F&EI Fire Risk_rev

7/31/2019 F&EI Fire Risk_rev

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Fire & Explosion Risk Analysis

at Flammables Terminal 2008Fatma Lestari, PhD


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Background

Fire, explosions and environmental pollution are the most serious

unpredictable life affecting and bussiness losses having an impacton the hydrocarbon industries (Nolan, 1996).

Along with its advantages and benefits to the society, the petroleumindustry has also brought along the hazards that need to bemanaged appropriately Unfortunately in some occurences, lack

of knowledge, technology, or failures in management systems hasled to tragic incidents (Suardin, 2005).

Hertfordshire Oil Storage Terminal (Buncefield Depot) Fire(http://www.en.wikipedia.org): Caused by a series of explosions early on the morning of 11 December 2005.

The tank fires were extinguished by the afternoon of 13 December 2005.

These were some of the largest explosions ever to occur in the country, andthe incident has been described as the biggest of its kind in peacetimeEurope.

There were 43 reported injuries; two people were deemed to be seriouslyinjured


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Objectives

to obtain fire risk profile

to estimate level of fire risk (hazard

categories)

to estimate the area of exposure

to provide recommendation for risks control


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Scope of Work Analysis

Classification of Hazards Category (Fire and

Explosions Index) Determination of Area of Exposure Area in

which all equipment in the area will be exposed to

the potential incident. Determination of Damage FactorThe overallef

fects resulting from a release of energy containedin the process unit.

Calculation of Loss Control Credit Factor

Represent the loss control (protective) featuresthat have been historically and statistically provenbeneficial in preventing or limiting seriousincidents.


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Fire & Explosion Index (F&EI) Dows Fire and Explosion Index (F&EI) is the most widely used

hazard index and has been revised six times since 1967 Thelatest edition (7th edition), which was published in 1994, isemployed in this research.

Dows Fire and Explosion Index is one of process hazard analysisinstrument, that objectively and realistically evaluate fire and

explosion risk, and reactivity from process equipment and itscontents in the process unit.

F&EI relates process hazards to process information (i.e., processconditions, materials, type of equipment, and other characteristicsof the process) in terms of penalties and credit factor.

The purpose of the F&EI system is to: QUANTIFY the expected damage of potential fire and explosion incidents in

realistic terms.

IDENTIFY equipment that would be likely to contribute to the creation orescalation of an incident.

COMMUNICATE the F&E risk potential to management.


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F&EI Methodology


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General Process Hazards Factor (F1)

General process hazard items have historically playedan important role in determining the magnitude ofpotential incidents, and are applicable to mostprocess condition.

General process hazards cover six items:(1)Exothermic chemical reactions, (2)Endothermicprocesses, (3)Material handling and transfer,(4)Enclosed or indoor process units, (5)Access,(6)Drainage and spill control.

F1 value is the total addition of all penalty on generalprocess hazards items and penalty from base factor(1.00).


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Special Process Hazards Factor (F2)

Special process hazard are the factors that play an important rolein increasing the probability of a potential incident andcomprise of the specific process condition that historicallyconttribute to the major causes of fire and explosion incidents.

Special process hazards cover 12 items: (1)Toxic material(s),

(2)Sub-atmospheric pressure, (3)Operation in or near flammablerange, (4)Dust explosion, (5)Relief pressure, (6)Low temperature,(7)Quantity of flammable/unstable material, (8)Corrosion anderosion, (9)Leakage-joints and packing, (10)Use of fireequipment, (11)Hot oil heat exchange system, (12)Rotating

equipment.

F2 value is the total addition of all penalty on special processhazards items and penalty from base factor (1.00).


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Process Unit Hazard Factor (F3)

Process unit hazard factor incorporates all

factors that are likely to contribute to the

occurence of fire and explosion incidents.

F3 is the product of the General Process

Hazards Factor (F1) times the Special Process

Hazards Factor (F2) F3 = F1 x F2


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Fire And Explosion Index (F&EI) Fire and Explosion Index (F&EI) is representing the hazard

potential which exist in the process unit.

F&EI is the product of the Process Unit Hazards Factor (F3)times the Material Factor (MF) F&EI = F3 x MF

F&EI is categorized based on degree of hazards at table:

F&EI Index Range Degree of Hazards

1-60 Light

61-69 Moderate

97-127 Intermediate128-158 Heavy

159-u Severe


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Radius of Exposure

Radius of Exposure is a radius around the tank whichwill be exposed if fire and explosion occur.

Radius of exposure is the product of F&EI value times0.84, the unit is on feet (ft).

For large pieces of equipment the radius starts fromthe surface of the equipment while for smallequipment the radius starts at the center of the itemconsidered.

The storage tank is a large process unit, then the realradius must be quantified from outside wall of thetank The real radius of exposure = Radius ofexposure + The radius of tank.


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Effected Area (T 103 & T 106) Based on the Radius of Exposure, we get effected area if fire and explosion occur

If fire and explosion occur at T-103, effected

process unit are T-102, T-107, T-108 and T-104

If fire and explosion occur at T-106 effected

process unit are T-105, T-102 and T-107


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Area of Exposure

Area of Exposure is a area around the tank

which will be exposed if fire and explosion

occur.

Area of exposure is a radian/circle area which

radius is comes from radius of exposure

Area of Exposure value is determined by the

area of circle calculation.


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Loss Control Credit Factor (LCCF) These factors represent the loss control (protective) feature that

have been historically and statistically proven beneficial in

preventing or limiting serious incidents. There are three categories of losss control credit factors:

Process Control Credit Factor (C1)

Process control credit factors consist of; emergency power, cooling,explosion control, emergency shutdown, computer control, inert gas,operating instruction/procedures, reactive chemical review, other processhazard analysis.

Material Isolation Credit Factor (C2)

Material isolation credit factors consist of; remote control valves,dump/blowdown, drainage, interlock.

Fire Protection Credit Factor (C3)

Fire protection credit factors consist of; leak detection, structural steel, firewater supply, special systems, sprinkler system, water curtain, foam, handextinguisher/monitors, cable protection.

The total credit factor is given by the following equation (AIChE,1994):

Ctotal (LCCF) = C1 x C2 x C3


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Recommendation

The recommendation is arranged to improve:

Weakness of the existing process design

Weakness of loss control design


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Recommendation for Loss Control Design Improvement

Operating Instruction / Procedures

Until the assessment is conducted, Operating

Instruction/Procedures has not available yet. Several proceduresneeds to be developed are: Start up

Routine shutdown

Normal operation condition

Turndown operation condition

Operation condition above normal

Immediate restart after shutdown

Restart after reparation

Maintenance procedures

Emergency shutdown Modification, addition of equipment

Estimated abnormal system

Reactive chemical review (MTBE)

To improve process control, we recommend to Oil Tanking to

conduct reactive chemical handling review as next step of theoperation


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Recommendation for Loss Control Design

Improvement

Leak Detection

The designed Gas detector is not able to activate thealarm system. To minimize the loss, we recommendOil Tanking to design Gas detector which able to

activate the alarm and protection system. Structural Steel

To improve fire protection, we recommend OilTanking to line all structural steel with fireproofing,

more than 10 meters in height.

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F&EI Fire Risk_rev