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RR1108 Research Report © Crown Copyright 2017 Liquid classification for flammable mists Prepared by the Health and Safety Executive RR1108 Research Report © Crown copyright 2017 Prepared 2012 First published 2017 You may reuse this information (not including logos) free of charge in any format or medium, under the terms of the Open Government Licence. To view the licence visit www.natio nalarchives.gov.uk/doc/open-government-licence/, write to the Information Policy Team, The National Archives, Kew, London TW9 4DU, or email [email protected]. Some images and illustrations may not be owned by the Crown so cannot be reproduced without permission of the copyright owner. Enquiries should be sent to [email protected]. Many types of industrial equipment can potentially produce an explosive oil mist if a fault develops. However, information on the conditions in which a mist can be ignited and continue to burn is limited. To help address this, HSE and 14 industry sponsors co-funded a Joint Industry Project (JIP) on oil mist formation and ignition. This report, produced for the JIP, addresses the contribution the fluid within a pressurised system makes to the risk of an ignitable mist forming if a leak develops. Fluids were put into three groups, based on their flashpoint and ease of atomization: “volatile fuels” include fuels and solvents which have a low flashpoint and atomize easily; “lubricants” include many actual lubricants and also heat transfer fluids and other oils with a relatively high flashpoint and poor atomization; “fuel oils” which have a low flashpoint but poor atomization. When heated, “fuel oils” should show similar behaviour to “volatile fuels”. This work was used to select a representative fluid from each group for use in experimental tests. This report and the work it describes were funded through a Joint Industry Project. Its contents, including any opinions and/or conclusions expressed, are those of the authors alone and do not necessarily reflect HSE policy or the views of the Joint Industry Project sponsors. ii LiquidLorem classification ipsum dolor for flammable sit amet mists consectetuer adipiscing elit Graham Burrell and Dr Simon Gant Health and Safety Executive Harpur Hill Buxton Derb yshire SK17 9JN iii SPONSORS This HSE Joint Industry Project was sponsored by: Office for Nuclear Regulation Maersk Oil North Sea UK Limited BP Exploration Operating Company Ltd ConocoPhillips (UK) Ltd Nexen Petroleum UK Ltd National Institute for Public Health and the Environment (RIVM) Statoil Petroleum AS GE Power and Water Atkins Ltd Frazer-Nash Consultancy Ltd Syngenta Ltd Rolls Royce Controls and Data Services Ltd Energy Institute RWE Generation UK iv CONTENTS 1 INTRODUCTION ......................................................................................... 3 2 LIQUID BREAK-UP .................................................................................... 4 2.1 Primary break-up ..................................................................................... 4 2.2 Secondary break-up ................................................................................ 5 3 DATA SOURCES FOR LIQUIDS ............................................................... 7 3.1 Lubricating Oil .......................................................................................... 7 3.2 Hydraulic Oil ............................................................................................ 7 3.3 Light Fuel Oil ........................................................................................... 8 3.4 Heavy Fuel Oil ......................................................................................... 8 3.5 Jet Fuel/Kerosene ................................................................................... 9 3.6 Diesel ....................................................................................................... 9 3.7 Bio-diesel ................................................................................................. 9 3.8 Vegetable Oil ......................................................................................... 10 3.9 Heat Transfer Fluid ................................................................................ 10 3.10 Transformer Oil ...................................................................................... 11 3.11 Process Fluids (Solvesso) ..................................................................... 11 3.12 White Spirit ............................................................................................ 11 4 RESULTS ................................................................................................. 12 5 CONCLUSIONS ........................................................................................ 16 6 REFERENCES .......................................................................................... 18 1 EXECUTIVE SUMMARY Objectives The purpose of this report is to propose a classification system in order to group together the following liquids according to their potential to form flammable mists from pressurised releases: • Lubricating Oil • Hydraulic Oil • Light Fuel Oil • Heavy Fuel Oil • Jet Fuel/Kerosene • Diesel • Bio-diesel • Vegetable Oil • Heat Transfer Fluid • Transformer Oil • Process Fluids (Solvesso) • White Spirit Main Findings A classification system has been developed based on the flashpoint and estimated ease of atomisation, and the above liquids have been separated into three groups. Group one, “volatile fuels and solvents” atomise easily and have a relatively low flashpoint, a typical example being diesel. Group two, “lubricants” consists of heat transfer fluids and various application oils that have both a high flashpoint and a high resistance to atomisation. Group three “fuel oils” consists of petroleum fractions that have a low flashpoint and high resistance to atomisation at ambient temperature. It is believed that at elevated temperatures (i.e. once pre-heated) the properties of “fuel oils” should be similar to that of diesel. The limited data that were found for the properties of bio-diesel indicate that its behaviour lies between groups one and two. Recommendations To investigate a range of different fluid properties, it is recommended to conduct mist flammability tests using the following five liquids: 1. Lubricating oil (group 1 exemplar) 2. Kerosene (group 2 exemplar) 3. Light Fuel Oil at ambient temperature (group 3 exemplar) 4. Light Fuel Oil pre-heated before release 5. Bio-diesel 2 1 INTRODUCTION A Joint Industry Project (JIP) is currently in progress to assess the risks resulting from flammable mists produced by pressurised releases of high flashpoint liquids through small orifices [1]. A number of liquids have been suggested for experimental investigation: • Lubricating Oil • Hydraulic Oil • Light Fuel Oil • Heavy Fuel Oil • Jet Fuel/Kerosene • Diesel • Bio-diesel • Vegetable Oil • Heat Transfer Fluid • Transformer Oil • Process Fluids (Solvesso) • White Spirit Experimental measurements of the flammable mist properties of each of these liquids would be costly, time-consuming and have limited benefits, since many of the liquids are variable in terms of their composition and material properties. To rationalise the selection of liquids for testing in the future JIP experiments, the present report presents a flammable mist classification system. This system uses two parameters to estimate the propensity for a liquid to form a flammable mist: the ignitability of the liquid (represented here by the flashpoint) and the tendency for a liquid jet to atomise into droplets when released through an orifice. For this latter measure, the atomisation behaviour is assessed using two different empirical correlations: the primary atomisation correlation from Ohnesorge [2] and the secondary atomisation correlation of Brodkey [3]. This results in a classification system separating the selected liquids into distinctive categories based on modelled behaviour. A number of exemplar liquids have been suggested including a representative liquid from each category. 3 2 LIQUID BREAK-UP 2.1 PRIMARY BREAK-UP In 1936, Ohnesorge [2] published the results from a series of experiments that examined the primary break-up of pressurised liquid jets through an orifice (Figure 1). The experiments were undertaken with various oils, glycerine, aniline, and water using orifice diameters of between 0.5 mm and 4.0 mm. Liquid jet break-up was characterised into three regimes: Rayleigh, wind- induced and atomisation, based on the Reynolds and Ohnesorge numbers. The mean diameters of the droplet distribution become progressively smaller from each of these regimes. Wind- Rayleigh Atomisation induced ρl Ul D Reynolds number, Rel = µl Figure 1 – Spray breakup regimes, from Ohnesorge [2] The Reynolds number was determined by Ohnesorge [2] from: ρlU O dO Rel = (1) µl where: -3 ρl = Density of liquid (kgm ); dO = Diameter of orifice (m); -1 -1 µl = Dynamic viscosity of liquid (kgm s ); and 4 -1 U O = Velocity of liquid at the orifice (ms ). The velocity here can be calculated from Bernoulli’s equation. 1 ∆PU = ρ 2 (2) 2 l O where ∆P is the difference in pressure across the orifice (Pa). The Ohnesorge number was determined from: µ Oh = l (3) ρld O σ l -2 where σ l is the surface tension (kgs ). By digitally scanning the graph presented by Ohnesorge [2] (Figure 1), the transition from wind-induced to atomisation break-up was determined by Gant [4] to occur at or above the critical Ohnesorge number, given by: −1.22 OhCr = 745Rel (4) In the present work, to classify
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