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Keeping and improving process and plant safety competence - what is needed, what should be done?
(2013)
In March 2004 with the position paper “Maintaining and improving competence in safety engineering” of the DECHEMA/GVC Research Committee "Safety Engineering in Chemical Plants", an initiative came up against the tendency that more and more process and plant safety (PPS) orientated professorships turn to other more fashionable research topics. The Research Committee was concerned that PPS in both academic teaching and research could suffer a negative development - despite of its importance. In 2009 a corresponding Dutch initiative followed. To bring these both and other similar initiatives together, within the 8th European Congress of Chemical Engineering held in Berlin in September 2011 a two days Special session on PPS competence was jointly organized by EFCE, ProcessNet and EPSC. All presentations and conclusions drawn by the organizers (the authors of this paper) are electronically available.
The paper addresses the before mentioned initiatives, highlights views and results from the ECCE 8’s special session on PPS competence, and indicates steps necessary to be taken and recent developments.
Rubbers are widely used as main sealing materials for Containers for low and intermediate level radioactive waste and as additional component to metal seals in spent fuel and high active waste containers. The save enclosure of the radioactive container inventory has to be guaranteed according to legislation and appropriate guidelines for long term storage periods as well as down to temperatures of -40 °C for transportation. Therefore the understanding of failure mechanisms that lead to leakage at low temperatures is necessary to ensure a proper material choice which is certainly also influenced by additional factors as e.g. the aging behavior.
Cylindrical casks made of ductile cast iron are used for transport, interim storage and final disposal of radioactive waste in Germany. A basic design criterion is the ability to withstand a horizontal drop without impact Binders onto a foundation representative for the real ground of a storage facility. The increasing use of more cost-effective material compositions requires optimized cask geometries to reduce stresses and strains in the cask structure. For example, a non-uniform wall thickness was introduced to reduce maximum wall bending stresses. As a result, the load characteristics changed from line load to point load at bottom and lid side under horizontal drop fest conditions. Hereby, the position of highest stress inside the structure has shifted significantly. This was the reason for a systematic investigation of effects caused by small design changes or small variations of fest conditions. It led to a better understanding of the positions of high local stresses, their time history and maximum value for cylindrical casks under horizontal drop test conditions. Hence, the paper presents the lessons learnt from modeling and simulating such scenarios considering an impact without limiters onto a realistic target.
Data and prediction for the mass burning rate of a tert-butyl-peroxy-benzoat (TBPB) pool fire (pool diameter = 3 m) is presented. The mass burning rates of TBPB fires are up to six times higher and less dependent on pool diameter compared to hydrocarbon pool fires caused by an additional heat release rate due to exothermic decomposition reaction in the liquid phase. This heat release rate is calculated using a 1st order reaction kinetic obtained from micro calorimetric measurements. A new model is derived considering the heat release rate due to the decomposition reaction which is shown to be 100 % of the heat release rate radiated to the pool surface. With the presented model, including also physical quantities, especially the limiting fuel concentration for upward flame propagation, it is possible to predict the mass burning rates of large TBPB pool fires. The predicted values are in very good agreement with the experiments.
Censorship of parts of written text was and is a common practice in totalitarian regimes. It is used to destroy information not approved by the political power. Recovering the censored text is of interest for historical studies of the text. This paper raises the question, whether a censored postcard from 1942 can be made legible by applying multispectral imaging in combination with laser cleaning. In the fields of art conservation (e.g. color measurements), investigation (e.g. Analysis of underdrawings in paintings), and historical document analysis, multispectral imaging techniques have been applied successfully to give visibility to information hidden to the human eye.
The basic principle of laser cleaning is to transfer laser pulse energy to a contamination layer by an absorption process that leads to heating and evaporation of the layer. Partial laser cleaning of postcards is possible; dirt on the surface can be removed and the obscured pictures and writings made visible again. We applied both techniques to the postcard. The text could not be restored since the original ink seems to have suffered severe chemical damage.
Dealing with first corrosion screening experiments to predict the reliability and safety of Germanys first Carbon Capture and Storage site in the northern Bassin of Germany, northwest of the Capital Berlin, laboratory experiments have been established to simulate the particular conditions at T=60 °C, highly saline aquifer water similar to 'Stuttgart Aquifer', but only at ambient pressure. With mounting 2 independent full 2-grade titanium autoclave systems (running up to 250 bar and 300 °C) pressures up to p=100 bar are possible. In 2010 a specific corrosion chamber of 2-grade titanium working up to 100 °C, flowing aqui fer water with different gas mixtures was designed to fit to a high cycle fatigue testing machine. Long term fatigue experiments simulating fatigue crack growth under corrosive environments will soon start. These experiments may not only help engineering a CCS site, but results can be used to improve the maintenance of geothermal energy production sites, especially moved parts such as pumps and shafts.
The CCS technique involves the compression of emission gasses in deep geological layers. To guarantee the safety of the site, CO2-corrosion of the injection pipe steels has to be given special attention when engineering CCS-sites. To get to know the corrosion behaviour samples of the heat treated steel 1.72252CrMo4, used for casing, and the stainless injection-pipe steel 1.4034 X46Cr13 were kept at T=60 °C and ambient pressure as well as p=100 bar for 700 h - 8000 h in a CC 2-saturated synthetic aquifer environment similar to possible geological on-shore CCS-sites in the northern German Basin. The isothermal corrosion behaviour obtained by mass gain of the steels in the gas phase, the liquid phase and the intermediate phase gives surface corrosion rates around 0.1 to 0.8 mm/year at ambient pressure and much lower about 0.02 to 0.2 mm/year at 100 bar where the CO 2 is in its supercritical state. Severe pit corrosion with pit heights around 4.5 mm are only located on the 42CrMo4 steel. Main phase of the continuous complicated multi-layered carbonate/oxide structure is siderite FeCO 3 in both types of steel.
Refinement of the weld metal grain structure can improve the mechanical properties of the weld and decrease the susceptibility to solidification cracking of the weld metal. In this study, commercial Al Ti5B1 grain refiner was used to refine the microstructure of LB (laser beam) and GTA (gas tungsten arc) aluminum welds by inoculation. The grain refiner additions led to a significant decrease in the weld metal mean grain size whereby a transition from columnar to equiaxed grain structure (Columnar to Equiaxed Transition, CET) was observed. The development of both grain size and shape depended upon the base metal (Al alloys 1050A, 5083 and 6082) and upon the welding process. The GTA welding process allowed a more pronounced and a more efficient refinement than in LB welds. Furthermore, the influence of the solidification conditions on the CET was investigated through temperature measurements in the weld metal. The temperature profiles revealed a faster solidification of LB welds than in GTA welds. The results from the temperature measurements were also used to estimate (according to an existing model) the critical thermal gradient at which the CET occurs.
Ultrasonic examination of anisotropic inhomogeneous austenitic welds is challenging, because of the columnar grain structure of the weld leads to beam skewing and splitting. Modeling tools play an important role in understanding the ultrasound field propagation and optimization of experimental parameters during the ultrasonic testing of austenitic welds as well as the interpretation of the test results. In this contribution, an efficient theoretical model based on the ray tracing concepts is developed to calculate the ultrasonic fields in inhomogeneous austenitic welds quantitatively. The developed model determines the ultrasound fields by taking into account the directivity of the ray source, the inhomogenity of the weld as well as ray transmission coefficients. Directivity of the ray source in columnar grained austenitic materials (including layback orientation) is obtained in three dimensions based on Lamb's reciprocity theorem. Ray energy reflection and transmission coefficients at an interface between two general columnar grained austenitic materials are calculated in three dimensions. The ray tracing model predictions on inhomogeneous austenitic weld material are compared against those from CIVA, a commercial non-destructive modeling and simulation tool. The ultrasonic modeling tools in CIVA are based on semi-analytical solutions. For beam propagation simulation, a so-called 'pencil method' is used, which involves modeling the probe as a set of individual source points, each radiating 'a bundle' of diverging rays into the medium and integrating those elementary contributions. Inhomogenity in the weld region is approximated by mapping the grain orientations on weld macrograph. Simulation results for ultrasonic field profiles for an austenitic weld are shown to be in good agreement with the corresponding experimental results.