Handbook for Process Safety in Laboratories and Pilot Plants

3 Leaks and Spills in the LAPP

Process safety focuses on the loss of control of hazardous materials and energies. When there are leaks or spills of hazardous materials in a LAPP, there is a loss of control, also known as a loss of containment, of the hazardous material. This short chapter introduces some processing conditions and equipment issues that are frequent causes of leaks and spills.

3.1 Leaks of Hazardous Materials

Leaks are common occurrences in LAPPs. When working with hazardous conditions, such as high pressures or cryogenic temperatures, or hazardous materials, such as toxic or flammable liquids, hazardous situations will occur if the contents in the apparatus cannot be contained. Leaks involve a breach or failure of some type of protection layer and may release gases / vapors, liquids, solids or mixtures of gases, liquids and solids. Fires and explosions may occur if flammable vapors or gases accumulate at concentrations within their flammable range. Acute toxic effects may follow a release if individuals receive a significant dose from exposure

The failure modes or causes of leakage discussed next should reinforce the need for careful selection of components and frequent, routine inspections and leak testing of laboratory or pilot plant systems. Some common causes of leakage that the R&D team should work to prevent include:

3.1.1 Thermal expansion and contraction of fluids

Thermal expansion is the primary cause of leakage for liquids in piping or tubing with ...