Particle impact is a significant hazard in industrial oxygen applications, particularly in high-pressure valves, where it can trigger ignition events leading to fires or burnout. This study investigates the risk of particle impact ignition in Samson FROSTY valves, which are designed for high-pressure cryogenic service in pure oxygen atmospheres. The research collaboration between Samson Aktiengesellschaft (Samson) and WHA International (WHA) involved a Level 3 Oxygen Hazards and Fire Risk Analysis (OHFRA) to identify the most relevant ignition mechanism, which was particle impact. This risk assessment covered both liquid oxygen (LOX) and gaseous oxygen (GOX) conditions inside the valve. To address the risk comprehensively, WHA conducted a Level 4 OHFRA that included a quantified ignition probability analysis (QIPA). While historical test data were available for certain flow conditions, they revealed significant gaps in the test points required for operating conditions in valves within air separation units (ASUs). These gaps prompted Samson to conduct further investigations using computational fluid dynamics (CFD) simulations and finite element method (FEM) analyses to better understand particle impact dynamics inside the valves. The CFD simulations analyzed gas flow and particle trajectories, while FEM simulations examined particle-target interactions. These results were used to design a specimen in which particles were accelerated with a maximum pressure up to 150 bar(a) through a nozzle onto a stainless steel target. Experimental tests varied particle velocity, size, shape, and material, with impact velocity identified as the most significant factor influencing ignition risk. The findings revealed that while particle ignition could occur, no sustained burning or kindling of the stainless steel target occurred. This research underscores the importance of combining simulation and experimental data to refine risk assessment methodologies for equipment operating above industry-recommended impingement velocity thresholds. The results contribute to a more accurate framework for evaluating ignition risks in oxygen service valves.
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