Varec In-Line Detonation Flame Arresters Manufactured by Westech.
Transcription
Varec In-Line Detonation Flame Arresters Manufactured by Westech.
WESTECH In-Line Detonation Flame Arresters Manufactured by Westech Flow Control E xplosions due to flame arrester failures are destructive, expensive and potentially deadly. Prior to 1989, no arrester provided protection against all types of flame propagation. In fact, no practical technology existed for testing detonation flame arresters used in piping systems. Existing flame arrester standards were clearly inadequate for in-line applications. Improper arrester selection and application lead to storage tank and processing unit explosions. Without an arrester designed and Flame Profile Curve tested to meet Pressure Waves the levels of protection required, the potential for a major disaster is high. The advent of USCG, CSA and CEN standards is a major step forward in safe facility operation. Investigations and research continue on Detonation Flame Arresters. 2000 [140] Shock Wave Pressure, psi [bar] With the existing and future guidelines for emissions control comes a new challenge for safe facility operations. Installation of marine vapor recovery and destruction systems creates a high potential for disaster. In fact, an earlier explosion at a marine vapor control system in the U.S., pointed out the need for enhanced standards and in particular, the need for an adequate test standard for in-line arresters. Detonation 200 [14] Deflagration Resricted 20 [1.4] Unresricted 0 Flame Travel Dostatmce (run up length) Contents Definitions . . . . . . . . . . . . . . . . . . 2 Series 55 - Groups C and D . . . 7 - 8 The Westech Breakthrough . . . . 2 Series 57 - Group D . . . . . . . . 9 - 10 Considerations for Arrester Application and Selection . . . . . . 5 Series 59 - Group D . . . . . . . . . . 11 Series 60 - Group C . . . . . . . . . . 12 Series 40 - Groups C and D ... 6 The Westech Breakthrough Westech is an international company which has been servicing the needs of oil, gas, chemical and municipal sewage industries for more than 30 years. Its detonation flame arrester program began by investigating the cause of flame arrester failures in vapor control systems. Westech discovered that existing flame arresters were not capable of preventing flame passage, regardless of piping configuration. It was also proven that existing standards governing flame arrester performance were inadequate for in-line use. Westech concentrated on developing a comprehensive inline detonation flame arrester standard which led to an advanced level of flame front arrestment technology. Actual tests were conducted rather than calculating results on paper, as had been the accepted practice in the past. Westech 18” diameter, 1002 foot test tube for momentum testing of detonation flame arresters. This is the longest arrester test tube in the world. Definitions End-of-Line Flame Arrester - This type of flame arrester is used where the potential ignition source is located outside the vessel or flow system that is being protected (unconfined); the flame travel length is no greater than that used for flame arrester testing (typically 5 feet/1.25 m), and there are no restrictions in the protected side piping. In-Line (Detonation) Flame Arrester - An arrester which has been designed and tested to arrest flame fronts of varying pressures and speeds with both restricted and unrestricted protected side piping as well as long run stable and overdriven detonations. Deflagration - A flame front that propagates by the transfer of heat and mass to the unburned gas ahead of the flame front. Flame speeds can range from less than 1 m/s to greater than 350 m/s (supersonic) for very high pressure, turbulent flames. Overpressures can range from a very small fraction to as much as twenty times the initial pressure. Detonations (Gaseous) - A flame front that propagates by shock Overdriven Detonation - Also referred to as unstable detonation. The condition that exists during the transition of a combustion process from a deflagration into a stable detonation. This transition usually has the characteristic of producing extremely high explosion pressures in a relatively short time frame. Stable Detonation - A detonation which has speed and pressure characteristics which do not vary significantly as the detonation progresses through a confined system, hence the term “stable”. Maximum Experimental Safe Gap (MESG) - The maximum gap between equatorial flanges in a spherical volume that will just prevent flame transmission from the vessel to the flammable gas mixture surrounding it. Momentum Impulse - A phenomenon associated with increasing lengths of stable detonation travel. As the detonation travels down the line, the duration of temperature and pressure effects associated with the detonation increases up to a run-up distance of 300 pipe diameters. wave compression ignition in a flammable gas mixture. Flame speeds are super-sonic with Mach numbers ranging from 5 to 15. The pressure of stable detonation usually ranges from about 20 to 30 times the initial pressure but an overdriven detonation can achieve compression ratios in excess of 300 at the moment of transition from deflagration to detonation. 2 Arrester Function Quenching of the flame is accomplished by using a device which breaks the flame into very small “flamelets” that are passed through small flame channels in the arrester element. These flame channels cool the flame front below the ignition temperature of the vapor mixture, thereby quenching it. The function of an in-line (detonation) flame arrester falls into three categories: • Quench Flame Propagation • Free Vapor Flow • Independent Passive Operation Overdriven detonations and long run stable detonations are two types of flame propagation seen in pipeline explosions. Overdriven detonations have the characteristic of very high pressure for short durations, whereas long run stable detonations create high sustained pressures. Both types of flame propagation subject the arrester to different pressure and temperature characteristics, which have to be addressed by additional testing. Superior Customer Service Through the years Westech has earned an excellent reputation worldwide for customer service before, during and after the order. Such services include help with project design, supervision of a customer’s installation, user training, startup/commissioning assistance, periodic maintenance and field warranty service. A large selection of stock flame arresters is available for immediate delivery. Trial units are available. Westech’s World Class Test Facilities Westech has the most sophisticated detonation flame arrester test facility in the world. Line sizes up to 18” in diameter and 1,000 feet [305 m] in length are used to test our arresters. Some of the most severe pipeline explosions in the world are generated at this facility. The arresters are subjected to test explosions which are continuously monitored by eight computers, each with a sample rate of 100,000 samples per second. Specialized instrumentation is used to collect data from highly responsive customized gas analyzers, and pressure, temperature and optical flame sensors. A single test explosion generates 4 megabytes of data which is analyzed to evaluate arrester performance. On-line analysis has recorded flame speeds of up to Mach 7 and explosion pressures in excess of 3,000 psi [200 bar]. Measurement of these kinds of speeds and pressures requires critical accuracy. All calibrations, gas analysis, pressure, temperature and optical measurements from the arrester tests are fully traceable and reproducible. All tests are monitored by independent third party review organizations and accredited by standards organizations. 3 Unrivaled Research and Design Westech’s first step was to evaluate a number of sites where explosions had occurred. This led to the writing of “A Summary of Investigations from Ten In-Line Flame Arrester Failures” which addressed the inadequacy of current arrester designs and test standards. From this investigation it was obvious that a true in-line arrester capable of providing protection, regardless of piping configuration, was required. The development of the USCG, UL, FM, CSA and CEN standards has advanced the area of arrester certification. However, research into flame propagation by Westech has established the need for further standards development. Rather than meeting the minimum standards, Westech voluntarily tests arresters for flame front phenomena such as momentum impulse shock, pre-compressed deflagration to detonation transition, thermal flux, reignition of downstream unburned gases, downstream reflected shock wave failure, lean mixture detonations and lower MESG vapors. In order to ensure maximum facility protection, Westech has also tested to established installation criteria related to upstream pipe size changes and the venting of combustion products. Westech has made the commitment to work with standards associations worldwide to ensure that new developments from research are incorporated into future test standards. Because of this commitment to continued research and development, our customers can be assured of the highest level of protection now and in the future. Raising Flame Arrester Standards Research testing discovered the primary reason for flame arrester failures in the past and this led to the development of Westech’s “A Comprehensive Test Method for In-Line Flame Arresters”. This test method has been used as the cornerstone for all existing Detonation Arrester Standards. For this work, Westech was awarded a Certificate of Merit in the invention category of the 1989 Canada Awards for Business Excellence and the 1990 Canadian Gas Processors’ Association (CGPA) Award for Innovative Excellence. A New Generation of Arresters from Westech From the ground breaking research into flame front phenomena came a new generation of true in-line detonation flame arresters. This extensive research and development lead to an arrester designed to provide protection when installed anywhere in the piping system. Although the first priority was to design an arrester that would provide maximum protection, this was not enough. Westech also designed a product that would solve many of the operational problems common with current flame arrester designs. 4 Considerations for Arrester Application and Selection Selection of the correct arrester requires a detailed look at the application and must be based on the following: Testing and Certification Acceptance testing which proves the capability of an arrester is the only guarantee of arrester performance. With the growing need for flame arresting devices, many companies are producing arresters. Unfortunately, only some of these devices are tested to minimum performance standards and some are not tested at all. Vapor Composition For the purposes of arrester selection, a gas classification used by the USCG and others is Maximum Experimental Safe Gap (MESG). There is no guarantee of performance if the arrester is used in an application where the vapor has a lower MESG value than that for which the arrester has been tested. Explosion Capability At the minimum, an arrester should be tested to meet a recognized standard which requires testing for overdriven detonations, stable detonations, long run stable detonations and deflagration testing with restricted and unrestricted (with and without elbows and/or valves) downstream piping. Operating Pressure The operating pressure for the system in which the arrester is to be installed should not exceed the pressure at which the arrester has been tested. Operating pressure is critical as the pressure associated with the flame in both detonation and deflagration modes is a direct function of initial line pressure at the time of ignition. Endurance Burn Capability Endurance burn capability refers to the ability of the arrester to withstand the heating effects of a flame which has stabilized on the face of the arrester. This condition is caused when a flame travels toward the arrester, is prevented from passing through to the protected side, yet remains burning at the face of the arrester. The intent of an endurance burn test is to determine the length of time an arrester can withstand this stabilized flame without heating the arrester element to the point where the flame is allowed to pass to the protected side. Establishing an endurance burn capability is important as it ensures a defined amount of response time allowed for disruption of the gas flow feeding the stabilized flame. 5 Arrester Location Once the ignition sources and the specific facility components requiring protection are identified, the detonation flame arrester can be placed anywhere between the two, regardless of distance and pipe configuration. In systems where tanks are manifolded together, there should be one arrester providing protection for each tank. When evaluating ignition sources in manifolded tank systems, each tank must be considered. In order to provide protection between tanks, in-line (detonation) flame arresters should be installed not only on the collection line, but on each tank. Series 40 In-Line Deflagration Flame Arrestor Sizes • Sizes 2” thru 18” IIA (NEC Group D, M.E.S.G. [0.9] Mechanical Design Standard construction is carbon steel housing fabricated in accordance with ASME/ANSI with 150 RF line flanges. Element is 316 stainless steel. • Sizes 2”, 3” and 4” IIB (NEC Group C, M.E.S.G. [0.65] Options • Arrester housing fabricated in 316 SS Protection Quenches deflagration. In-line installation is limited to 50 pipe diameters as per test protocol. Can be installed at the end of a vent line. Groups C and D Test Protocol Tested in accordance with the European Standard EN12874: 2001, 6.3 Flame Transmission Test, 6.3.2 Deflagration Test, 6.3.2.1 End-of-Line Flame Arrester and 6.3.2.2 In-Line Flame Arrester. • Class 300 ANSI RF or DIN mating flange connections • Instrument and drain connections • Special alloy fabrication and internal coatings Installation The Series 40 can be installed in the vertical or horizontal position. • Special surface finishes • Special testing and designs • Weatherhood Passive Operation Completely self-contained with no reliance on power supplies, sensors, actuators or any external components. A B Dimensions and Weights Model Line Size inches [mm] Overall Length1 (A) Housing Diameter (B) Arrester Weight (lb.) WFA40-002 2” [50] 12.88 9.00 70 WFA40-003 WFA40-004 3” [75] 4” [100] 16.75 18.38 11.00 16.00 110 260 WFA40-006 WFA40-008 6” [150] 8” [200] 22.88 38.13 19.63 23.50 305 600 WFA40-010 WFA40-012 10” [250] 12” [300] 34.00 46.00 27.50 32.00 1014 1500 WFA40-014 WFA40-016 14” [350] 16” [400] 55.38 55.38 38.75 38.75 1650 1700 WFA40-018 18” [450] 62.50 46.00 2250 1. Overall length may vary +/- 0.25” [6]. 6 Series 55 In-Line Detonation Flame Arrestor Detonation Momentum Attenuators Incorporates Westech’s patented Detonation Momentum Attenuator (D.M.A.) plates to provide shock wave protection, as well as particulate knock out of entrained solids in the vapor stream. Large Element Surface Area Designed with up to 30 times the surface area of conventional arresters, minimizing pressure drop and fouling effects, thus decreasing downtime for maintenance. Low Pressure Drop The element has the lowest pressure drop and fouling rate of any conventional arrester. Reduces arrester costs as well as costs associated with piping systems and components. Groups C and D U.S. Coast Guard Accepted Accepted by the U.S. Coast Guard (U.S.C.G CFR154) for 3”, 4”, 6”, 8”, 10”, 12”, 14”, 16” and 18” line sizes. They can be installed in any identical line size piping configuration regardless of length and restrictions. True In-Line Maintenance Maintenance can be performed in-line without requiring the line to be broken for element removal, reducing maintenance costs and downtime. Element inspection does not require element removal. 3” thru 18” ATEX 94/9/EC accepted. Protection Independent of Location Can arrest flame fronts anywhere in the piping system regardless of pipe length and configuration. Tested in Excess of Existing Standards (CSA, USCG, FM, UL, PTB, BSI, IMO and CEN) Complete testing through the “Flame Profile Curve”. Tested for actual field conditions not mandated by existing standards, such as momentum impulse (long run stable detonation), thermal failure and reignition of downstream unburned gases providing maximum protection against all modes of flame propagation. Passive Operation Completely self-contained with no reliance on power supplies, sensors, actuators or any external components. Type I Accepted Accepted by the U.S. Coast Guard for Type I continuous burn protection. Due to the increased stabilized flame protection, Type I arresters do not require additional temperature monitors, quick closing valves and associated equipment as is the case with Type II arresters. 7 Multiple Element Design Multiple element design (sizes 8” and larger) decreases element weight for ease of maintenance. Self-Sealing Element Design Unique self-sealing element design is impervious to impact damage from repeated high pressure (4000+ psig [276+ barg]) detonation shock waves. Actual protection increases when exposed to these forces. Easily Cleaned Unique element design allows for ease of removal and cleaning. Increased Element Thickness 0.025” [0.65] standard element thickness provides substantial corrosion allowance for increased protection and longer element life. Optional Features • ASME VII, Div I construction (standard on 3”, 4”, 6” cast units) • 316 SS element • Arrester housing in aluminum, 304 or 316 SS • DIN mating flange connections • Special paint • Jib crane High Operation Pressure Accepted by the U.S. Coast Guard for operating pressures up to 22.7 psig [1.57 barg] allowing for installation in systems operating at elevated pressures. Series 55 Element: Cylindrical Design Series 55 Specifications Flow Chart Pressure Drop, Inches of H20 [mbar] 100 [250] Connection Sizes in inches 3 10 [25] 4 6 8 10 12 14 16 18 1 [2.5] 0.11 [0.25] 10 [4.72] 1 [0.472] 100 [47.2] 1000 [472] Flow Capacity, SCFH Air x 1000 [m3/min.] Outside Diameter Outside Diameter Overall Length Overall Length Dimensions and Weights Model WFA55-03 Line Size inches [mm] 3” [75] Overall Length1 inches [mm] 187/8 Outside Diameter inches [mm] Overall Weight lbs. (kg) Element Weight lbs. (kg) [480] 151/2 [395] 340 (155) 65 (30) [660] [755] 2015/16 251/2 [530] [650] 1100 1500 (505) (680) 75 135 (35) (60) WFA55-04 WFA55-06 4” 6” [100] [150] 26 293/4 WFA55-08 WFA55-10 8” 10” [200] [250] 63 65 [1600] [1650] 353/4 421/4 [910] [1075] 2800 3800 (1270) (1725) 165 165 (75) (75) WFA55-12 WFA55-14 12” 14” [300] [350] 67 775/8 [1700] [1970] 421/4 55 [1075] [1395] 4100 6400 (1860) (2900) 210 215 (95) (95) WFA55-16 WFA55-18 16” 18” [400] [450] 81 80 [2055] [2030] 55 611/2 [1395] [1560] 7300 12000 (3310) (5445) 270 315 (120) (145) 1. Overall length may vary +/- 0.25” [6]. 8 Series 57 In-Line Detonation Flame Arrestor Protection Independent of Location Can arrest flame fronts anywhere in the piping system regardless of pipe length and configuration. Detonation Momentum Attenuators Incorporates Westech’s patented Detonation Momentum Attenuator (D.M.A.) plates to provide shock wave protection, as well as particulate knock out of entrained solids in the vapor stream. Large Element Surface Area Designed with up to 30 times the surface area of conventional arresters, minimizing pressure drop and fouling effects, thus decreasing downtime for maintenance. Group D U.S. Coast Guard Accepted Accepted by the U.S. Coast Guard (U.S.C.G CFR154) for 2”, 3”, 4”, 6”, 8”, 10”, 12”, 14”, 16” and 18” line sizes. They can be installed in any identical line size piping configuration regardless of length and restrictions. Accepted by PTB/CE (Europe) for 4”, 6”, 8” and 10” sizes. Full line approval pending. 2” thru 18” ATEX 94/9/EC accepted. Tested in Excess of Existing Standards (CSA, USCG, FM, UL, PTB, BSI, IMO and CEN) Complete testing through the “Flame Profile Curve”. Tested for conditions not mandated by existing standards, including momentum impulse (long run stable detonation), thermal failure and reignition of downstream unburned gases providing maximum protection against all modes of flame propagation. Passive Operation Completely self-contained with no reliance on power supplies, sensors, actuators or any external components. Type I Accepted Accepted by the U.S. Coast Guard for Type I continuous burn protection. Due to the increased stabilized flame protection, Type I arresters do not require additional temperature monitors, quick closing valves and associated equipment as is the case with Type II arresters. Self-Sealing Element Design Unique self-sealing element design is impervious to impact damage from repeated high pressure (4000+ psig [276+ barg]) detonation shock waves. Actual protection increases when exposed to these forces. Low Pressure Drop The element has the lowest pressure drop and fouling rate of any conventional arrester. Reduces arrester costs, as well as costs associated with piping systems and components. Easily Cleaned Unique element design allows for ease of removal and cleaning. Increased Element Thickness 0.025” [0.65] standard element thickness provides substantial corrosion allowance for increased protection and longer element life. Optional Features • 316 SS element • Arrester housing fabricated in 304 or 316 SS • Class 300 ANSI RF mating flange connections • DIN mating flange connections • Instrument and drain connections • Special paint Series 57 Element: Cylindrical Design 9 Series 57 Specifications Flow Chart Pressure Drop, Inches of H20 [mbar] 100 [250] Connection Sizes in inches 2 10 [25] 3 4 6 12 16 8 10 14 18 1 [2.5] 0.11 [0.25] 1 [0.472] 10 [4.72] 100 [47.2] 1000 [472] Flow Capacity, SCFH Air x 1000 [m3/min.] Outside Dia. Overall Length 2 - 18 in [50 - 450 mm] Dimensions and Weights Model WFA57-02 Line Size inches [mm] 2” [50] Overall Length1 inches [mm] 25 351/4 Outside Diameter inches [mm] Overall Weight lbs. (kg) Element Weight lbs. (kg) [635] 131/2 [340] 175 (80) 45 (20) [900] [935] 131/2 16 [340] [410] 225 350 (100) (160) 75 100 (35) (45) WFA57-03 WFA57-04 3” 4” [75] [100] 3613/16 WFA57-06 WFA57-08 6” 8” [150] [200] 51 531/4 [1300] [1350] 21 231/2 [530] [600] 775 1020 (350) (465) 285 495 (130) (225) WFA57-10 WFA57-12 10” 12” [250] [300] 567/8 707/8 [1450] [1800] 271/2 32 [700] [810] 1570 2190 (710) (995) 685 950 (310) (430) WFA57-14 WFA57-16 14” 16” [350] [400] 721/2 733/8 [1825] [1865] 341/4 361/2 [870] [925] 2790 3115 (1270) (1410) 1195 1355 (540) (615) WFA57-18 18” [450] 767/8 [1950] 383/4 [985] 3840 (1740) 1480 (670) 1. Overall length may vary +/- 0.25” [6]. 10 Series 59 In-Line Detonation Flame Arrestor Sizes • Sizes 2” thru 12” NEC Group D vapors (IIA/M.E.S.G. [0.9mm]) Protection Independent Location Bi-directional. Quenches deflagrations, stable and overdriven detonations regardless of piping configuration. Complete testing through the flame profile curve. Installation The Series 59 can be installed in the vertical or horizontal position. Mechanical Design Standard construction is carbon steel housing fabricated in accordance with ASME/ANSI with 150 RF line flanges. Element is 316 stainless steel. Options • Arrester housing fabricated in 316 SS • Class 300 ANSI RF or DIN mating flange connections • Instrument and drain connections • Special alloy fabrication and internal coatings • Special surface finishes Passive Operation Completely self-contained with no reliance on power supplies, sensors, actuators or any external components. Group D Test Protocol Tested in accordance with the United States Coast CFR 154. Multiple Element Design Elements easily removed, separated and cleaned in the field. A B Dimensions and Weights Model Line Size inches [mm] Overall Length1 (A) inches Housing Diameter (B) inches Arrester Weight (lb.) WFA59-002 2” [50] 15.88 9.00 80 WFA59-003 WFA59-004 3” [75] 4” [100] 19.75 21.38 11.00 16.00 135 280 WFA59-006 WFA59-008 6” [150] 8” [200] 25.88 41.13 19.63 23.50 365 740 WFA59-010 WFA59-012 10” [250] 12” [300] 37.00 49.00 27.50 32.00 1132 1480 1. Overall length may vary +/- 0.25” [6]. 11 • Special testing and designs Series 60 In-Line Detonation Flame Arrestor Sizes • Sizes 2” thru 12” - see test protocol above. Mechanical Design Standard construction is carbon steel housing fabricated in accordance with ASME/ANSI with 150 RF line flanges. Elements are 316 stainless steel. Protection Independent Location Bi-directional. Quenches deflagrations, stable and overdriven detonations regardless of piping configuration. Complete testing through the flame profile curve. Options • Arrester housing fabricated in 316 SS • Class 300 ANSI RF or DIN mating flange connections • Instrument and drain connections Installation The Series 60 can be installed in the vertical or horizontal position. • Special alloy fabrication and internal coatings • Special surface finishes Groups C and D FM Approved 4” thru 12” line sizes accepted by Factory Mutual for NEC Groups C (IIB/M.E.S.G. [0.65 mm]) and D (IIA/M.E.S.G. [0.9 mm]) vapors. Passive Operation Completely self-contained with no reliance on power supplies, sensors, actuators or any external components. • Special testing and designs Multiple Element Design Elements easily removed, separated and cleaned in the field. 2” thru 12” ATEX 94/9/EC accepted. A B Dimensions and Weights Model Line Size inches [mm] Overall Length1 (A) Housing Diameter (B) Arrester Weight (lb.) WFA60-002 2” [50] 15.88 9.00 80 WFA60-003 WFA60-004 3” [75] 4” [100] 19.75 24.38 11.00 16.00 135 330 WFA60-006 WFA60-008 6” [150] 8” [200] 28.88 47.13 19.63 23.50 405 810 WFA60-010 WFA60-012 10” [250] 12” [300] 43.00 55.00 27.50 32.00 1450 2050 1. Overall length may vary +/- 0.25” [6]. 12 Tyco Valves & Controls incorporates many market-leading brand names in the manufacture of valves, actuators and control systems, including... ✦ Anderson Greenwood - Pressure relief valves ✦ Anderson Greenwood Instrumentation - Hand valves, gauge valves, manifolds ✦ AVID - Position, control and network monitors, electro- pneumatic and smart positioners ✦ Biffi - Gas, electric and pneumatic quarter-turn and multi-turn actuators ✦ Cash Valve - Pressure relief valves, control valves and pressure regulators ✦ Clarkson - Slurry valves ✦ Crosby - Pressure relief valves ✦ Descote - Globe valves for hazardous fluids ✦ Dewrance - Parallel slide gate valves ✦ FCT - Split body trunnion mounted ball valves ✦ Fasani - Gate, globe and check valves ✦ Gimpel - Steam valves ✦ Gulf - Double-door wafer check ✦ Hancock - Forged steel gate, globe and check ✦ Hovap - Hygienic valves ✦ Intervalve - High pressure isolation gate, globe and check valves ✦ Keystone - Resilient seated and high-performance butterfly valves ✦ KTM - Ball valves With sales and distribution operations in strategic locations throughout the world, Tyco Valves and Controls is a global, single-source supplier of innovative flow control solutions. 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