System Protection

The protection system is that part of a safety system which detects departures from acceptable plant conditions and initiates actions to prevent an unsafe or potentially unsafe condition. Various system configurations are used for this purpose, and the term protection system is not nniversal in all Member States. The guidance given in the section on protection systems applies to whichever systems perform these fnnctions. 

The protection system is provided to maintain safety in situations in which the control systems fail to maintain plant variables within defined limits. Such situations may arise either because a fault has occurred within a control system or because an event has occnrred that causes process variables to change too rapidly for the control systems to react adequately, or because of failure of an item important to safety. In such situations, prompt action is necessary to prevent the situation from developing into a potential accident. 

Generally, the action necessitated by a particular situation, namely the safety task for that situation, involves the operation of numerous items of the plant in a coordinated manner. The protection system is provided to perform all specified safety tasks, in conjunction with the safety actuation systems and safety system support features. 

The protection system monitors relevant plant variables. These may be process variables such as neutron fluence rates (fluxes) or coolant temperatures and pressures, or they may be variables specific to anticipated operational occurrences or 

The Requirements for Design require (Ref. [1], para. 6.80) that the protection system be designed so as to  

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Unprotected steel corrodes at a rate which is generally assumed to be 0.1 to 0.2mm per annum. Factors that influence the actual rate of corrosion include the maintenance program applied by the owner - particularly preservation of protective coatings, efficiency of cathodic protection systems in ballast tanks, corrosive properties of the cargo carried and environmental factors such as temperature and humidity. Under extreme conditions it has been known for the annual rate of corrosion on unprotected steel exposed on both surfaces to approach 1mm. 

Corrosion due to stray current—the metal is attacked at the point where the current leaves. Typically, this kind of damage can be observed in buried stmctures in the vicinity of cathodic protection systems or the DC stray current can stem from railway traction sources. 

Fig. 2. A simplified material thermal performance analysis for a reentry vehicle thermal protection system where = density x surface recession thickness = total aerodynamic heat/heat of ablation ...

The practice of employing reusable thermal protection systems for reentry is becoming more common. These are essentially ablative materials exposed to environments where veryHtde ablation actually occurs. Examples iuclude the space shuttle tiles and leading edges, exhaust no22le flaps for advanced engines, and the proposed stmctural surface skin for the National Aerospace plane. 

The thermal protection system of the space shutde is composed mainly of subliming or melting ablators that are used below their fusion or vaporization reaction temperatures (42). In addition to the carbon-carbon systems discussed above, a flexible reusable surface insulation composed of Nomex felt substrate, a Du Pont polyamide fiber material, is used on a large portion of the upper surface. High and low temperature reusable surface insulation composed of siHca-based low density tiles are used on the bottom surface of the vehicle, which sees a more severe reentry heating environment than does the upper surface of the vehicle (43). 

C. WiUiams and L. RonquiUo, Thermal Protection System for the Space Shuttle External Tanks, 6th SPI Inti., Tech. /Mark. Conf, 1983, pp. 90—100. 

Emulsion Adhesives. The most widely used emulsion-based adhesive is that based upon poly(vinyl acetate)—poly(vinyl alcohol) copolymers formed by free-radical polymerization in an emulsion system. Poly(vinyl alcohol) is typically formed by hydrolysis of the poly(vinyl acetate). The properties of the emulsion are derived from the polymer employed in the polymerization as weU as from the system used to emulsify the polymer in water. The emulsion is stabilized by a combination of a surfactant plus a coUoid protection system. The protective coUoids are similar to those used paint (qv) to stabilize latex. For poly(vinyl acetate), the protective coUoids are isolated from natural gums and ceUulosic resins (carboxymethylceUulose or hydroxyethjdceUulose). The hydroHzed polymer may also be used. The physical properties of the poly(vinyl acetate) polymer can be modified by changing the co-monomer used in the polymerization. Any material which is free-radically active and participates in an emulsion polymerization can be employed. Plasticizers (qv), tackifiers, viscosity modifiers, solvents (added to coalesce the emulsion particles), fillers, humectants, and other materials are often added to the adhesive to meet specifications for the intended appHcation. Because the presence of foam in the bond line could decrease performance of the adhesion joint, agents that control the amount of air entrapped in an adhesive bond must be added. Biocides are also necessary many of the materials that are used to stabilize poly(vinyl acetate) emulsions are natural products. Poly(vinyl acetate) adhesives known as "white glue" or "carpenter s glue" are available under a number of different trade names. AppHcations are found mosdy in the area of adhesion to paper and wood (see Vinyl polymers). 

Dow Fire and Explosion Index. The Dow Eire and Explosion Index (3) is a procedure usehil for determining the relative degree of hazard related to flammable and explosive materials. This Index form works essentially the same way as an income tax form. Penalties are provided for inventory, extended temperatures and pressures, reactivity, etc, and credits are appHed for fire protection systems, process control (qv), and material isolation. The complete procedure is capable of estimating a doUar amount for the maximum probable property damage and the business intermptionloss based on an empirical correlation provided with the Index. 

Cathodic Protection Systems. Metal anodes using either platinum [7440-06 ] metal or precious metal oxide coatings on titanium, niobium [7440-03-17, or tantalum [7440-25-7] substrates are extensively used for impressed current cathodic protection systems. A prime appHcation is the use of platinum-coated titanium anodes for protection of the hulls of marine vessels. The controUed feature of these systems has created an attractive alternative... 

A Russian ammonia pipeline of nearly 2400 km extends from Togliatti on the Volga River to the Port of Odessa on the Black Sea, and a 2200-km, 250-mm dia branch line extends from Godovka in the Ukraine to Panioutino. The pipeline is constmcted of electric-resistance welded steel pipe with 7.9-mm thick walls but uses seamless pipe with 12.7-mm thick walls for river crossings. The pipeline is primed and taped with two layers of polyethylene tape and suppHed with a cathodic protection system for the entire pipeline. Mainline operating pressure is 8.15 MPa (1182 psi) and branch-line operating pressure is 9.7 MPa (1406 psi) (11). 

Process Hazards Analysis. Analysis of processes for unrecogni2ed or inadequately controUed ha2ards (see Hazard analysis and risk assessment) is required by OSHA (36). The principal methods of analysis, in an approximate ascending order of intensity, are what-if checklist failure modes and effects ha2ard and operabiHty (HAZOP) and fault-tree analysis. Other complementary methods include human error prediction and cost/benefit analysis. The HAZOP method is the most popular as of 1995 because it can be used to identify ha2ards, pinpoint their causes and consequences, and disclose the need for protective systems. Fault-tree analysis is the method to be used if a quantitative evaluation of operational safety is needed to justify the implementation of process improvements. 

It should be noted that corrosion inhibitors and protection systems ate generally designed for specific conditions, and the effectiveness of the inhibitor can change with conditions. 

Protective Systems. As in the case of sulfur vulcani2ation, there have been many research workers in the field of natural mbber oxidation and its protection (39,40). The principal problem has always been to find an antioxidant that provides protection against flex-cracking, and yet does not stain. None has been found as of the mid-1990s, hence it is best to categori2e the various types according to their capabiUties. 

Armor. Sihcon carbide is used as a candidate in composite armor protection systems. Its high hardness, compressive strength, and elastic modulus provide superior baUistic capabihty to defeat high velocity projectile threats. In addition, its low specific density makes it suitable for apphcations where weight requirements are critical (11). 

The low cost, light weight, and exceUent electrical conductivity of graphite anodes have made this impressed current protection system valuable for cathodic protection of pipelines, storage vessels, process equipment, and also for weU casings both on- and offshore. 

Stanley Grossel, President, Process Safety Design, Inc. Fellow, American Institute of Chemical Engineers Member, American Chemical Society Member, The Combustion Institute Member, Explosion Protection Systems Committee of NFPA (Section 26, Process Safety)... 

Where hazardous conditions can develop within a process, a protective system of some type must be provided. Sometimes these are in the form of process hardware such as pressure rehef devices. However, sometimes logic must be provided for the specific purpose of taking the process to a state where the hazardous condition cannot exist. The term safety interlock. system is normally used to designate such logic. 

Depending upon the design criteria of the installed suppression system, an unsuppressed explosion overpressure of around 7 to 10 bar is reduced to a suppressed reduced explosion overpressure which lies in the range of Fred,max = 0-2 to 1 bar. Thus, vessels need to be explosion resistant for an overpressure of maximum 1 bar (ISO Standard 6184/4, Explosion Protection Systems Paii 4 Determination of Efficacy of Explosion Suppression Systems, Geneva, 1985). 

Carbon steel heat exchangers, cast iron water boxes, screens, pump components, service water system piping, standpipes, fire protection systems, galvanized steel, engine components, and virtually all non-stainless ferrous components are subject to significant corrosion in oxygenated water. 

Cathodic protection can be useful, although its ability to protect tube interiors is generally limited to the first 4 to 6 in. of tube length. Such systems, however, must be properly designed and maintained to be effective. Corrosion can be intensified if the polarity of the cathodic protection system is inadvertently reversed. 

Coat both materials or the noble material. Do not coat just the active material (see Area effects above). Coatings should be maintained, especially the one covering the active member of the couple. Use of cathodic protection systems in association with coatings is often recommended. 

NFPA 750 Standard on Water Mist Fire Protection Systems. National Fire Protection Association, Quincy, MA. 

Critical Equipment Equipment, instrumentation, controls, or systems whose malfunction or failure would likely result in a catastrophic release of highly hazardous chemicals, or whose proper operation is required to mitigate the consequences of such release. (Examples are most safety systems, such as area LEL monitors, fire protection systems such as deluge or underground systems, and key operational equipment usually handling high pressures or large volumes.)... 

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