2. In the heat transfer oil circuit, the electrical resistance heater was installed between a check valve and a manual valve with no pressure relief. The cryogenic heat exchanger was adjacent to the manual valve. If the oil in the cryogenic heat exchanger froze, it would behave like a closed valve.rn3. There was an interlock linking the oil temperature to the actuation of the electrical heater, but the temperature sensor was located far from the location of the heater. When the cryogenic heat exchanger froze, it isolated the temperature sensor from the oil in the immediate vicinity of the heating coils. This created the opportunity for a runaway heater.rn4. The design documentation and functional specifications provided by the refrigeration system manufacturer was inadequate for an independent hazard analysis.rnThe lessons learned from this incident can be applied by facilities to evaluate similar specialty refrigeration packages before integrating them into their plants.
机译:当低温制冷系统过热然后爆炸时,对制造工厂的烟雾报警器做出反应的紧急响应人员受伤。制冷系统是撬装式包装单元,它依靠液氮作为致冷剂,传热油作为辅助制冷剂,以及电阻加热器作为热源,以对传热油温度进行分段控制。事故调查表明,该事件不是简单的单一原因造成的。进行了详细的根本原因调查和故障分析,以找出根本原因。爆炸是由截留液体的热膨胀引起的。已确定设备设计者未考虑良好的工程实践的几个要素,这些要素被认为是化学加工厂的基本安全措施。指出以下缺陷:rn1。传热油的凝固点低于低温热交换器中氮气的接近温度。如果由于任何原因停止了油循环,则油可能会冻结。在传热油回路中,电阻加热器安装在单向阀和手动阀之间,无压力释放。低温热交换器与手动阀相邻。如果低温热交换器中的油结冰,其行为将类似于关闭的阀门。有一个联锁装置将机油温度与电加热器的致动联系起来,但是温度传感器的位置远离加热器的位置。当低温热交换器冻结时,它将温度传感器与加热线圈附近的油隔离开。这为加热器失控创造了机会。制冷系统制造商提供的设计文档和功能规格不足以进行独立的危害分析。rn从此事件中汲取的教训可以被设施应用到评估类似的特种制冷包装中,然后再将其整合到工厂中。

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