RISK ASSESSMENT
(QRA)
RISK ASSESSMENT HAZOP
STUDY
ON SITE DISASTER CONTROL PLAN OFF SITE
DISASTER CONTROL PLAN
For
Proposed API Manufacturing Unit
At
LIVIA LIFE SCIENCES PVT. LTD.
PLOT NO. f-17, MIDC CHINCHOLI, SOLAPUR, MAHARASHTRA,
Prepared By
Enviro Resources
(NABET Certificate No: NABET/EIA/1821/IA0038)
E-604, Crystal Plaza, Opp. Infiniti Mall, New Link Road, Andheri West, Mumbai – 400 053. E-mail: [email protected]
MAY 2020
TABLE NO. 2.1: THE PROPOSED PRODUCTION CAPACITY OF PRODUCTS
Sr. No Name of Product CAS NO Qty in MTPA 1 Azacyclonol 115-46-8 384.00 2 Ethyl Iso Nipecotate 5006-62-2 102.00 3 Nicotinic Acid Methyl Ester 93-60-7 50.40 4 1-Benzylpiperidine-4-
Carboxaldehyde 22065-85-6 7.20
5 By-product Ammonium Sulfate
7783-20-2 120.96
Total 55.38 664.56
Figure no 1: Site Layout
SN. Name Of The Building Configuration Sn. Name Of The Building Configuration 1 Solvent Tank Farm PESO area. UG Laboratory Above office
2 Acid Tank Farm. UG Hazardous Waste Storage
3 Work Shed 1 -Utility Block. Ground + 1 Fire Water Storage
4 Work Shed 2 - Ware House. Ground + 1 RWH area. 5 Work Shed 3- Production Block. Ground + 1 Guard House & Entrance. 6 Work Shed 4- Production Block. Ground + 1 Parking. 7 Work Shed 5 - Ware House. Ground + 1 Future Expansion Blocks. 8 API Block Two Lines. ETP. 9 Boiler Area And Stack. Office. Ground + 1
10 Pollution Control Equipments. Coal Storage. Open yard /shed?
SECTION 3: IDENTIFICATION OF HAZARDS
TABLE NO. 3.1: FLAMMABILITY HAZARD MATERIAL
SN.
Name
CAS NO.
LEL
UEL
Flash Point
Boiling Point
NFPA Hazard
Index % % oC oC Nf
1 Mono Chloro Benzene 108-90-7 1.3 7.1 23.8 132.2 3 2 Triethyl Amine 121-44-8 1.2 8 -6.6 89.2 3 3 Vitride 22722-98-1 NA NA 4 110 3 4 Hydrogen
1333-74-0 4 75 gas gas 4
5 Ethyl Alcohol. 64-17-5 3.3 19 13 79 3 6 Tetra Hydro Furan. 109-99-9 2 11.8 -14.5 66 3 7 Toluene. 108-88-3 1.27 7.1 12.7 110.4 3 8 Methanol 67-56-1 6 36.5 11 64.7 3
TABLE NO. 3.1A: TOP FIVE - LOWEST BOILING POINT LIQUIDS
SN NAME CAS NUMBER BOILING POINT (oC) 1 Oxalyl Chloride 79-37-8 63
2 Tetra Hydro Furan. 109-99-9 66 3 Methanol. 67-56-1 64.7 4 Ethyl Alcohol. 64-17-5 79 5 Triethyl Amine 121-44-8 89.2
TABLE NO. 3.1B: TOP FIVE - WIDEST FLAMMABILITY RANGE MATERIALS
SN. NAME CAS NUMBER
LEL (%)
UEL (%)
RANGE 1 Hydrogen 1333-74-0 4 75 71
2 Methanol. 67-56-1 6 36.5 30.5 3 Ethyl Alcohol 64-17-5 3.3 19 15.7 4 Tetra Hydro Furan. 109-99-9 2 11.8 9.8 5 Triethyl Amine 121-44-8 1.2 8 6.8
TABLE NO. 3.2: TOXICITY HAZARD MATERIALS
S. No.
Name of RM CAS NO.
Oral LD50
Dermal LD50
Inhal. LC50
NFPA Hazard Index
mg/kg mg/kg ppm Nh
1 4-
Cyanopyridine
100-48-1 710 >20 Not listed 2
2 Ammonia
Gas 7664-41-
7 >90 112000 4230 3
3 Benzyl
Chloride 100-44-7 625 Not listed 0.74 3
4 Caustic Soda 1310-73-
2 Not listed 1350 Not listed 3
5 D.S. / Ethyl
Alcohol 64-17-5 3450 Not Listed 20000 2
6 Dimethyl sulfoxide
67-68-5 14500 40 5.33 2
7 Ethyl
Isonipecotate 1126-09-
6 Not listed Not listed Not listed 2
8 HCL 7647-01-
0 3124 900 NA 3
9 Methylene dichloride
75-09-2 2000 2000 53 2
10 Mono Chloro
Benzene 180-90-7 4000 7940 13.5 2
11 nicotinic acid 59-67-6 7000 2000 Not Listed 2
12 Oxalyl
Chloride 79-37-8 Not Listed Not Listed 1840 3
12 Sulfuric Acid 7664-93-
9 2140 250 g 510 mg/m3 3
14 Triethyl Amine
121-44-8 460 415 1250 3
15 Vitride 22722-
98-1 5000 12000 26700 3
TABLE NO. 3.3: REACTIVITY HAZARD MATERIALS
S. No. Name of RM
NFPA Hazard Index Material Factor Nh Nf Nr
1 4-Cyano Pyridine 2 1 0 4 2 Ammonia Gas 3 1 0 4 3 Benzyl Chloride 3 2 1 14 4 Caustic Soda 3 0 1 14 5 D.S. / Ethyl Alcohol 2 3 0 16 6 Dimethyl Sulforide 2 2 0 10 7 Ethyl Isonipecotate 2 2 1 14 8 HCL 3 0 1 1 9 Magnesium 0 1 1 4 10 MDC 2 1 0 4 11 Mono Chloro Benzene 2 3 0 16 12 Oxalyl Chloride 3 1 1 4 13 Sodium Sulfate 1 0 1 0 14 Sulfuric Acid 3 0 2 24 15 Tetrahydrofuran 2 3 1 16 16 Toluene 2 3 0 16 17 Triethyl Amine 3 3 0 16 18 Vitride 3 3 2 24 19 Methanol 1 3 0 16
TABLE NO. 3.4B: INVENTORY: NON BULK STORAGE
SN.
Name Mode of Storage
Consumption
Max. Qty. Stored
Kg/M Kg
1 4-Cyano Pyridine Bags 4000 1920
2 Ammonia Gas
Cylinder 5840 200
3 Benzyl Chloride Drum 750 360
4 Caustic Soda Bags 26176 12564.5
5 D.S. / Ethyl Alcohol Drums 19080 9158.4
6 Dimethyl Sulforide Drums 810 388.8
7 Ethyl Isonipecotate Drums 750 360
8 Isonicotinic Acid Drums 19200 9216
9 Magnesium Bags 18432 8847.4
10 MDC Drum 6000 2880
11 Nicotininc Acid Drum 4550 2184
12 Oxalyl Chloride Drum 420 201.6
13 Palladium catalyst Bags 1536 737.28
14 Palladium on Carbon Bags 192 92.16
15 Sodium Sulfate Bags 600 288
16 Triethyl Amine Drum 2295 1101.6
17 Vitride Drum 1125 540
18 Methanol Drum 1600 500
TABLE NO: 3.4C: INVENTORY: ACID STORAGE TANK
SN.
Name
CAS
Number
Mode of
Storage
Max. Qty.
St d
Consumption
Mt. Mt./M
1 Sulfuric Acid. 7664-93-9 Tank 10 13.82 2 Hydrochloric Acid. 7647-01-0 Tank 25 55.308
TABLE NO: 3.4D: INVENTORY: SOLVENT STORAGE TANK
SN.
Name
CAS
Number
Mode of
Storage
Max. Qty.
Stored
Consumption
Mt. Mt./M
1 Toluene 108-88-3 Tank 20X 2 78.95 2 Tetrahydrofuran 109-99-9 Tank 20X 2 69.12 3 Mono Chloro
180-90-7 Tank 20X 2 94.72
TABLE NO: 3.4E: INVENTORY: FUEL STORAGE
SN.
Name
CAS
Number
Mode of
Storage
Max. Qty.
Stored
Consumption
Mt. Mt./D
1 HSD 8052-41-3 Dum 0.2 0.107
2 Coal NA Open 60 18.8
TABLE NO: 3.4F: INVENTORY: GAS STORAGE
Sr.
No.
Gas Type Storage
pressure bar
Diameter
(mm)
Length /
height
(mm)
Capacity
1 Hydrogen 4 cylinder 151.2 B 200 mm 1600 mm 7 m3
2 Ammonia 4 cylinder 8.2 B 340 mm 1120 mm 50 kg
The DOW index is performed for all flammable chemicals which is to be stored in raw
material storage building (non bulk storage in drum) for proposed activity. The DOW index
has been performed for chemicals having Nf factor 3 or more than 3. Details of DOW index
is given in table below
Recommendation/Suggestions for non-PESO area
1. The storage in godown should be in a systematic way proper roads should be marked
by “Yellow” colour & should be kept free of obstruction all the time.
Chemical Ethyl Alcohol Triethyl Amine Vitride Methanol
Storage Considered Drum Drum Drum Drum N
h 2 3 3 1
N f 3 3 3 3
N r 0 0 2 0
Material Factor, MF 16 16 24 16 F1 (General Process
Hazard) 2.80 2.80 2.80 2.80
F2 (Special Process Hazard)
1.73 1.80 1.80 1.40
F3 (Hazard Factor) 4.844 5.04 5.04 3.92 Fire & Explosion Index 77.50 80.64 120.96 62.72
Degree of Hazard Moderate Moderate Intermediate Moderate Radius of Exposure in ft 65.1 67.73 101.6 52.68
Area of Exposure in sq.ft.
13307.3 14404.2 32412.8 8714
Damage Factor 0.5 0.52 0.80 0.45
2. The maximum stacking height should be marked on the walls in RED colour. The
stacking height should not be more than the red line. Red line should be marked on
1.5 mtrs. From lowest roof level.
3. All electrical fitting, fixtures should be flameproof & confirming to relevant IS. All
electrical wiring, fitting & fixture should be above the red line (stacking limit line)
4. The indication mark like Exits, Fire Escape, etc. should be prominently marked with
florescent paint so that it can be seen in darkness.
5. 3 Nos. of Alcohol Resistance Foam Extinguishers having capacity of 50 Ltrs. to be
installed in the Plant area.
6. Vitride is highly shall be kept away from Strong oxidizing agents, Acids, Acid
anhydrides, Acid chlorides, Alcohols.
7. Provide Safety Shower & Eye Wash Fountains and Portable Fire Extinguishers.
8. Personnel Protective Equipment (PPE) especially SCBA sets and training.
9. Provide Fire hydrant system.
10. Provide suitable arrangement at storm drain to avoid any organic contaminated water
/spill / fire water going out of the site
Monds Index
The principle and general approach used in the DOW method of hazard evaluation have been further developed by ICI Mond Division, the revised Mond Fire, Explosive and Toxicity index is a series of papers by Lewis (1979).
The main developments made to the DOW Index in the Mond Index are:
1. It covers a wider range of process and storage installation
2. It covers the processing of chemicals with explosive properties
3. A calculation procedure is included to allow for the off-setting effects of good design and
control and safety instrumentation
4. The procedure has been extended to cover plant layout
5. Separate indices are calculated to access the hazards of fire, internal explosion and aerial
explosion.
To estimate the Monds Index for raw materials in storage area following, All the raw materials stored in the industry premises are tabulated and data for their N (H) levels and TLV levels are obtained. Based on their highest toxicity factor and lowest TLV level Mond’s Index was calculated for chemicals with Nh =3 or more.
Table : Monds Toxicity index of toxic chemicals
Sr. No Raw Materials
Qty. at any given time in MT or
KL
Flash Point in 0C
UN Classification Health Hazard
(Nh)
TLV in ppm
1 Benzyl chloride 0.36 67.2
Class 8: Corrosive material
Class 6.1: Poisonous Material
3 10
2 Caustic Soda 12.56 NA Class 8: Corrosive
material 3 2
3 Triethylamine 1.10 -6.66
Class 3: Flammable material
Class 8: Corrosive material
3 5
4 Ammonia gas 2.80 132 Class 8: Corrosive
material 3 35
5 Oxalyl Chloride 0.201 NA
Class 4.3: Flammable material Class 8: Corrosive
material
3 50
6 Vitride 0.540 4
Class 4.3: Flammable material Class 8: Corrosive
material
3 20
Table 7.6: Calculated Mond’s Index and degree of Hazard for Hazardous chemicals.
Sr. No.
Raw Materials Th (Toxicity factor)
Ts ( Correction
factor)
Mond’s Index
Degree of hazard
1 Benzyl chloride 250 75 6.1 Moderate 2 Caustic Soda 250 125 8.0 Moderate 3 Triethylamine 250 125 9.01 High 4 Ammonia gas 250 75 5.80 Moderate 5 Oxalyl Chloride 250 75 5.80 Moderate 6 Vitride 250 75 5.51 Moderate
Toxicity (Mond) Index recommendations:
1. The raw materials are stored according to their compatibility.
2. Toxic materials are stored in cool place and kept away from heat.
3. Toxic material can cause breathing difficulty therefore storage area is well ventilated.
4. Good housekeeping practice is implemented in storage area.
5. Appropriate drainage with the slope of 2 % is provided to remove small and large
spillage of the chemicals.
6. The provision of fire water supply is provided through the hydrant line passing from the
raw material storage area
7. PPE’s are used wherever necessary.
8. MSDS recommendations are strictly followed while chemical storage and handling.
Recommendations for ‘High’ Mond Index chemical storage:
1. The chemicals are isolated from another chemical in well ventilated area and hazard
warning information is shown.
2. SOP is prepared for handling such chemicals and it should be strictly followed.
3. Spill kit is provided for storage to limit the spill of materials. Suitable Absorbent like
sodium bi carbonate is used to absorb the spill.
4. Proper training is provided to workers prior to handling and transporting chemicals.
5. PPE’s like face shield, goggles, apron, gloves, gumboots are used while handling the
chemicals to avoid exposure to chemicals.
Aerial Location of Hazardous Atmosphere (ALOHA):
A Quantitative Risk Assessment based on the software ALOHA – Aerial Locations of
Hazardous Atmospheres was carried out. The criteria failure scenarios considered for
ALOHA depend on the type of storage whether above ground tank, tank in storage area or
pressurized cylinders as well as physical state of the chemical stored and chemical properties
of the chemical.
ALOHA (Arial Locations of Hazards Atmosphere) is an atmospheric dispersion model used
for evaluating releases of hazardous chemical vapors. ALOHA is a part of software called
CAMEO (Computer Aided Management of Emergency Operation). CAMEO is one of the
tools developed by EPA’s Chemical Emergency Preparedness and Prevention Office
(CEPPO) and the National Oceanic and Atmospheric Administration Office of Response and
Restoration (NOAA), to assist front-line chemical emergency planners and responders. For
the present calculation version 5.4.4 is used.
CAMEO suite consists of three parts viz.
1. CAMEO: It is basically a chemical data base provided for calculations.
2. ALOHA: ALOHA allows the user to estimate the downwind dispersion of a chemical
cloud based on the toxicological/physical characteristics of the released chemical,
atmospheric conditions, and specific circumstances of the release.
3. MARPLOT (Mapping Applications for Response, Planning, and Local Operational
Tasks): Graphical outputs include a "cloud footprint" that can be plotted on maps with
MARPLOT to display the location of other facilities storing hazardous materials and
vulnerable locations, such as hospitals and schools. Specific information about these
locations can be extracted from CAMEO information modules to help make decisions
about the degree of hazard posed.
Acute Exposure Guideline Levels (AEGL):
Figure : Description of AEGL levels
THERMAL RADITION EFFECTS:
A Thermal Radiation Level of Concern (LOC) is a threshold level of thermal radiation,
usually the level above which a hazard may exist.
10 kW/(sq m) -- potentially lethal within 60 sec;
5 kW/(sq m) -- second-degree burns within 60 sec; and
2 kW/(sq m) -- pain within 60 sec.
Below are some effects at specific thermal radiation levels for which software was run.
37.5 kw / m2 (100% lethality),
12.5 kw/m2 (1% lethality),
1.6 kw/m2 (no discomfort)
The thermal radiation effects that people experience depend upon the length of time they are
exposed to a specific thermal radiation level. Longer exposure durations, even at a lower
thermal radiation level, can produce serious physiological effects.
OVERPRESSURE EFFECTS:
A major hazard associated with any explosion is overpressure. Overpressure, also called a
blast wave, refers to the sudden onset of a pressure wave after an explosion. This pressure
wave is caused by the energy released in the initial explosion—the bigger the initial
explosion, the more damaging the pressure wave. Blast waves can damage buildings or even
knock them flat—often injuring or killing the people inside them. The sudden change in
pressure can also affect pressure-sensitive organs like the ears and lungs. The damaging
effects of the overpressure will be greatest near the source of the explosion and lessen as you
move farther from the source.
An Overpressure Level of Concern (LOC) is a threshold level of pressure from a blast wave,
usually the pressure above which a hazard may exist. In vapor cloud explosion scenario,
ALOHA will suggest three default LOC values. ALOHA uses three threshold values to create
the default threat zones:
• Red: 8.0 psi (destruction of buildings);
• Orange: 3.5 psi (serious injury likely); and
• Yellow: 1.0 psi (shatters glass).
ALOHA software is used to estimate the risk associated with release of pressurized gases.
Following table represent the list of chemicals tank with their storage quantity for which
aloha is performed.
SN.
Name
CAS
Number
Mode of
Storage
Max. Qty.
Stored
Consumption
Dyke Area
Mt. Mt./M
1 Toluene 108-88-3 Tank 20X 2 78.95 Common dyke of 132
sq.m 2 Tetrahydrofuran 109-99-9 Tank 20X 2 69.12 3 Mono Chloro
Benzene 180-90-7 Tank 20X 2 94.72
Sr.
No.
Gas Type Storage
pressure bar
Diameter
(mm)
Length /
height
(mm)
Capacity
1 Hydrogen 4 cylinder 151.2 B 200 mm 1600 mm 7 m3
2 Ammonia 4 cylinder 8.2 B 340 mm 1120 mm 50 kg
ALOHA Footprint:
Table : ALOHA Footprints
Substance Scenario. Effects considered
LOC Distance, m
Toulene Spill of entire chemical
contained in tank-
evaporating puddle
Toxic area of vapor cloud
AEGL-3 3700 ppm 29 AEGL-2 560 ppm 80 AEGL-1 67 ppm 278
Flammable area of vapor cloud
60% LEL 6600 ppm 20
10% LEL 1100 ppm 54
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
LOC was never exceeded
3.5 psi serious injury likely
14
1.0 psi shatters glass
20
Burning Puddle/
Pool Fire Thermal
radiation from pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
35
5.0 kW/(sq m)
2nd degree burns
within 60 sec
51
2.0 kW/(sq m)
pain within 60
sec
81
Tank Failure (Leak from hole
Toxic area of vapor cloud
AEGL-3 3700 ppm 11 AEGL-2 560 ppm 39
in Horizontal cylindrical
tank)- Flammable chemical
escaping from tank (not burning)
AEGL-1 67 ppm 133
Flammable area of vapor cloud
60% LEL 6600 ppm Less than 10 meters
10% LEL 1100 ppm 26
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
LOC never exceeded
3.5 psi serious injury likely
Less than 10 meters
1.0 psi shatters glass
11 meters
Tank Failure
(Leak from hole in horizontal
cylindrical tank) - Flammable chemical is burning as it escapes from
tank
Thermal radiation from
pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
Less than 10 meters
5.0 kW/(sq m)
2nd degree burns
within 60 sec
Less than 10 meters
2.0 kW/(sq m)
pain within 60
sec
Less than 10 meters
Tank Failure
(Leak from hole in Horizontal
cylindrical tank)- BLEVE of flammable
liquid in Horizontal
cylindrical tank
Thermal radiation from
fireball
10.0 kW/(sq m)
potentially lethal
within 60 sec
312
5.0 kW/(sq m)
2nd degree burns
within 60 sec
441
2.0 kW/(sq m)
pain within 60
sec
688
Tetrahydrof
uran Spill of entire
chemical contained in
Tank- evaporating
puddle
Toxic area of vapour cloud
ERPG-3 5000 ppm 70 ERPG-2 500 ppm 228 ERPG-1 100 ppm 560
Flammable area of vapour cloud
60% LEL 12000 ppm
47
10% LEL 2000 ppm 111
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
LOC never exceeded
3.5 psi serious injury likely
37
1.0 psi shatters glass
51
Burning Puddle
/ Pool Fire Thermal
radiation from pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
28
5.0 kW/(sq m)
2nd degree burns
within 60 sec
42
2.0 kW/(sq m)
pain within 60
sec
66
Leak from hole in Horizontal
cylindrical tank- Flammable chemical
escaping from tank (not burning)
Toxic Area of Vapor Cloud
ERPG-3 5000 ppm 21 ERPG-2 500 ppm 67 ERPG-1 100 ppm 176
Flammable Area of Vapor Cloud
60% LEL 12000 ppm
12
10% LEL 2000 ppm 33
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
LOC was never exceeded
3.5 psi serious injury likely
Less than 10 meters
1.0 psi shatters glass
20
Leak from hole in Horizontal
cylindrical tank- Flammable chemical is burning as it
Thermal radiation from
pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
less than 10 meters
5.0 kW/(sq 2nd degree burns
less than 10
escapes from tank
m) within 60 sec
meters
2.0 kW/(sq m)
pain within 60
sec
less than 10 meters
Leak from hole in Horizontal
cylindrical tank- BLEVE of flammable liquid in
Horizontal cylindrical tank
Thermal radiation from
fireball
10.0 kW/(sq m)
potentially lethal
within 60 sec
279
5.0 kW/(sq m)
2nd degree burns
within 60 sec
396
2.0 kW/(sq m)
pain within 60
sec
620
Monochloro
bezene
Spill of entire chemical
contained in Tank-
evaporating puddle
Toxic Area of Vapor Cloud
AEGL-3 400 ppm 57 AEGL-2 150 ppm 104 AEGL-1 10 ppm 573
Flammable Area of Vapor Cloud
60% LEL 43080 ppm
LOC was never exceeded
10% LEL 7180 ppm 29 meters
Overpressure (blast force) from vapor
cloud explosion
-- -- No explosion: no part of the cloud is above the LEL at any
time
Burning Puddle / Pool Fire
Thermal radiation from
pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
23
5.0 kW/(sq m)
2nd degree burns
within 60 sec
35
2.0 kW/(sq m)
pain within 60
sec
56
Leak from hole in Horizontal
cylindrical tank- Flammable
Toxic Area of Vapor Cloud
AEGL-3 400 ppm 30 AEGL-2 150 ppm 53 AEGL-1 10 ppm 296
chemical escaping from
tank (not burning)
Flammable Area of Vapor Cloud
60% LEL 7800 ppm less than 10 meters
10% LEL 1300 ppm 13
Overpressure (blast force) from vapor
cloud explosion
-- -- No explosion: no part of the cloud is above the LEL at any
time
Leak from hole in Horizontal
cylindrical tank- Flammable chemical is burning as it escapes from
tank
Thermal radiation from
pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
less than 10 meters
5.0 kW/(sq m)
2nd degree burns
within 60 sec
less than 10 meters
2.0 kW/(sq m)
pain within 60
sec
less than 10 meters
Leak from hole in Horizontal
cylindrical tank- BLEVE of flammable liquid in
Horizontal cylindrical tank
Thermal radiation from
fireball
10.0 kW/(sq m)
potentially lethal
within 60 sec
269
5.0 kW/(sq m)
2nd degree burns
within 60 sec
385
2.0 kW/(sq m)
pain within 60
sec
605
Hydrogen Leak from
vertical cylindrical tank-
not burning
Toxic Area of Vapor Cloud
PAC-3 400000 ppm
13
PAC-2 230000 ppm
17
PAC-1 65000 ppm
32
Flammable Area of Vapor Cloud
60% LEL 24000 ppm
74
10% LEL 4000 ppm 162
Overpressure 8.0 psi destruction 55
(blast force) from vapor
cloud explosion
of buildings
3.5 psi serious injury likely
56
1.0 psi shatters glass
67
Leak from
vertical cylindrical tank-
burning
Thermal radiation from
pool fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
Less than 10 meters
5.0 kW/(sq m)
2nd degree burns
within 60 sec
Less than 10 meters
2.0 kW/(sq m)
pain within 60
sec
Less than 10 meters
Catastrophic
failure of cylinder (Direct
Source)
Toxic Area of Vapor Cloud
PAC-3 400000 ppm
142
PAC-2 230000 ppm
177
PAC-1 65000 ppm
284
Flammable Area of Vapor Cloud
60% LEL 24000 ppm
520
10% LEL 4000 ppm 1000
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
441
3.5 psi serious injury likely
446
1.0 psi shatters glass
495
Ammonia Leak from
vertical cylindrical tank-
not burning
Toxic Area of Vapor Cloud
AEGL-3 1100 ppm 78 AEGL-2 160 ppm 178 AEGL-1 331 ppm 331
Flammable Area of Vapor Cloud
60% LEL 90000 ppm
12
10% LEL 15000 ppm
30
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
LOC never exceeded
3.5 psi serious injury likely
LOC never exceeded
1.0 psi shatters glass
Less than 10 meters
Leak from
vertical cylindrical tank-
burning
Thermal radiation from
jet fire
10.0 kW/(sq m)
potentially lethal
within 60 sec
Less than 10 meters
5.0 kW/(sq m)
2nd degree burns
within 60 sec
Less than 10 meters
2.0 kW/(sq m)
pain within 60
sec
Less than 10 meters
Catastrophic
failure of cylinder (Direct
Source)
Toxic Area of Vapor Cloud
AEGL-3 1100 ppm 473 AEGL-2 160 ppm 957 AEGL-1 30 ppm 1800
Flammable Area of Vapor Cloud
60% LEL 90000 ppm
116
10% LEL 15000 ppm
234
Overpressure (blast force) from vapor
cloud explosion
8.0 psi destruction of
buildings
LOC was never exceeded
3.5 psi serious injury likely
LOC was never exceeded
1.0 psi shatters glass
91
HCL (30%) Spill of entire chemical
contained in Tank-
evaporating puddle
Gaussian- Toxic area of vapour
cloud
AEGL-3 100 ppm 161 AEGL-2 22 ppm 370 AEGL-1 1.8 ppm 1500
Interpretation
Based on the unsafe distances identified by the ALOHA software output file, the MCLS
(maximum credible loss scenario) for the factory works out to about 1800 meter for
Ammonia with 30 ppm concentration impact in the environment.
The scenario considered for assessing the impact by quantitative risk assessment was taken
from standard guideline.
The probability of occurrence of the scenario is very less. The Disaster management plan
highlights the suggestive measures to be taken during the occurrence of such an accident.
Recommendations – For storage tanks
The periodic inspection and maintenance program on the tank would be ensured.
The periodic maintenance of the pumps and piping would be ensured.
Least number of flanged joints will be provided in the pipelines.
The pipelines will be supported adequately so as to avoid sagging of the same during
operation.
Visual inspection of the pipelines will be done periodically to ascertain external
pitting and corrosion.
Protective painting on the tank and pipeline shall be provided.
Protective equipment such as gloves, lab coat, vapor respirator, splash goggles shall
be ensured while handling the substance.
Prominent signage of hazards (such as “Danger”, No smoking”) of the substances
shall be provided on the tank and surroundings
The tank installation will be protected against lightening.
All Electric Equipment & Fittings (e.g. Pump-motors, lamps, junction boxes, switches
etc.) shall be of Flame-proof Type, conforming to IS/IEC 60079 i.e. old IS 2148:1981,
suitable for GR. II A/II B and shall be of type approved by the CCoE.
Recommendations:
A) Hydrogen Cylinders
1. The area shall not be used for any purpose other than for keeping of compressed gas filled
in cylinders.
2. Compressed gas cylinders shall be stored only in the storage shed, which shall be
constructed of suitable non-flammable materials provided that, when only non-flammable gas
filled in cylinder is stored, the beams, rafters, columns, windows and doors may be of wood.
3. The storage shed shall be adequately ventilated near the ground level and near or in the
roof.
4. Store only where temperature will not exceed 52°C.
5. Hydrogen can form explosive mixture with oxidizing agent therefore storage should be
away from sodium hypochlorite storage.
6. The storage shed and the area surrounding it shall at all times be kept clean and free from
all flammable materials, waste vegetation and, rubbish.
7. No fire, furnace or other source of heat or light other than flameproof electric light and
fittings shall be allowed in the storage shed and within the safety zone required to be
maintained under condition
8. No person shall smoke in the storage shed or carry matches, fuses, mobile phones or other
appliances producing ignition in the premises. Conspicuous ‘No smoking signs in Hindi,
English and the regional language shall be pasted or hung up at prominent places outside the
storage shed.
B) For Ammonia Cylinder
1. Store in cool and well ventilated area.
2. Excess ammonia should be scrubbed.
3. Leakage Emergency Tool Kit for Ammonia should be provided and Self Contained
Breathing Apparatus (SCBA) should be provided in storage shed if needed.
DOW INDEX
1. Methanol
Tank No. NA Equipment Name Methanol ( Drum Storage-631 Liters)
Basic Material for Material factor Methanol Density, kg/l 0.792
Properties of material N h 1 N f 3 N r 0 M.F. 16 Boil. pt. 148.3 0F 64.6 0C Flash pt. 52 0F 11.11 0C
∆HC = Heat of Comb. 8600 BTU / lb Quantity of the material 631 l 500 kg 1102.3 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty
factor range Penalty factor used
1.General Process
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.25 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.80 2.Special Process
Base Factor 1.00 1.00
Toxic material(s) 0.20 to 0.80 0.20 Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00 Operation in or near flammable range
_____inerted ______noninerted 0.00 to 0.80
1. Tank farm storage flammable liquids 0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable material 1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.10 3. Combustible Solids in Storage, Dust in
Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.10 Leakage - Joints & Packing 0.10 to 1.50 0.00 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.40
Process Unit Hazard Factor ( F3 = F1 x F2) 3.92 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 62.72 Degree of Hazard Moderate Radius of Exposure 52.68 ft Area of Exposure 8714 ft2
Degree of Hazard for F & EI Degree of Hazard for F & EI F & EI Index Range Degree of Hazard 1-60 Light 61-96 Moderate 97-127 Intermediate 128-158 Heavy 159-up Severe RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX
Preventive & Protective Features
Fire & Explosion Index Number Index for the present case
0-20 20-40 40-60 60-75 75-90 >90 62.72 Feature
optional Suggested Recommen
ded Feature required
1) Fireproofing 1 2 2 3 4 4 √ 2) Water spray a) directional 1 2 3 3 4 4 √ b) area 1 2 3 3 4 4 √ c) curtain 1 1 2 2 2 4 √ 3) Special instrumentation
a) temperature 1 2 3 3 4 4 √ b) pressure 1 2 3 3 3 4 √ c) flow control 1 2 3 4 4 4 √
4) Dust, blowdown, spill
control 1 1 2 3 3 4 √
5) Internal examination 1 2 3 3 4 4 √ 6) Combustible gas monitors
a) signal alarm 1 1 2 3 3 4 √ b) actuate equipment 1 1 2 2 3 4 √ 7) Remote operation 1 1 2 3 3 4 √
8) Diking, (Not Applicable as barrel storage)
1 4 4 4 4 4 √
9) Blast & barrier walls separation
1 1 2 3 4 4 √
1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required
2. Ethanol
Tank No. -- Equipment Name Ethanol Drum Storage (9.16 MT)
Basic Material for Material factor Ethanol Density, kg/l 0.789
Properties of material N h 2 N f 3 N r 0 M.F. 16 Boil. pt. 173.3 0F 78.5 0C Flash pt. 55 0F 12.7 0C
∆HC = Heat of Comb. 11500 BTU / lb Quantity of the material 11609 l 9160 kg 20194.3 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty
factor range Penalty factor used
1.General Process
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.25 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.80 2.Special Process
Base Factor 1.00 1.00
Toxic material(s) 0.20 to 0.80 0.40 Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00 Operation in or near flammable range
_____inerted ______noninerted 0.00 to 0.80
1. Tank farm storage flammable liquids 0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable material 1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.23
3. Combustible Solids in Storage, Dust in Process
0.00
Corrosion & Erosion 0.10 to 0.75 0.10 Leakage - Joints & Packing 0.10 to 1.50 0.00 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.73 Process Unit Hazard Factor ( F3 = F1 x F2) 4.844 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 77.50 Degree of Hazard Moderate Radius of Exposure 65.1 ft Area of Exposure 13307.3 ft2
Degree of Hazard for F & EI Degree of Hazard for F & EI F & EI Index Range Degree of Hazard 1-60 Light 61-96 Moderate 97-127 Intermediate 128-158 Heavy 159-up Severe RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX
Preventive & Protective Features
Fire & Explosion Index Number Index for the present case
0-20 20-40 40-60 60-75 75-90 >90 77.50 Feature
optional Suggested Recommen
ded Feature required
1) Fireproofing 1 2 2 3 4 4 √ 2) Water spray a) directional 1 2 3 3 4 4 √ b) area 1 2 3 3 4 4 √ c) curtain 1 1 2 2 2 4 √ 3) Special instrumentation
a) temperature 1 2 3 3 4 4 √ b) pressure 1 2 3 3 3 4 √ c) flow control 1 2 3 4 4 4 √
4) Dust, blowdown, spill
control 1 1 2 3 3 4 √
5) Internal examination 1 2 3 3 4 4 √ 6) Combustible gas monitors
a) signal alarm 1 1 2 3 3 4 √ b) actuate equipment 1 1 2 2 3 4 √ 7) Remote operation 1 1 2 3 3 4 √ 8) Diking, (Not Applicable as barrel storage)
1 4 4 4 4 4 √
9) Blast & barrier walls separation
1 1 2 3 4 4 √
1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required
3. Triethylamine
Tank No. -- Equipment Name Triethylamine (1.10 MT)
Basic Material for Material factor Triethylamine Density, kg/l 0.726
Properties of material N h 3 N f 3 N r 0 M.F. 16 Boil. pt. 192.7 0F 89.3 0C Flash pt. 20 0F -6.66 0C
∆HC = Heat of Comb. 17800
BTU / lb Quantity of the material 1515 l 1100 kg 2425 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty
factor range Penalty factor used
1.General Process
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.25 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.80 2.Special Process
Base Factor 1.00 1.00
Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00 Operation in or near flammable range
_____inerted ______noninerted 0.00 to 0.80
1. Tank farm storage flammable liquids 0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable material 1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.10 3. Combustible Solids in Storage, Dust in
Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.10 Leakage - Joints & Packing 0.10 to 1.50 0.00 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.80
Process Unit Hazard Factor ( F3 = F1 x F2) 5.04 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 80.64 Degree of Hazard Moderate Radius of Exposure 67.73 ft Area of Exposure 14404.2 ft2
Degree of Hazard for F & EI Degree of Hazard for F & EI F & EI Index Range Degree of Hazard 1-60 Light 61-96 Moderate 97-127 Intermediate 128-158 Heavy 159-up Severe RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX
Preventive & Protective Features
Fire & Explosion Index Number Index for the present case
0-20 20-40 40-60 60-75 75-90 >90 80.64 Feature
optional Suggested Recommen
ded Feature required
1) Fireproofing 1 2 2 3 4 4 √ 2) Water spray a) directional 1 2 3 3 4 4 √ b) area 1 2 3 3 4 4 √ c) curtain 1 1 2 2 2 4 √ 3) Special instrumentation
a) temperature 1 2 3 3 4 4 √ b) pressure 1 2 3 3 3 4 √ c) flow control 1 2 3 4 4 4 √
4) Dust, blowdown, spill
control 1 1 2 3 3 4 √
5) Internal examination 1 2 3 3 4 4 √ 6) Combustible gas monitors
a) signal alarm 1 1 2 3 3 4 √ b) actuate equipment 1 1 2 2 3 4 √ 7) Remote operation 1 1 2 3 3 4 √
8) Diking, (Not Applicable as barrel storage)
1 4 4 4 4 4 √
9) Blast & barrier walls separation
1 1 2 3 4 4 √
1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required
3. Vitride
Tank No. -- Equipment Name Vitride (0.54 MT)
Basic Material for Material factor Vitride Density, kg/l 1.036
Properties of material N h 3 N f 3 N r 2 M.F. 24 Boil. pt. 230 0F 110 0C Flash pt. 39.2 0F 4 0C
∆HC = Heat of Comb. -
BTU / lb Quantity of the material 521.23 l 540 kg 1190.5 Lb Storage conditions Temp 30 0C Pressure 1.0 Bar Penalty
factor range Penalty factor used
1.General Process
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.25 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.80 2.Special Process
Base Factor 1.00 1.00
Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm Hg) 0.50 0.00 Operation in or near flammable range
_____inerted ______noninerted 0.00 to 0.80
1. Tank farm storage flammable liquids 0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable material 1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.10 3. Combustible Solids in Storage, Dust in
Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.10 Leakage - Joints & Packing 0.10 to 1.50 0.00 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.80
Process Unit Hazard Factor ( F3 = F1 x F2) 5.04 Fire & Explosion Index (F.& E.I.= F3 x M.F. ) 120.96 Degree of Hazard Intermediate Radius of Exposure 101.6 ft Area of Exposure 32412.8 ft2
Degree of Hazard for F & EI Degree of Hazard for F & EI F & EI Index Range Degree of Hazard 1-60 Light 61-96 Moderate 97-127 Intermediate 128-158 Heavy 159-up Severe RECOMMENDED MINIMUM FEATURES ACCORDING TO DOW FIRE AND EXPLOSION INDEX
Preventive & Protective Features
Fire & Explosion Index Number Index for the present case
0-20 20-40 40-60 60-75 75-90 >90 120.96 Feature
optional Suggested Recommen
ded Feature required
1) Fireproofing 1 2 2 3 4 4 √ 2) Water spray a) directional 1 2 3 3 4 4 √ b) area 1 2 3 3 4 4 √ c) curtain 1 1 2 2 2 4 √ 3) Special instrumentation
a) temperature 1 2 3 3 4 4 √ b) pressure 1 2 3 3 3 4 √ c) flow control 1 2 3 4 4 4 √
4) Dust, blowdown, spill
control 1 1 2 3 3 4 √
5) Internal examination 1 2 3 3 4 4 √ 6) Combustible gas monitors
a) signal alarm 1 1 2 3 3 4 √ b) actuate equipment 1 1 2 2 3 4 √ 7) Remote operation 1 1 2 3 3 4 √
8) Diking, (Not Applicable as barrel storage)
1 4 4 4 4 4 √
9) Blast & barrier walls separation
1 1 2 3 4 4 √
1) Feature optional 2) Feature suggested 3) Feature recommended 4) Feature required
Monds Index
The principle and general approach used in the DOW method of hazard evaluation have been further developed by ICI Mond Division, Their revised Mond fire, explosive and toxicity index is a series of papers by lewis (1979). The main development made to the DOW Index in the Mond Index are:
1. It covers a wider range of process and storage installation 2. It covers the processing of chemicals with explosive properties 3. A calculation procedure is included to allow for the off-setting effects of good
design and control and safety instrumentation 4. The procedure has been extended to cover plant layout 5. Separate indices are calculated to access the hazards of fire, internal explosion and
aerial explosion.
Table No. : Toxicity factor Index
NFPA Index Number Toxicity Factor (Th)
0 0
1 50
2 125
3 250
4 325
Table No. : Correction factor for Toxicity
MAC (in ppm) Ts
5 and below 125
Between 5 and 50 75
50 and more 50
Table No. : Toxicity Index
The resulting TI values are ranked into three categories:
1-5 Light
6-9 Moderate
10-up High
1) Mond’s Index of Benzyl chloride General & Special Process Hazard 1.General
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.40 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.10 2.Special
Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm
0.50 0.00
Operation in or near flammable range
0.00 to 0.80
1. Tank farm storage flammable
0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable
1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage,
Dust in Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 2.10 and 1.70 respectively. Calculation of Toxicity Index:
Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 2.10 + 1.70)]/100 Toxicity Index : 6.1
The Toxicity Index for Benzyl chloride is calculated to be around 6.1 which indicate that the degree of hazard is moderate.
2) Mond’s Index of Caustic Soda General & Special Process Hazard 1.General
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.00 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 1.70 2.Special
Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm
0.50 0.00
Operation in or near flammable range
0.00 to 0.80
1. Tank farm storage flammable
0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable
1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage,
Dust in Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 1.70 and 1.70 respectively. Calculation of Toxicity Index:
Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 125 (1 + 1.70 + 1.70)]/100 Toxicity Index : 8.0 The Toxicity Index for Caustic Soda is calculated to be around 8.0 which indicate that the degree of hazard is moderate.
3) Mond’s Index of Triethylamine General & Special Process Hazard 1.General
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.55 2.Special
Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm
0.50 0.00
Operation in or near flammable range
0.00 to 0.80
1. Tank farm storage flammable
0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable
1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage,
Dust in Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 2.55 and 1.70 respectively. Calculation of Toxicity Index:
Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 125 (1 + 2.55 + 1.70)]/100 Toxicity Index : 9.06 The Toxicity Index for Triethylamine is calculated to be around 9.06 which indicate that the degree of hazard is high.
4) Mond’s Index of Ammonia General & Special Process Hazard 1.General
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.00 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 1.70 2.Special
Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm
0.50 0.00
Operation in or near flammable range
0.00 to 0.80
1. Tank farm storage flammable
0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable
1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage,
Dust in Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 1.70 and 1.70 respectively. Calculation of Toxicity Index:
Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 1.70 + 1.70)]/100 Toxicity Index : 5.80 The Toxicity Index for ammonia is calculated to be around 5.80 which indicate that the degree of hazard is moderate.
5) Mond’s Index of Oxalyl Chloride General & Special Process Hazard 1.General
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.00 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 1.70 2.Special
Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm
0.50 0.00
Operation in or near flammable range
0.00 to 0.80
1. Tank farm storage flammable
0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable
1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.00 3. Combustible Solids in Storage,
Dust in Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.70 Therefore, from the above table the GPH and SPH is coming to be around 1.70 and 1.70 respectively.
Calculation of Toxicity Index: Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 1.70 + 1.70)]/100 Toxicity Index : 5.80 The Toxicity Index for Oxalyl Chloride is calculated to be around 5.80 which indicate that the degree of hazard is moderate.
6) Mond’s Index of Vitride General & Special Process Hazard 1.General
Base Factor 1.00 1.00 Exothermic Chemical Reaction 0.30 to 1.25 0.00 Endothermic Processes 0.20 to 0.40 0.00 Material handling and transfer 0.25 to 1.05 0.85 Enclosed or Indoor Process Units 0.25 to 0.90 0.00 Access 0.20 to 0.35 0.20 Drainage and Spill Control 0.25 to 0.50 0.50 General Process Hazard Factor ( F1 ) 2.55 2.Special
Base Factor 1.00 1.00 Toxic material(s) 0.20 to 0.80 0.60 Sub atmospheric pressure (< 500 mm
0.50 0.00
Operation in or near flammable range
0.00 to 0.80
1. Tank farm storage flammable
0.50 0.00 2. Process upset or purge failure 0.30 0.00 3. Always in contact of Flame
0.80 0.00
Dust Explosion 0.25 to 2.00 0.00 Pressure Operating pressure psig
0.00
Low temperature 0.20 to 0.30 0.00 Quantity of flammable / unstable
1. Liquids or gases in process 0.00 2. Liquids or gases in storage 0.10 3. Combustible Solids in Storage,
Dust in Process 0.00
Corrosion & Erosion 0.10 to 0.75 0.00 Leakage - Joints & Packing 0.10 to 1.50 0.10 Use of Fired Equipment 0.00 Hot oil heat exchange system 0.15 to 1.15 0.00 Rotating Equipment 0.50 0.00 Special Process Hazard Factor ( F2 ) 1.80 Therefore, from the above table the GPH and SPH is coming to be around 2.55 and 1.80 respectively. Calculation of Toxicity Index:
Toxicity Index : Th + Ts (1+GPH+SPH) 100 Toxicity Index : [250 + 75 (1 + 2.55 + 1.80)]/100 Toxicity Index : 6.51 The Toxicity Index for Vitride is calculated to be around 6.51 which indicate that the degree of hazard is moderate.
The summary of ALOHA
The basic data used for running ALOHA
SITE DATA:
Location: GOGA INDUSTRIES, AVADHAN MID, INDIA Building Air Exchanges Per Hour: 0.37 (unsheltered single storied) Time: May 8, 2020 2022 hours ST (using computer's clock)
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
Wind: 1.5 meters/second from N at 10 meters Ground Roughness: open country Cloud Cover: 5 tenths Air Temperature: 30° C Stability Class: F (user override) No Inversion Height Relative Humidity: 50%
1) CHEMICAL DATA FOR TOLUENE:
CAS Number: 108-88-3 Molecular Weight: 92.14 g/mol AEGL-1 (60 min): 67 ppm AEGL-2 (60 min): 560 ppm AEGL-3 (60 min): 3700 ppm IDLH: 500 ppm LEL: 11000 ppm UEL: 71000 ppm Ambient Boiling Point: 228.7° F Vapor Pressure at Ambient Temperature: 0.048 atm Ambient Saturation Concentration: 50,246 ppm or 5.02%
The ALOHA Footprints (Toluene)
I) Source :-Puddle
i) Scenario :- Evaporating Puddle of Flammable Chemical
1. Toxic area of vapour cloud SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 6.46 kilograms/min
(averaged over a minute or more)
Total Amount Released: 377 kilograms
THREAT ZONE:
Model Run: Heavy Gas
Red : 29 meters --- (3700 ppm = AEGL-3 [60 min])
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Orange: 80 meters --- (560 ppm = AEGL-2 [60 min])
Yellow: 278 meters --- (67 ppm = AEGL-1 [60 min])
2. Flammable area of vapour cloud
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 6.46 kilograms/min
(averaged over a minute or more)
Total Amount Released: 377 kilograms
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas
Red : 20 meters --- (6600 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 54 meters --- (1100 ppm = 10% LEL)
3. Blast Area of Vapor Cloud Explosion
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 6.46 kilograms/min
(averaged over a minute or more)
Total Amount Released: 377 kilograms
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)
Orange: 14 meters --- (3.5 psi = serious injury likely)
Yellow: 20 meters --- (1.0 psi = shatters glass)
The ALOHA Footprints (Toluene)
I) Source :-Puddle
ii) Scenario :- Burning Puddle/ Pool Fire
1. Thermal radiation from pool fire
SOURCE STRENGTH:
Burning Puddle / Pool Fire
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Initial Puddle Temperature: 30° C
Flame Length: 29 meters
Burn Duration: ALOHA limited the duration to 1 hour
Burn Rate: 1,050 kilograms/min
Total Amount Burned: 63,295 kilograms
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Red : 35 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 51 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 81 meters --- (2.0 kW/(sq m) = pain within 60 sec)
The ALOHA Footprints (Toulene)
II) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
i) Scenario :- Flammable chemical escaping from tank (not burning)
1. Toxic Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,145 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 1.4 kilograms/min
(averaged over a minute or more)
Total Amount Released: 49.3 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 7.3 meters.
THREAT ZONE:
Model Run: Heavy Gas
Red : 11 meters --- (3700 ppm = AEGL-3 [60 min])
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Orange: 39 meters --- (560 ppm = AEGL-2 [60 min])
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 133 meters --- (67 ppm = AEGL-1 [60 min])
2. Flammable Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,145 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 1.4 kilograms/min
(averaged over a minute or more)
Total Amount Released: 49.3 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 7.3 meters.
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas
Red : less than 10 meters(10.9 yards) --- (6600 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 26 meters --- (1100 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Th re a t Mo d e le d : F la m m a b le Are a o f Va p o r Clo u d
Mo d e l R u n : He a v y Ga s
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (6 6 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
Ye llo w: 2 6 m e te rs --- (1 1 0 0 p p m = 1 0 % LE L)
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
3. Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,145 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 1.4 kilograms/min
(averaged over a minute or more)
Total Amount Released: 49.3 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 7.3 meters.
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)
Orange: less than 10 meters(10.9 yards) --- (3.5 psi = serious injury likely)
Yellow: 11 meters --- (1.0 psi = shatters glass)
II) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
ii) Scenario :- Flammable chemical is burning as it escapes from tank
1. Thermal radiation from pool fire
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical is burning as it escapes from tank
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,145 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Max Puddle Area: 216 square meters
Max Flame Length: 4 meters
Burn Duration: ALOHA limited the duration to 1 hour
Max Burn Rate: 3.79 kilograms/min
Total Amount Burned: 225 kilograms
Note: The chemical escaped as a liquid and formed a burning puddle.
The puddle spread to a diameter of 1.0 meters.
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)
) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
iii) Scenario :- BLEVE of flammable liquid in horizontal cylindrical tank
1. Thermal radiation from fireball
SOURCE STRENGTH:
BLEVE of flammable liquid in horizontal cylindrical tank
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m p o o l fire
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 0 .0 kW /(s q m ) = p o te n tia lly le th a l with in 6 0 s e c )
Ora n g e : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (5 .0 kW /(s q m ) = 2 n d d e g re e b u rn s with in 6 0 s e c )
Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (2 .0 kW /(s q m ) = p a in with in 6 0 s e c )
Tank contains liquid
Internal Storage Temperature: 30° C
Chemical Mass in Tank: 17,145 kilograms
Tank is 100% full
Percentage of Tank Mass in Fireball: 100%
Fireball Diameter: 150 meters Burn Duration: 10 seconds
THREAT ZONE:
Threat Modeled: Thermal radiation from fireball
Red : 312 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 441 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 688 meters --- (2.0 kW/(sq m) = pain within 60 sec)
2) CHEMICAL DATA FOR TETRAHYDROFURAN:
CAS Number: 109-99-9 Molecular Weight: 72.11 g/mol
ERPG-1: 100 ppm ERPG-2: 500 ppm ERPG-3: 5000 ppm
IDLH: 2000 ppm LEL: 20000 ppm UEL: 118000 ppm
Ambient Boiling Point: 64.8° C
Vapor Pressure at Ambient Temperature: 0.26 atm
Ambient Saturation Concentration: 274,231 ppm or 27.4%
The ALOHA Footprints (Tetrahydrifuran)
III) Source :-Puddle
iii) Scenario :- Evaporating Puddle of Flammable Chemical
1. Toxic area of vapour cloud
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 30.5 kilograms/min
(averaged over a minute or more)
Total Amount Released: 1,796 kilograms
THREAT ZONE:
Model Run: Heavy Gas
Red : 70 meters --- (5000 ppm = ERPG-3)
Orange: 228 meters --- (500 ppm = ERPG-2)
Yellow: 560 meters --- (100 ppm = ERPG-1)
2. Flammable area of vapour cloud
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 30.5 kilograms/min
(averaged over a minute or more)
Total Amount Released: 1,796 kilograms
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas
Red : 47 meters --- (12000 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 111 meters --- (2000 ppm = 10% LEL)
3. Blast Area of Vapor Cloud Explosion
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 30.5 kilograms/min
(averaged over a minute or more)
Total Amount Released: 1,796 kilograms
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)
Orange: 37 meters --- (3.5 psi = serious injury likely)
Yellow: 51 meters --- (1.0 psi = shatters glass)
The ALOHA Footprints (Tetrahydrofuran)
III) Source :-Puddle
iv) Scenario :- Burning Puddle/ Pool Fire
2. Thermal radiation from pool fire
SOURCE STRENGTH:
Burning Puddle / Pool Fire
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Initial Puddle Temperature: 30° C
Flame Length: 25 meters
Burn Duration: ALOHA limited the duration to 1 hour
Burn Rate: 879 kilograms/min
Total Amount Burned: 52,754 kilograms
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Red : 28 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 42 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 66 meters --- (2.0 kW/(sq m) = pain within 60 sec)
The ALOHA Footprints (Tetrahydrofuran)
IV) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
iv) Scenario :- Flammable chemical escaping from tank (not burning)
4. Toxic Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,450 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 3.04 kilograms/min
(averaged over a minute or more)
Total Amount Released: 127 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 5.5 meters.
THREAT ZONE:
Model Run: Heavy Gas
Red : 21 meters --- (5000 ppm = ERPG-3)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Orange: 67 meters --- (500 ppm = ERPG-2)
Yellow: 176 meters --- (100 ppm = ERPG-1)
5. Flammable Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,450 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 3.04 kilograms/min
(averaged over a minute or more)
Total Amount Released: 127 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 5.5 meters.
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas
Red : 12 meters --- (12000 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 33 meters --- (2000 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Th re a t Mo d e le d : F la m m a b le Are a o f Va p o r Clo u d
Mo d e l R u n : He a v y Ga s
R e d : 1 2 m e te rs --- (1 2 0 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
Ye llo w: 3 3 m e te rs --- (2 0 0 0 p p m = 1 0 % LE L)
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
6. Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,450 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 3.04 kilograms/min
(averaged over a minute or more)
Total Amount Released: 127 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 5.5 meters.
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)
Orange: less than 10 meters(10.9 yards) --- (3.5 psi = serious injury likely)
Yellow: 20 meters --- (1.0 psi = shatters glass)
IV) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
v) Scenario :- Flammable chemical is burning as it escapes from tank
2. Thermal radiation from pool fire
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical is burning as it escapes from tank
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 17,450 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Max Puddle Area: 216 square meters
Max Flame Length: 4 meters
Burn Duration: ALOHA limited the duration to 1 hour
Max Burn Rate: 3.83 kilograms/min
Total Amount Burned: 226 kilograms
Note: The chemical escaped as a liquid and formed a burning puddle.
The puddle spread to a diameter of 1.1 meters.
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)
vi) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
Scenario :- BLEVE of flammable liquid in horizontal cylindrical tank
Thermal radiation from fireball
SOURCE STRENGTH:
BLEVE of flammable liquid in horizontal cylindrical tank
Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m p o o l fire
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 0 .0 kW /(s q m ) = p o te n tia lly le th a l with in 6 0 s e c )
Ora n g e : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (5 .0 kW /(s q m ) = 2 n d d e g re e b u rn s with in 6 0 s e c )
Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (2 .0 kW /(s q m ) = p a in with in 6 0 s e c )
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid
Internal Storage Temperature: 30° C
Chemical Mass in Tank: 17,450 kilograms
Tank is 100% full
Percentage of Tank Mass in Fireball: 100%
Fireball Diameter: 150 meters Burn Duration: 10 seconds
THREAT ZONE:
Threat Modeled: Thermal radiation from fireball
Red : 279 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 396 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 620 meters --- (2.0 kW/(sq m) = pain within 60 sec)
3) CHEMICAL DATA FOR MONO CHLORO BENZENE:
CAS Number: 108-90-7 Molecular Weight: 112.56 g/mol
AEGL-1 (60 min): 10 ppm AEGL-2 (60 min): 150 ppm AEGL-3 (60 min): 400 ppm
IDLH: 1000 ppm LEL: 13000 ppm UEL: 96000 ppm
Ambient Boiling Point: 130.5° C
Vapor Pressure at Ambient Temperature: 0.021 atm
Ambient Saturation Concentration: 21,331 ppm or 2.13%
The ALOHA Footprints (MCB)
V) Source :-Puddle
v) Scenario :- Evaporating Puddle of Flammable Chemical
1. Toxic area of vapour cloud SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 3.24 kilograms/min
(averaged over a minute or more)
Total Amount Released: 187 kilograms
THREAT ZONE:
Model Run: Heavy Gas
Red : 57 meters --- (400 ppm = AEGL-3 [60 min])
Orange: 104 meters --- (150 ppm = AEGL-2 [60 min])
Yellow: 573 meters --- (10 ppm = AEGL-1 [60 min])
2. Flammable area of vapour cloud
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 3.24 kilograms/min
(averaged over a minute or more)
Total Amount Released: 187 kilograms
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas
Red : LOC was never exceeded --- (7800 ppm = 60% LEL = Flame Pockets)
Yellow: 29 meters --- (1300 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
3. Blast Area of Vapor Cloud Explosion
SOURCE STRENGTH:
Evaporating Puddle (Note: chemical is flammable)
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 3.24 kilograms/min
(averaged over a minute or more)
Total Amount Released: 187 kilograms
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Th re a t Mo d e le d : F la m m a b le Are a o f Va p o r Clo u d
Mo d e l R u n : He a v y Ga s
R e d : LOC wa s n e v e r e x c e e d e d --- (7 8 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )
Ye llo w: 2 9 m e te rs --- (1 3 0 0 p p m = 1 0 % LE L)
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
Level of Congestion: congested
Model Run: Heavy Gas
No explosion: no part of the cloud is above the LEL at any time
Th re a t Mo d e le d : Ov e rp re s s u re (b la s t fo rc e ) fro m v a p o r c lo u d e x p lo s io n
Ty p e o f Ig n itio n : ig n ite d b y s p a rk o r fla m e
Le v e l o f Co n g e s tio n : c o n g e s te d
Mo d e l R u n : He a v y Ga s
No e x p lo s io n : n o p a rt o f th e c lo u d is a b o v e th e LE L a t a n y tim e
The ALOHA Footprints (MCB)
V) Source :-Puddle
vi) Scenario :- Burning Puddle/ Pool Fire
3. Thermal radiation from pool fire
SOURCE STRENGTH:
Burning Puddle / Pool Fire
Puddle Area: 216 square meters Puddle Volume: 132 cubic meters
Initial Puddle Temperature: 30° C
Flame Length: 23 meters
Burn Duration: ALOHA limited the duration to 1 hour
Burn Rate: 760 kilograms/min
Total Amount Burned: 45,577 kilograms
THREAT ZONE:
Threat Modeled: Thermal radiation from pool fire
Red : 23 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 35 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 56 meters --- (2.0 kW/(sq m) = pain within 60 sec)
The ALOHA Footprints (MCB)
VI) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
vii) Scenario :- Flammable chemical escaping from tank (not burning)
7. Toxic Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 21,853 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 739 grams/min
(averaged over a minute or more)
Total Amount Released: 24.9 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 7.4 meters.
THREAT ZONE:
Model Run: Heavy Gas
Red : 30 meters --- (400 ppm = AEGL-3 [60 min])
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Orange: 53 meters --- (150 ppm = AEGL-2 [60 min])
Yellow: 296 meters --- (10 ppm = AEGL-1 [60 min])
8. Flammable Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 21,853 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 739 grams/min
(averaged over a minute or more)
Total Amount Released: 24.9 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 7.4 meters.
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Heavy Gas
Red : less than 10 meters(10.9 yards) --- (7800 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 13 meters --- (1300 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
.
Th re a t Mo d e le d : F la m m a b le Are a o f Va p o r Clo u d
Mo d e l R u n : He a v y Ga s
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (7 8 0 0 p p m = 6 0 % LE L = Fla m e P o c ke ts )
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
Ye llo w: 1 3 m e te rs --- (1 3 0 0 p p m = 1 0 % LE L)
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
9. Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 21,853 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Ground Type: Concrete Ground Temperature: 30° C
Max Puddle Area: 216 square meters
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 739 grams/min
(averaged over a minute or more)
Total Amount Released: 24.9 kilograms
Note: The chemical escaped as a liquid and formed an evaporating puddle.
The puddle spread to a diameter of 7.4 meters.
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Heavy Gas
No explosion: no part of the cloud is above the LEL at any time
VI) Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
viii) Scenario :- Flammable chemical is burning as it escapes from tank
3. Thermal radiation from pool fire
SOURCE STRENGTH:
Leak from hole in horizontal cylindrical tank
Flammable chemical is burning as it escapes from tank
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid Internal Temperature: 30° C
Chemical Mass in Tank: 21,853 kilograms
Tank is 100% full
Circular Opening Diameter: 1 centimeters
Opening is 0.67 meters from tank bottom
Max Puddle Area: 216 square meters
Max Flame Length: 4 meters
Burn Duration: ALOHA limited the duration to 1 hour
Max Burn Rate: 4.28 kilograms/min
Total Amount Burned: 251 kilograms
Note: The chemical escaped as a liquid and formed a burning puddle.
The puddle spread to a diameter of 1.2 meters.
THREAT ZONE:
Th re a t Mo d e le d : Ov e rp re s s u re (b la s t fo rc e ) fro m v a p o r c lo u d e x p lo s io n
Ty p e o f Ig n itio n : ig n ite d b y s p a rk o r fla m e
Le v e l o f Co n g e s tio n : c o n g e s te d
Mo d e l R u n : He a v y Ga s
No e x p lo s io n : n o p a rt o f th e c lo u d is a b o v e th e LE L a t a n y tim e
Threat Modeled: Thermal radiation from pool fire
Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)
Source :-Tank Failure (Leak from hole in horizontal cylindrical tank)
ix) Scenario :- BLEVE of flammable liquid in horizontal cylindrical tank
2. Thermal radiation from fireball
SOURCE STRENGTH:
SOURCE STRENGTH:
BLEVE of flammable liquid in horizontal cylindrical tank
Tank Diameter: 1.905 meters Tank Length: 7 meters
Tank Volume: 20.0 cubic meters
Tank contains liquid
Internal Storage Temperature: 30° C
Chemical Mass in Tank: 21,853 kilograms
Tank is 100% full
Percentage of Tank Mass in Fireball: 100%
Fireball Diameter: 162 meters Burn Duration: 11 seconds
THREAT ZONE:
Threat Modeled: Thermal radiation from fireball
Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m p o o l fire
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 0 .0 kW /(s q m ) = p o te n tia lly le th a l with in 6 0 s e c )
Ora n g e : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (5 .0 kW /(s q m ) = 2 n d d e g re e b u rn s with in 6 0 s e c )
Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (2 .0 kW /(s q m ) = p a in with in 6 0 s e c )
Red : 269 meters --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: 385 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: 605 meters --- (2.0 kW/(sq m) = pain within 60 sec)
ALOHA (Hydrogen)
CHEMICAL DATA:
Chemical Name: HYDROGEN
CAS Number: 1333-74-0 Molecular Weight: 2.02 g/mol
PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000 ppm
LEL: 40000 ppm UEL: 750000 ppm
Ambient Boiling Point: -252.9° C
Vapor Pressure at Ambient Temperature: greater than 1 atm
Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
1) Scenario - Hydrogen 1 - Leak from hole in vertical cylindrical tank,
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 0.2 meters Tank Length: 1.6 meters
Tank Volume: 0.050 cubic meters
Tank contains gas only Internal Temperature: 30° C
Chemical Mass in Tank: 0.61 kilograms
Internal Press: 150 atmospheres
Circular Opening Diameter: 0.6 centimeters
Release Duration: 1 minute
Max Average Sustained Release Rate: 9.98 grams/sec
(averaged over a minute or more)
Total Amount Released: 599 grams
THREAT ZONE:
Model Run: Gaussian
Red : 13 meters --- (400000 ppm = PAC-3)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Orange: 17 meters --- (230000 ppm = PAC-2)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 32 meters --- (65000 ppm = PAC-1)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Mo d e l R u n : Ga u s s ia n
R e d : 1 3 m e te rs --- (4 0 0 0 0 0 p p m = P AC-3 )
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
Ora n g e : 1 7 m e te rs --- (2 3 0 0 0 0 p p m = P AC-2 )
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
Ye llo w: 3 2 m e te rs --- (6 5 0 0 0 p p m = P AC-1 )
No te : Th re a t z o n e wa s n o t d ra wn b e c a u s e e ffe c ts o f n e a r-fie ld p a tc h in e s s
m a ke d is p e rs io n p re d ic tio n s le s s re lia b le fo r s h o rt d is ta n c e s .
2) Scenario - Hydrogen 2 - Leak from hole in vertical cylindrical tank, Flammable chemical escaping from tank (not burning), Flammable Area of Vapor Cloud
SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 0.2 meters Tank Length: 1.6 meters Tank Volume: 0.050 cubic meters Tank contains gas only Internal Temperature: 30° C Chemical Mass in Tank: 0.61 kilograms Internal Press: 150 atmospheres Circular Opening Diameter: 0.6 centimeters Release Duration: 1 minute Max Average Sustained Release Rate: 9.98 grams/sec (averaged over a minute or more) Total Amount Released: 599 grams THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian Red : 74 meters --- (24000 ppm = 60% LEL = Flame Pockets) Yellow: 162 meters --- (4000 ppm = 10% LEL)
3) Scenario - Hydrogen 3 - Leak from hole in vertical cylindrical tank, Flammable chemical escaping from tank (not burning),Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 0.2 meters Tank Length: 1.6 meters Tank Volume: 0.050 cubic meters Tank contains gas only Internal Temperature: 30° C Chemical Mass in Tank: 0.61 kilograms Internal Press: 150 atmospheres Circular Opening Diameter: 0.6 centimeters Release Duration: 1 minute Max Average Sustained Release Rate: 9.98 grams/sec (averaged over a minute or more) Total Amount Released: 599 grams THREAT ZONE: Threat Modeled: Overpressure (blast force) from vapor cloud explosion Type of Ignition: ignited by spark or flame Level of Congestion: congested Model Run: Gaussian Red : 55 meters --- (8.0 psi = destruction of buildings) Orange: 56 meters --- (3.5 psi = serious injury likely) Yellow: 67 meters --- (1.0 psi = shatters glass)
4) Scenario - Hydrogen 4 - Leak from hole in vertical cylindrical tank, Flammable chemical is burning as it escapes from tank
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical is burning as it escapes from tank
Tank Diameter: 0.2 meters Tank Length: 1.6 meters
Tank Volume: 0.050 cubic meters
Tank contains gas only Internal Temperature: 30° C
Chemical Mass in Tank: 0.61 kilograms
Internal Press: 150 atmospheres
Circular Opening Diameter: 0.6 centimeters
Flame Length: 0 meters Burn Duration: 20 seconds
Burn Rate: 161 grams/sec
Total Amount Burned: 599 grams
THREAT ZONE:
Threat Modeled: Thermal radiation from jet fire
Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)
5) Scenario - Hydrogen 5 - Catastrophic failure of cylinder (Direct Source), Toxic area of vapor cloud
SOURCE STRENGTH:
Direct Source: 7 cubic meters Source Height: 0
Source State: Gas
Source Temperature: 30° C
Source Pressure: 150 atmospheres
Release Duration: 1 minute
Release Rate: 1.42 kilograms/sec
Total Amount Released: 85.1 kilograms
THREAT ZONE:
Model Run: Gaussian
Red : 142 meters --- (400000 ppm = PAC-3)
Orange: 177 meters --- (230000 ppm = PAC-2)
Yellow: 284 meters --- (65000 ppm = PAC-1)
Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m je t fire
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 0 .0 kW /(s q m ) = p o te n tia lly le th a l with in 6 0 s e c )
Ora n g e : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (5 .0 kW /(s q m ) = 2 n d d e g re e b u rn s with in 6 0 s e c )
Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (2 .0 kW /(s q m ) = p a in with in 6 0 s e c )
6) Scenario - Hydrogen 6 - Catastrophic failure of cylinder (Direct Source) , Flammable area of vapor cloud
SOURCE STRENGTH:
Direct Source: 7 cubic meters Source Height: 0
Source State: Gas
Source Temperature: 30° C
Source Pressure: 150 atmospheres
Release Duration: 1 minute
Release Rate: 1.42 kilograms/sec
Total Amount Released: 85.1 kilograms
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Gaussian
Red : 520 meters --- (24000 ppm = 60% LEL = Flame Pockets)
Yellow: 1.0 kilometers --- (4000 ppm = 10% LEL)
7) Scenario - Hydrogen7 - Catastrophic failure of cylinder (Direct Source), Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH:
Direct Source: 7 cubic meters Source Height: 0
Source State: Gas
Source Temperature: 30° C
Source Pressure: 150 atmospheres
Release Duration: 1 minute
Release Rate: 1.42 kilograms/sec
Total Amount Released: 85.1 kilograms
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Gaussian
Red : 441 meters --- (8.0 psi = destruction of buildings)
Orange: 446 meters --- (3.5 psi = serious injury likely)
Yellow: 495 meters --- (1.0 psi = shatters glass)
Ammonia Cylinder - Gas
Chemical Name: AMMONIA
CAS Number: 7664-41-7 Molecular Weight: 17.03 g/mol
AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm AEGL-3 (60 min): 1100 ppm
IDLH: 300 ppm LEL: 150000 ppm UEL: 280000 ppm
Ambient Boiling Point: -28.2° F
Vapor Pressure at Ambient Temperature: greater than 1 atm
Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
1) Scenario - Ammonia 1 - Leak from hole in vertical cylindrical tank, Flammable chemical escaping from tank (not burning), Gaussian SOURCE STRENGTH: Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning) Tank Diameter: 0.34 meters Tank Length: 1.12 meters Tank Volume: 0.10 cubic meters Tank contains gas only Internal Temperature: 30° C Chemical Mass in Tank: 0.59 kilograms Internal Press: 8 atmospheres Circular Opening Diameter: 1 centimeters Release Duration: 1 minute Max Average Sustained Release Rate: 8.47 grams/sec (averaged over a minute or more) Total Amount Released: 508 grams THREAT ZONE: Model Run: Gaussian Red : 78 meters --- (1100 ppm = AEGL-3 [60 min]) Orange: 178 meters --- (160 ppm = AEGL-2 [60 min]) Yellow: 331 meters --- (30 ppm = AEGL-1 [60 min])
2) Scenario - Ammonia 2 - Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning), Flammable Area of Vapor Cloud
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 0.34 meters Tank Length: 1.12 meters
Tank Volume: 0.10 cubic meters
Tank contains gas only Internal Temperature: 30° C
Chemical Mass in Tank: 0.59 kilograms
Internal Press: 8 atmospheres
Circular Opening Diameter: 1 centimeters
Release Duration: 1 minute
Max Average Sustained Release Rate: 8.47 grams/sec
(averaged over a minute or more)
Total Amount Released: 508 grams
THREAT ZONE:
Threat Modeled: Flammable Area of Vapor Cloud
Model Run: Gaussian
Red : 12 meters --- (90000 ppm = 60% LEL = Flame Pockets)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
Yellow: 30 meters --- (15000 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field patchiness
make dispersion predictions less reliable for short distances.
3) Scenario - Ammonia 3 - Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not burning), Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical escaping from tank (not burning)
Tank Diameter: 0.34 meters Tank Length: 1.12 meters
Tank Volume: 0.10 cubic meters
Tank contains gas only Internal Temperature: 30° C
Chemical Mass in Tank: 0.59 kilograms
Internal Press: 8 atmospheres
Circular Opening Diameter: 1 centimeters
Release Duration: 1 minute
Max Average Sustained Release Rate: 8.47 grams/sec
(averaged over a minute or more)
Total Amount Released: 508 grams
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Gaussian
Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)
Orange: LOC was never exceeded --- (3.5 psi = serious injury likely)
Yellow: less than 10 meters(10.9 yards) --- (1.0 psi = shatters glass)
4) Scenario - Ammonia 4 - Leak from hole in vertical cylindrical tank, Leaking tank chemical is burning as a jet fire, Thermal radiation from jet fire
SOURCE STRENGTH:
Leak from hole in vertical cylindrical tank
Flammable chemical is burning as it escapes from tank
Tank Diameter: 0.34 meters Tank Length: 1.12 meters
Tank Volume: 0.10 cubic meters
Tank contains gas only Internal Temperature: 30° C
Chemical Mass in Tank: 0.59 kilograms
Internal Press: 8 atmospheres
Circular Opening Diameter: 1 centimeters
Th re a t Mo d e le d : Ov e rp re s s u re (b la s t fo rc e ) fro m v a p o r c lo u d e x p lo s io n
Ty p e o f Ig n itio n : ig n ite d b y s p a rk o r fla m e
Le v e l o f Co n g e s tio n : c o n g e s te d
Mo d e l R u n : Ga u s s ia n
R e d : LOC wa s n e v e r e x c e e d e d --- (8 .0 p s i = d e s tru c tio n o f b u ild in g s )
Ora n g e : LOC wa s n e v e r e x c e e d e d --- (3 .5 p s i = s e rio u s in ju ry like ly )
Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 .0 p s i = s h a tte rs g la s s )
Flame Length: 1 meter Burn Duration: 20 seconds
Burn Rate: 69 grams/sec
Total Amount Burned: 508 grams
THREAT ZONE:
Threat Modeled: Thermal radiation from jet fire
Red : less than 10 meters(10.9 yards) --- (10.0 kW/(sq m) = potentially lethal within 60 sec)
Orange: less than 10 meters(10.9 yards) --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)
Yellow: less than 10 meters(10.9 yards) --- (2.0 kW/(sq m) = pain within 60 sec)
5) Scenario - Ammonia 5 - Catastrophic failure of cylinder (Direct Source), Toxic area of vapor cloud
SOURCE STRENGTH: Direct Source: 50 kilograms Source Height: 0 Release Duration: 1 minute Release Rate: 833 grams/sec Total Amount Released: 50.0 kilograms Note: This chemical may flash boil and/or result in two phase flow. Use both dispersion modules to investigate its potential behavior. THREAT ZONE: Model Run: Gaussian Red : 473 meters --- (1100 ppm = AEGL-3 [60 min]) Orange: 957 meters --- (160 ppm = AEGL-2 [60 min]) Yellow: 1.8 kilometers --- (30 ppm = AEGL-1 [60 min])
Th re a t Mo d e le d : Th e rm a l ra d ia tio n fro m je t fire
R e d : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (1 0 .0 kW /(s q m ) = p o te n tia lly le th a l with in 6 0 s e c )
Ora n g e : le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (5 .0 kW /(s q m ) = 2 n d d e g re e b u rn s with in 6 0 s e c )
Ye llo w: le s s th a n 1 0 m e te rs (1 0 .9 y a rd s ) --- (2 .0 kW /(s q m ) = p a in with in 6 0 s e c )
6) Scenario - Ammonia 7 - Catastrophic failure of cylinder, Direct Source,
Flammable Area of vapor cloud
SOURCE STRENGTH: Direct Source: 50 kilograms Source Height: 0 Release Duration: 1 minute Release Rate: 833 grams/sec Total Amount Released: 50.0 kilograms Note: This chemical may flash boil and/or result in two phase flow. Use both dispersion modules to investigate its potential behavior. THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian Red : 116 meters --- (90000 ppm = 60% LEL = Flame Pockets) Yellow: 234 meters --- (15000 ppm = 10% LEL)
1) Scenario - Ammonia 7 - Catastrophic failure of cylinder, Direct Source, Overpressure (blast force) from vapor cloud explosion
SOURCE STRENGTH:
Direct Source: 50 kilograms Source Height: 0
Release Duration: 1 minute
Release Rate: 833 grams/sec
Total Amount Released: 50.0 kilograms
Note: This chemical may flash boil and/or result in two phase flow.
Use both dispersion modules to investigate its potential behavior.
THREAT ZONE:
Threat Modeled: Overpressure (blast force) from vapor cloud explosion
Type of Ignition: ignited by spark or flame
Level of Congestion: congested
Model Run: Gaussian
Red : LOC was never exceeded --- (8.0 psi = destruction of buildings)
Orange: LOC was never exceeded --- (3.5 psi = serious injury likely)
Yellow: 91 meters --- (1.0 psi = shatters glass)
4) CHEMICAL DATA FOR HCL:
Chemical Name: HYDROCHLORIC ACID
Solution Strength: 30% (by weight)
Ambient Boiling Point: 89.4° C
Partial Pressure at Ambient Temperature: 0.028 atm
Ambient Saturation Concentration: 28,738 ppm or 2.87%
Hazardous Component: HYDROGEN CHLORIDE
CAS Number: 7647-1-0 Molecular Weight: 36.46 g/mol
AEGL-1 (60 min): 1.8 ppm AEGL-2 (60 min): 22 ppm AEGL-3 (60 min): 100 ppm
IDLH: 50 ppm
The ALOHA Footprints (Toluene)
VII) Source :-Puddle
vii) Scenario :- Evaporating Puddle of Toxic Chemical
1. Toxic area of vapour cloud
SOURCE STRENGTH:
Evaporating Puddle
Puddle Area: 52.5 square meters Puddle Volume: 38.5 cubic meters
Ground Type: Concrete Ground Temperature: 30° C
Initial Puddle Temperature: 30° C
Release Duration: ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 444 grams/min
(averaged over a minute or more)
Total Amount Hazardous Component Released: 26.2 kilograms
THREAT ZONE:
Model Run: Gaussian
Red : 161 meters --- (100 ppm = AEGL-3 [60 min])
Orange: 370 meters --- (22 ppm = AEGL-2 [60 min])
Yellow: 1.5 kilometers --- (1.8 ppm = AEGL-1 [60 min])
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