Safety D esign Criteria for Industrial Plants Volume II Editors Maurizio Cumo Antonio Naviglio Professors University of Rome Rome, Italy Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business CRCPress Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 Reissued 2019 by CRC Press © 1989 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an lnforma business No claim to original U.S. Government works This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint. Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www. copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MAO 1923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. A Library of Congress record exists under LC control number: Publisher's Note The publisher has gone to great lengths to ensure the quality of this reprint but points out that some imperfections in the original copies may be apparent. Disclaimer The publisher has made every effort to trace copyright holders and welcomes correspondence from those they have been unable to contact. ISBN 13: 978-0-367-25974-7 (hbk) ISBN 13: 978-0-429-29086-2 (ebk) Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the CRC Press Web site at http://www.crcpress.com DEDICATION To my son Fabrizio Maurizio Cumo To my parents Anna Maria and Luigi Eros Antonio Naviglio PREFACE The aim of this book is to provide a picture of safety-related aspects of the design, operation, and maintenance of a high-risk plant or — more generally — of a plant where substances potentially harmful for human health are handled. The book is addressed to people looking for an introduction to safety design criteria of industrial plants, namely students, engineers, and technicians involved in the design, op- eration, or maintenance of industrial plants, people working for local or national authorities or agencies, with a responsibility in licensing or control of industrial plants. The book is not an exhaustive handbook including all the aspects and methodologies employed for the design of industrial plants using hazardous matter, but it is an introductory guide addressing the reader to the most relevant items and aspects that should be known when operating, designing, and licensing this kind of plant. The most relevant concepts and methodologies are introduced and a continuous reference to specialized books or papers dealing with the specific themes is done to allow a deeper insight for people looking for a better knowledge. A trial has been done for a unique treatment for all kinds of medium and high-risk plants; explicit references to the specific kinds of plants are used whenever necessary. The wide range of topics, including general safety design criteria, risk analysis method- ologies, the main damage causes for the plants, the effects of dispersion of pollutants into the environment, and the human health effects of most relevant pollutants is aimed at giving a picture of the various aspects that could or should be considered in the safety or risk assessment of an industrial plant. The description of the various external and internal events that could prove as initiating events of accidents does not imply that all of them must be considered in the design of a plant; what is important is to know their existence, while the applicability of the single design criterion will be judged by the designer, also on the basis of the rules and regulations locally in force. The subject has been subdivided into six sections. The first, dedicated to the concept and definition of industrial risks, is aimed at introducing the concept of the technological risk (Chapter 1) and at the quantitative indentification of the risk for human health, relative to the main high-risk substances (chemical, radiological) (Chapter 2). Section II, dedicated to the main aspects of risk analyses of industrial plants, includes the definitions of the main magnitudes commonly employed in risk analyses and assessment (Chapter 3), the main phases of such analyses and assessment (Chapter 4), and the description of methodologies for a system reliability assessment (Chapter 5). The third section, dedicated to the main design criteria of a general validity and to the causes of damage for the components of an industrial plant, internal to the process, includes a description of general safety design criteria (Chapter 6), the analysis of causes of damage potentially responsible for a release of hazardous substances of thermodynamic nature (Chap- ter 7) and chemical nature (Chapter 8), and the analysis of the relevance and of the role of instrumentation and control for the operation and protection of risky plants and for the timely monitoring of hazardous matters releases (Chapter 9). The fourth section assumes that damage to a plant might happen and analyzes the dispersion mechanisms of pollutants into the environment, with the aim of identifying methods to limit the exposure to risk for population and operation personnel. It includes a description of methods for the evaluation of the consequences of effluents dispersion (Chapter 10), methods to limit exposure during normal operation of plants (Chapter 11), and methods to limit exposure following accidents (Chapter 12). Section I in Volume II, dedicated to the potential causes of damage for the components of an industrial plant external to the process, includes the analysis and criteria to defend the plant against natural events, comprehending the soil-structure interactions (Chapter 1), flood- ing (Chapter 2), the analysis and design criteria against man-induced events, comprehending fire (Chapter 3), clouds explosions, toxic clouds, and sabotage actions (Chapter 4), and area events (Chapter 5); an insight is performed on the role of human factors for the safety of plants (Chapter 6). The first five sections are especially addressed to plants handling high-risk substances and to associated criteria to limit the entity of the health risk; Section II in Volume II, on the contrary, is focused on “conventional risks” in industrial plants, which are by far mainly responsible for injuries to personnel involved in operation and maintenance of industrial plants. This section includes an analysis of general industrial risk-protection criteria and a description of most common health risks for personnel operating in industrial plants. The relevance of the analyzed topics, together with their multidisciplinarity, would justify a very deep analysis; they are only introduced in this book, whose aim is to give a general feeling on the variety and complexity of aspects to be considered, so as to allow the most appropriate decisions in view of further research. Nevertheless, the modem approach to safety is of a global nature, considering and comparing the different points of view to build a system assessment which needs specific contributions of different nature and sciences in harmonic construction. In this sense the book may offer a method and a sensibility for the new mind which is necessary to master the safety of high-risk installations. Maurizio Cumo Antonio Naviglio University of Rome May 31, 1987 THE EDITORS Maurizio Cumo is Professor of Nuclear Plants at the University La Sapienza of Rome, where he is also director of the postgraduate School for Nuclear Safety and Radioprotection. He received his doctorate in Nuclear Engineering at the Politechnic University of Milan in 1962. Since that year, without discontinuities, he has participated in much thermohydraulic research at the ENEA Research Center Casaccia near Rome as well as at the University of Rome. In this field he has authored or coauthored more than 150 scientific publications both international and national as well as 2 books. A member of the Assembly for International Heat Transfer Conferences, the Executive Committee of the International Center for Heat and Mass Transfer, the EUROTHERM Committee, and the European Two-Phase Flow Group with particular attention to experimental developments, presently he is acting as President of the Italian Commission for Nuclear Safety and Health Protection and as a member of the board of the Italian State Agency for Nuclear and Alternative Energies (ENEA). He is also Chairman of the Italian Association of Nuclear Engineering (ANDIN), Vice Chairman of the Italian Society of Standards (UNI), a member of the board of directors of the International Solar Energy Society (ISES), the American Nuclear Society, the American Institute of Chemical Engineers, and the New York Academy of Sciences. Biographical references are provided by Who’s Who in the World, Who’s Who in Europe, International Book of Honor, International Who’s Who in Education, Dictionary of Inter- national Biography, World Nuclear/World Energy Directory, and the International Directory of Distinguished Leadership. Antonio Naviglio is Professor of Thermal Hydraulics in the Department of Energetics, Faculty of Engineering, University of Rome. He received the Italian “Laurea” in Nuclear Engineering in 1973 from the University of Rome. During 1973 to 1975 he worked as a process engineer in a major Italian engineering company. In 1975 and 1976 he worked for the Italian Agency for Nuclear Safety and Radiological Protection (ENEA-DISP). During 1976 to 1981 he worked as a process engineer mainly in the field of thermal hydraulics, for the Italian Electric Power Authority (ENEL). Since 1981, he has been working at the University of Rome, first as assistant professor and then as Professor of Thermal Hydraulics. Professor Naviglio is an expert member of the Italian Committee for Nuclear Safety and Radiological Protection, the executive committee of ANDIN, the Italian Association of Nuclear Engineers and of ANIAI, the Italian Association of Architects and Engineers, and the Director of UNITAR/UNDP Centre on Small Energy Resources in Rome. Professor Naviglio has authored or coauthored some 90 scientific publications in the field of heat transfer and energy exploitation. The research activity of Professor Naviglio has been mainly devoted to heat transfer phenomena, to complex thermal hydraulic phenomenologies affecting the performance and safety of equipment both for nuclear and for chemical plants, and to the development of innovative processes allowing energy saving and minimizing environmental impact. CONTRIBUTORS Claudia Bartolomei Rinaldo Paciucci Facolta Di Ingegneria IAEIR Universita Degli Studi Di Roma Rome, Italy Rome, Italy Alberto Ferreli Sergio Paribelli ENEA ENEA Sede Centrale Rome, Italy Rome, Italy Leonardo Lojelo c n ^ TJ w A Salvatore Ragusa TecnoIdroMeteo A „ T , Managing Director ome, tay S.I. Safety Improvement Francesco Mazzini Milan, Italy Direttore del Centro Studi ed Esperienze Ivo Tripputi Corpo Nazionale Vigili del Fuoco ENEL - DCO Rome, Italy Rome, Italy TABLE OF CONTENTS Volume I SECTION Is THE RISK Introduction.....................................................................................................................................3 Chapter 1 The Technological Risk................................................................................................................5 Giuseppe Volta Chapter 2 High-Risk Plants and Risk Identification..................................................................................15 Sergio Paribelli and Antonio Moccaldi SECTION II: RISK ANALYSIS AND ASSESSMENT METHODOLOGIES Introduction..................................................................................................................................31 Chapter 3 Elements of Statistic and Event Analysis.................................................................................33 Augusto Gandini Chapter 4 Risk Analysis as an Instrument of Design...............................................................................77 Remo Galvagni and Stefano Clementel Chapter 5 System Reliability Assessment via Sensitivity Analysis......................................................121 Augusto Gandini SECTION III: INTERNAL DAMAGE RISK CAUSES Introduction.................................................................................................................................137 Chapter 6 General Safety-Related Design Criteria...................................................................................141 Sebastiano Serra Chapter 7 Thermodynamic Damage Causes — Safety Analyses...........................................................149 Giovanni Lelli Chapter 8 Chemical Damage Causes — Explosive Substances Management.....................................171 Salvatore Ragusa Chapter 9 The Role of Instrumentation and Control...............................................................................191 Fausto Zambardi SECTION IV: EXPOSURE AND CONSEQUENCES LIMITATION Introduction................................................................................................................................215 Chapter 10 Effluents Dispersion and Methods to Evaluate Their Effects 217 Luciano Bramati Chapter 11 Exposure Limitation in Normal Operating Conditions........................................................239 Luciano Bramati Chapter 12 Exposure Limitation Following Accidents: Siting and Emergency Planning...................247 Giancarlo Tenaglia INDEX........................................................................................................................................263 Volume II SECTION Is EXTERNAL DAMAGE CAUSES Introduction.....................................................................................................................................3 Chapter 1 Natural Events: Seismic and Geotechnical Aspects..................................................................5 Leonardo Lojelo Chapter 2 Natural Events: Severe Meteorological Events.......................................................................41 Alberto Ferreli Chapter 3 Artificial Events: Fire Risk.........................................................................................................51 Francesco Mazzini Chapter 4 Artificial Events: Clouds Explosions, Dangerous Clouds, and Physical Protection........79 Salvatore Ragusa Chapter 5 Artificial Events: Area Events....................................................................................................93 Alberto Ferreli Chapter 6 Artificial Events: Human Factors.............................................................................................101 Ivo Tripputi SECTION II: CONVENTIONAL RISKS Introduction.................................................................................................................................121 Chapter 7 Conventional Risks.....................................................................................................................123 Rinaldo Paciucci