The Hong Kong University of Science and Technology

Health, Safety and Environment Office

Pressure Safety
Dr. C. M. LI
Senior HSE Manager

PRESSURE SAFETY
This subject is designed to provide basic concepts
and knowledge of Pressure Safety to students.

At the end of the course, students should:
have a better understanding on the hazards
associated with common pressure systems and
equipment.

know how to work safely with those systems and
equipment.

be aware of the relevant legislation.
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Common Pressure Systems/Equipment

Boilers
Pressure Vessels
Hydraulic Systems
Compressed Gas Cylinders

Boiler
Boiler means any
closed vessel in
which for any
purpose steam is
generated under
pressure greater
than atmospheric
pressure.
For examples:
Boiler for central
heating/ hot water
supply, Autoclaves.
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Boiler
The process by which a boiler
rupture occurs:When heat is applied to water in
the boiler, its temperature increases
to the boiling point, causing it to
evaporate, and the steam to exert
pressure.
Generally the steam leaves the
boiler and is replaced by new
supplies of water. When the input
of heat from the boiler equals that
removed by the system flow,
equilibrium is reached and pressure
remains constant.
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Pressure Vessel - Rupture

The automatic controls failure is the most frequent cause of boiler failure than other
damages.

The rupture of a pressure vessel occurs when the total expansive force acting to
cause the rupture exceeds the vessels strength. For example:

If steam flow output is restricted so it is inadequate to remove all the excess heat
supplied, the temperature and pressure in the boiler will increase.

Boiler overheating / explosion due to low water level. If inadequate supplies of fresh
water , any water vapor can turn to dry gas and then increase in pressure.

If a safety device is not provided or is inadequate to limit gas pressure to safe valve,
the strength of the boiler might be exceeded, causing it to fail.

Boiler may present fire / explosion due to unburned oil vaporize to hydrocarbon gases
inside the furnace.

Pressure Vessel - Steam Receiver

Steam Receiver means any vessel or apparatus (other than a
boiler, a steam container, a steam pipe or coil, or a part of a
prime-mover ) used for containing steam under pressure
great than atmospheric pressure.

Pressure Vessel - Steam Receiver

Pressure Vessel - Air Receiver

any vessel (other than a pipe or coil, or a accessory
fitting or part of a Compressor) for containing
compressed air and which is connected with an air
compression plant.

any fixed vessel for containing compressed air or
compressed exhaust gases that is use for the purpose of
starting an internal combustion engine;

any fixed or portable vessel (not being part of a spraying
pistol) used for the purpose of spraying, by means of
compressed air, any paint, varnish lacquer of similar
material; and

any pressurized fuel container.
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Pressure Vessel - Air Receiver

Any air receiver shall be examined by an appointed examiner
within 26 months after the date of fitness issued.
It is contravention of the Boiler and Pressure Vessels Ordinance to
"alter" the safety valve pressure set by the appointed examiners.
Compressed air are either arranged to run continuously since they are fitted with
unloading devices to allow running light when desired supply line pressure is
reached, or have pre-set cut in and cut out pressure switches.

Air pressure vessels should not be located near sources of heat,

such as radiators, boilers, or furnaces. For example, the vapor
pressure of carbon dioxide is 835 psi at 70F and 2530 psi at
140F. Also, gas compression can cause an increase in temperature
and very high pressures.
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Hazards and their Controls

Pressure vessels - explosion
errors in design, construction, and installation
corrosion or erosion of construction materials
failure to inspect thoroughly, properly, and frequently
improper application of equipment
lack of planned preventive maintenance
human failure, such as lack of understanding, inadequate
training of operators, failure to follow safe operating
procedures, lack of functional coordination
mechanical breakdown, failure, or blocking of automatic
control devices
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Hazards and their Controls

Control Measures: Engineering
Administrative
Statutory Control
Codes and Standards

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Engineering Controls
Proper design /construction/ materials
to withstand the maximum allowable working pressure
with sufficient safety margin.
Barrier/ Enclosure/ Segregation
Safety devices
Automatic control equipment is to provide precise
control over combustion and feed-water requirements in
order to meet output fluctuations. For example, Pressure
and Temperature Sensing and Control Devices.
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Types of Pressure Relief Device

PRV is designed to release excessive pressure buildup. Outlet of
PRV must not be obstructed and must not directed towards areas
having access by people.
Spring loaded pressure relief valve

pressure adjustable
can be tested

Only be set by an
Appointed Examiner

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Administrative Controls
Establish a testing and servicing program.
Keep a boiler log. These records will provide you with a
historical profile of the boiler. Report any defects, accident
and incident.
Certification and re-certification. Procedures to ensure legal
compliance.
Risk assessments /Operation Safety Plan (OSP)
Safety Rules and Procedures for operation, maintenance etc.
Operation of boilers and steam receivers to be supervised
by competent persons
Maintain good housekeeping in boiler rooms
Emergency response procedures
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Statutory Controls
Complying the Legal Requirements:The existing legislation on pressure equipment in Hong Kong is covered by
the Boilers and Pressure Vessels Ordinance Chapter 56 and subsidiary
regulation.
Precautions for entering boilers and furnaces (Confined Spaces):Observe rules and regulations for working into the confined spaces: Implement Work Permit System
Conduct Risk Assessment
Gases Detection, Ventilation
Proper PPE and Equipment
Approved breathing apparatus and suitable reviving apparatus
Be kept under constant observation by a person.

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Hazards of Hydraulic system

Water hammer
Water hammer is caused by a sudden stoppage of liquid flow so a shock
effect occurs which can cause the rupture of a line.
The mass of liquid has momentum. If the flow is terminated abruptly by
closing a valve at the downstream end of a line, the momentum of the liquid
is transformed into a shock wave (water hammer) which is transmitted back
upstream.
The shock is transmitted back through the liquid because liquids are
practically incompressible. The energy shock involved may be adequate to
break fittings and lines, especially if they are made of brittle materials which
do not stand shock well. To avoid damage to liquid lines, the use of quickclosing valves should be avoided. If they must be used, the shock can be
alleviated by a suitable air chamber or accumulator connected to the lines
slightly upstream of the valve.
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Hazards of Hydraulic system

Blast Effects due to overpressurized the system.
Piercing effect of high
velocity leaking liquid.
(The hydraulic drum of a
crane-truck leaked while
lifting a load. Hydraulic fluid
ejected out and hit the
windscreen of a passing-by
vehicle. The windscreen of the
vehicle was shattered as a
result.)

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Hazards of Hydraulic system

Fragment Effects, damage and injury caused by expelled fragments.
Accident: The cooling coil of an a/c system explode when being
pressurized. A piece of copper tube was blown off and stabbed a
technician to death.

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Hazards Control for Hydraulic System

Proper design, materials and construction
Use hydraulic oil with high flash point
Protection of pipe lines from damage, e.g.
enclosure
Fix Hose strap to restrain whipping motion
of flexible hose when dislocation occurs
Pressurize pipe lines and equipment in stages
Segregate work area and post warning signs
Frequent inspections for damages
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Hazards Control for Hydraulic System

Testing of Pressure System
Pressure system should be tested prior to use, and should be tested
periodically after that to determine their adequacy for continued service.
Using water as a fluid for hydrostatic testing have two major
advantages:1.) Leaks created by pressurization of a vessel can be detected easily.
2.) Because fluids expand little, in case of a vessels rupture, no shock
wave will be generated.
Gas such as steam or compressed air should not be used. If the vessel
being tested fails suddenly, the rapid expansion of gas might cause the
rupture to be violent, possibly generating a blast wave with injury or
damage.
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Hazards of Using Of Compressed Gases

Dynamic Pressure
Cylinders pressure of compressed air, oxygen, or carbon
dioxide are over 2000 psig when the cylinders are full
charged. Accident will occur, if damaged of the cylinders
valve. The force or thrust generated by gas leaking through
the a broken valve can be 50 to 20 times greater than the
cylinder weight (about 200 pound). This can be compared to
the propulsion system of a rocket or guided missile.
Over Pressurized
If the vessel is over pressurized, it will fail at a weak point,
where a flaw exists. If the flaw is serious enough, failure may
occur at or below the normal operating pressure. For
example, the bursting of a balloon.
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Hazards of Using Of Compressed Gases

Whipping of disconnected
hoses: Reactive forces at nozzles caused by fluid
moving out. If forces large enough, they
can cause the nozzle and the hose to move
or whip.
(Flexible hose of pneumatic breaker
detached. The hose whipped violently and
struck the worker)

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Using Of Compressed Gases - Gas Cylinders

Check the label to make sure the gas is the one you want. Never accept any
cylinder with defects. Know the MSDS of such gas.
Regular inspection for signs of defects, rusting or leakage.Use proper solution
for leak test .
Use only the right type of regulators and gauges. Do not force fit regulators or
fittings to cylinders. Do not force open or close cylinder valve. Using valve key.
Ensure that hoses/ tubes are appropriate types and properly fitted.
Reverse flow check valves and flashback arresters must be fitted for
each gas cylinder whenever an oxidizer and a flammable gas are used. If
flashback (flammable gas cylinders) occurs, flame burns back into the cylinder.

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Using Of Compressed Gases

Gas Cylinders
Cylinders must be kept upright, especially for acetylene.
Fittings and tubing which contain copper must not be
used for acetylene gas cylinders to prevent formation of
explosive compounds.
Cylinders and fittings must be kept free of oily or greasy
substances. This is important especially for Oxygen. Not
observing this may result in EXPLOSION.
Close cylinder valves when not in active use.
Empty cylinders should be marked EMPTY.
Never strike an electric arc or direct a flame at a
cylinder, or make a cylinder as part of an electric circuit.

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References

BOILERS AND PRESSURE VESSELS ORDINANCE, CHAPTER 56, PRINTED AND PUBLISHED BY THE
GOVERNMENT PRINTER, HONG KONG.

BOILER AND PRESSURE VESSELS REGULATIONS, CHAPTER 56, SUBSIDIARY LEGISLATION,

PRINTED AND PUBLISHED BY THE GOVERNMENT PRINTER, HONG KONG.

BOILER AND PRESSURE VESSELS (FORMS) ORDER, CHAPTER 56, SUBSIDIARY LEGISLATION,
PRINTER AND PUBLISHED BY THE GOVERNMENT PRINTER, HONG KONG.

CODE OF PRACTICE FOR STEAM RECEIVERS, ISSUED UNDER SECTION 18A OF THE BOILER AND
PRESSURE VESSELS ORDINANCE.

OCCUPATIONAL SAFETY MANAGEMENT AND ENGINEERING, 4TH EDITION, WILLIE HAMMER

NICHOLAS P. CHEREMISINOFF, 1998, PRESSURE SAFETY DESIGN PRACTICES FOR REFINERY AND
CHEMICAL OPERATIONS, NOYES PUBLICATIONS, U.S.A.

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