risk assessment for furnace oil storage tank...in such cases contents of the biggest vessel / tank...
TRANSCRIPT
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 1 of 18
RISK ASSESSMENT FOR FURNACE OIL STORAGE TANK:
Overview
Risk Analysis is proven valuable as a management tool in assessing the overall safety
performance of the chemical process industry and hazardous substance handling operations
at a specific location. Although management systems such as engineering codes, checklists,
and reviews by experienced engineers have provided substantial safety assurances, major
incidents involving numerous casualties, injuries and significant damage can occur - as
illustrated by recent world-scale catastrophes. Risk Analysis techniques provide advanced
quantitative means to supplement other hazard identification, analysis, assessment, control
and management methods to identify the potential for such incidents and to evaluate
control strategies.
Risk in general is defined as a measure of potential economic loss or human injury in terms
of the probability of the loss or injury occurring and magnitude of the loss or injury if it
occurs. Risk thus comprises of two variables; magnitude of consequences and the
probability of occurrence. The results of Risk Analysis are often reproduced as Individual and
groups risks and are defined as below.
Individual Risk is the probability of death occurring as a result of accidents at a plant,
installation or a transport route expressed as a function of the distance from such an
activity. It is the frequency at which an individual or an individual within a group may be
expected to sustain a given level of harm (typically death) from the realization of specific
hazards. Such a risk actually exists only when a person is permanently at that spot (out of
doors). The exposure of an individual is related to the following factors such as:
The likelihood of occurrence of an event involving a release and
Ignition of hydrocarbon,
The vulnerability of the person to the event,
The proportion of time the person will be exposed to the event (which is termed
'occupancy' in the QRA terminology).
The second definition of risk involves the concept of the summation of risk from events
involving many fatalities within specific population groups. This definition is focused on the
risk to society rather than to a specific individual and is termed 'Societal Risk'. In relation to
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 2 of 18
the process operations we can identify specific groups of people who work on or live close
to the installation; for example communities living or working close to the plant.
PHAST v6.7 and PHAST Risk Micro v6.7
The software developed by DNV is used for risk assessment studies involving flammable and
toxic hazards where individual and societal risks are also to be identified. It enables the user
to assess the physical effects of accidental releases of toxic or flammable chemicals.
PHAST v6.7 is used for consequence calculations and PHAST Risk Micro v6.7 is used for risk
calculations.
Risk Assessment Methodology
Hazard identification and risk assessment involves a series of steps as follows:
Step 1: Identification of the Hazard
Hazard Identification is a critical step in Risk Analysis. Many aids are available, including
experience, engineering codes, checklists, detailed process knowledge, equipment failure
experience, hazard index techniques, What-if Analysis, Hazard and Operability (HAZOP)
Studies, Failure Mode and Effects Analysis (FMEA), and Preliminary Hazard Analysis (PHA). In
this phase all potential incidents are identified and tabulated. Site visit and study of
operations and documents like drawings, process write-up etc are used for hazard
identification.
Step 2: Assessment of the Risk
Consequence Estimation is the methodology used to determine the potential for damage or
injury from specific incidents. A single incident (e.g. rupture of a pressurized flammable
liquid tank) can have many distinct incident outcomes, (e.g. Thermal radiation due to Pool
fire). Likelihood assessment is the methodology used to estimate the frequency or
probability of occurrence of an incident. Estimates may be obtained from historical incident
data on failure frequencies or from failure sequence models, such as fault trees and event
trees. In this study the historical data developed by software models and those collected by
CPR18E – Committee for Prevention of Disasters, Netherlands (Edition: PGS 3, 2005) are
used. Risks arising from the hazards are evaluated for its tolerability to personnel, the
facility and the environment. The acceptability of the estimated risk must then be judged
based upon criteria appropriate to the particular situation.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 3 of 18
Step 3: Elimination or Reduction of the Risk
This involves identifying opportunities to reduce the likelihood and/or consequence of an
accident Where deemed to be necessary. Risk Assessment combines the consequences and
likelihood of all incident outcomes from all selected incidents to provide a measure of risk.
The risk of all selected incidents are individually estimated and summed to give an overall
measure of risk. Risk-reduction measures include those to prevent incidents (i.e. reduce the
likelihood of occurrence) to control incidents (i.e. limit the extent and duration of a
hazardous event) and to mitigate the effects (i.e. reduce the consequences). Preventive
measures, such as using inherently safer designs and ensuring asset integrity, should be
used wherever practicable. In many cases, the measures to control and mitigate hazards
and risks are simple and obvious and involve modifications to conform to standard practice.
The general hierarchy of risk reducing measures is:
Prevention (by distance or design)
Detection (e.g. fire and gas, Leak detection)
Control (e.g. emergency shutdown and controlled depressurization)
Mitigation (e.g. fire fighting and passive fire protection)
Emergency response (in case safety barriers fail)
The current study is limited to evaluation of risk associated with the Flammable inventory
in the furnace oil tank farm area.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 4 of 18
Overview of Risk Assessment Methodology
Consequence Assessment:
Accidental release of flammable liquids can result in severe consequences. Delayed ignition
of flammable liquid results in pool Fire. Furnace Oil having very less vapour pressure i.e. less
tendency to evaporate. Considering this Flash fire and Explosion are not envisaged in case of
release of furnace oil.
The effect of fire on a human being is in the form of burns. There are three categories of
burn such as first degree, second degree and third degree burns. The consequences caused
by exposure to heat radiation are a function of:
The radiation energy onto the human body [kW/m2]; The exposure duration [sec]; The protection of the skin tissue (clothed or naked body). The lethality of a pool fire is assumed to be 100% for the people who are caught in
the flame. Outside the flame area, the lethality depends on the heat radiation distances.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 5 of 18
The limits for 1% of the exposed people to be killed due to heat radiation, and for second-
degree burns are given in the table below (Reference from Guidelines for Hazard Evaluation
Procedures, Centre for Chemical Process Safety, American Institute of Chemical Engineers)
Exposure Duration Radiation energy
(1% lethality, kW/m2
Radiation energy for 2nd degree burns,
kW/m2
Radiation energy for first degree burns,
kW/m2
10 Sec 21.2 16 12.5
30 Sec 9.3 7.0 4.0
Table 1 – Damages to Human Life Due to Heat Radiation
Incident
Radiation
(kW/m2)
Type of Damage
0.25-0.7 Equivalent to Solar Radiation
1.6 No discomfort for long exposure
4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are
likely)
9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.
12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing
etc.
37.5 Heavy Damage to process equipments
Table 2– Effects Due To Incident Radiation Intensity
Meteorological Data:
The consequence of released flammable material is largely dependent on the prevailing
weather conditions. For the risk analysis of major scenarios the most important
meteorological parameters are wind speed, atmospheric stability, relative humidity, surface
roughness and temperature as they directly affect the atmospheric dispersion of the
released material. Risk analysis, modelling is based on the following weather categories as
derived from metrological data provided by client.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 6 of 18
Windrose Diagram
Wind Speed
(m/s)
Stability
Class Description
1.5 F This is typical of during night time with low wind speed.
5 D This is typical of day time situation, with moderate wind
fluctuations
Table 3 – Wind Speed and Stability Class
Atmospheric Temperature : 33 C
Surface Roughness : 0.3m
Average Relative Humidity : 70%
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 7 of 18
Scenarios Considered for the Risk Estimations
The following scenarios have been considered for the consequence-distance calculations,
which have been computed for the accidental release and fire scenarios considered.
Leak of furnace oil from tank
Pool fire at furnace oil storage tank
Summary of assumptions considered in the modeling
Leak of tank containing solvent is for 10 minutes
1.5 F and 5D Weather condition is considered
All furnace oil storage tanks are at 1atm pressure and temperature of 30degC
Bund area considered for furnace oil storage tank is 182.25 m2
Bund height considered for the study 2 m
Population details inside SPB-PC Facility 1259
Population details outside SPB-PC Facility
Village Name Population
Odapalli 4879
Pudhupalayam 5704
Hazards Identification:
As per CPR 18E - Guidelines for Quantitative Risk Assessment, developed by the Committee
for the Prevention of Disasters, Netherlands, for each of scenario two leak sizes i.e., hole
sizes are considered for analysis,
Leak – Leak size 10 mm
Rupture – Catastrophic rupture of storage tanks
The following tables present the potential initiating events and credible accident scenarios
identified and quantitatively analysed:
Sr. No. Scenario Description Inventory (Kl)
Pressure (Bar)
Temperature ( C)
1 Leak of furnace oil storage tank (200 Kl) 200 Atmospheric 30
2 Rupture of furnace oil storage tank (200 Kl) 200 Atmospheric 30
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 8 of 18
Frequency Assessment:
For this study the failure data is taken from CPR 18E – Guidelines for Quantitative Risk
Assessment, developed by the Committee for the Prevention of Disasters, Netherlands.
Internal domino effects are not explicitly covered in QRA. An internal domino needs to be
considered only in case of a situation in which the failure of one component clearly leads to
the failure of another component. In Such cases contents of the biggest vessel / tank needs
to be taken for Instantaneous failure.
The failure frequencies, as per CPR 18E, are provided below
Sr. No. Scenario Description Frequency
(per annum)
1 Leak of furnace oil storage tank (200 Kl) 4.16E-06
2 Rupture of furnace oil storage tank (200 Kl) 2.08E-06
Event Tree:
A release can result in several possible outcomes or scenarios (fire, explosions, unignited
release etc.). This is because the actual outcome depends on other events that may or may
not occur following the initial release. Event tree analysis is used to identify potential
outcomes of a release and to quantify the risk associated with each of these outcomes.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 9 of 18
The sample event tree is shown below
Initiating Event
Frequency
Probability of
Immediate Ignition
Probability of Delayed
Ignition
Explosion Probability
Outcome Frequency Event Outcome
Yes 0.01 FF Immediate Pool Fire Explosion
FF 0.4 FF Explosion Yes 0.7 No
0.99 0.6 FF Flash Fire/ Late Pool Fire
No 0.3 FF No Ignition
Please refer Annexure 1 for event tree Analysis.
Consequence Results for Pool Fire:
Sr. No. Scenario Description
Consequence Modeling Results : Pool Fire Weather Condition : 1.5F Weather Condition : 5D
4 kW/m2
12.5 kW/m2
37.5 kW/m2
4 kW/m2
12.5 kW/m2
37.5 kW/m2
1 Leak of furnace oil storage tank (200 Kl) 60 34 14 67 44 21
2 Rupture of furnace oil storage tank (200 Kl) 85 49 21 92 60 31
Analysis of the results
Maximum damage due to pool fire radiations will be caused by Rupture of furnace oil
storage tank (200 Kl), at a weather condition of 1.5F. The pool fire radiation of 37.5 kW/m2
(corresponding to 100% fatality) will reach up to a distance of 21 m at 1.5F weather
condition. The pool fire radiation of 12.5 kW/m2 will reach up to a distance of 49 m at 1.5F
weather condition. The equipments within a distance of 49 m will be subjected to major
damage or piloted ignition of wood, melting of plastics tubings etc is possible within this
distance. The pool fire radiation of 4 kW/m2 will reach up to a distance of 85 m at 1.5F
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 10 of 18
weather condition. First degree burns may be caused for persons who are within 85 m
distance.
S.No. Facilities
Approximate distance for the facilities (m)
from furnace oil storage tank as per the
layout
Pool Fire
Damage
Distance (m) for
12.5 kW/ m2
1 11Kv transformer yard 12 49
2 Proposed PCC plant 40 49
3 WBL tank 9 49
4 Primary mud washer 20 49
In case of pool fire effect in the furnace oil storage tank, heat radiation level of 12.5 KW/m2
will prevail up to a distance of 49m at 1.5F weather condition. From the above pool fire
consequence values all the nearby existing and proposed facilities like 11Kv transformer
yard, Proposed PCC plant, WBL tank and primary mud washer near to Furnace oil storage
tank are falling under 12.5Kw/m2 heat radiation level region.
Hence it is recommended to provide concrete blocks of 355 mm thickness or of R.C.C. of 200
mm thickness shall be constructed between 11Kv transformer yard transformers, WBL tank
and furnace oil storage tanks.
These walls shall be extended horizontally 600 mm beyond the extremities of the furnace oil
tank and vertically 600 mm above the highest point of the tank.
Estimated Heat Radiation Levels due to Furnace oil Accidental Fires
Heat Radiation Level (KW/m2)
Heat Radiation Distance for Furnace oil storage tank Fire (Pool Fire Scenario) (meters)
Leak 200 Kl Rupture 200 Kl 37.5 14 21 25.0 20 30 12.5 34 49 9.5 40 57 4 60 85
1.6 90 126
Pool fire contours
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 11 of 18
1. Leak of furnace oil storage tank (200 Kl)
A) 1.5F Weather Condition
B) 5D Weather Condition
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 12 of 18
2. Rupture of furnace oil storage tank (280 Kl)
A) 1.5F Weather Condition
B) 5D Weather Condition
Legends Heat Radiation Level (KW/m2) 37.5 25 12.5 9.5 4 1.6
Colour
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 13 of 18
Risk Assessment:
Population Data:
It is necessary to know the population exposure in order to estimate the consequences and
the risk resulting from an incident. The exposed population is often defined using a
population density. Population densities are an important part of a QRA for several reasons.
The most notable is that the density is typically used to determine the number of people
affected by a given incident with a specific hazard area. Sometimes, population data are
available in sketchy forms. In the absence of specific population data default categories can
be used.
The population density can be averaged over the whole area that may be affected or the
area can be subdivided into any number of segments with a separate population density for
each individual segment.
Population details inside SPB-PC Facility 1259
Population details outside SPB-PC Facility
Village Name Population
Odapalli 4879
Pudhupalayam 5704
Individual Risk and Societal Risk:
The Individual Risk per annum (IRPA) measure expresses the risk exposure to any Individual
who is continuously present in a particular area for the whole year. The risk exposure is
calculated for all relevant hazards and summed to give the overall risks for area of the
installation.
Risk Summary
Sr. No. Scenarios Individual Risk (Avg. per Year)
Societal Risk (Avg. per Year)
1 Leak of furnace oil storage tank (200 Kl)
1.33E-06 9.28E-07
2 Rupture of furnace oil storage tank (200 Kl)
1.13E-06 1.10E-06
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 14 of 18
Individual Risk and Societal Risk Presentation:
1. Leak of furnace oil storage tank (200 Kl)
Individual Risk: 1.33E-06 per avg year
Societal Risk: 9.28E-07 per avg year
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 15 of 18
2. Rupture of furnace oil storage tank (200 Kl)
Individual Risk: 1.13E-06 per avg year
Societal Risk: 1.10E-06 per avg year
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 16 of 18
Risk Acceptance Criteria:
The IS 15656 HSE criteria have been proposed for application to average individual risk as
follows:
Authority and Application Maximum Tolerable
Risk (Per Year)
Negligible Risk
(Per Year)
VROM, The Netherlands (New) 1.0E-06 1.0E-08
VROM, The Netherlands (existing) 1.0E-05 1.0E-08
HSE, UK (existing hazardous industry) 1.0E-04 1.0E-06
HSE, UK (New nuclear power station) 1.0E-05 1.0E-06
HSE, UK (Substance transport) 1.0E-04 1.0E-06
HSE, UK (New housing near plants) 3 x 1.0E-06 3 x 1.0E-07
Hong Kong Government (New plants) 1.0E-05 Not used
Table 1 – Risk Criteria
UK HSE Criteria for existing hazardous industry, highlighted in the above table is used for the
study.
Plant workers are working in the Industry on 10 times higher Risk than Social people.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 17 of 18
Conclusion:
It is concluded from the above study that Individual Risk and Societal risk curve (F-N Curve) were falls within the tolerable and acceptable region. In case of pool fire effect in the furnace oil storage tank, heat radiation level of 12.5 KW/m2 will prevail up to a distance of 49m at 1.5F weather condition. From the above pool fire consequence values all the nearby existing and proposed facilities like 11Kv transformer yard, Proposed PCC plant, WBL tank and primary mud washer near to Furnace oil storage tank are falling under 12.5Kw/m2 heat radiation level region. Hence it is recommended to provide concrete blocks of 355 mm thickness or of R.C.C. of 200 mm thickness shall be constructed between 11Kv transformer yard transformers, WBL tank and furnace oil storage tanks. These walls shall be extended horizontally 600 mm beyond the extremities of the furnace oil tank and vertically 600 mm above the highest point of the tank. Risk Control Measures
Mitigation measures should also aim at minimizing the quantity of release that may get released during major releases, detection of such leaks and minimizing the consequences due to such incidents. Proposed Facilities to be provided as per Pre feasibility report
Extension of existing plant hydrant network (with augmentation of pumps, if required) for new project facilities will be done.
Further, it will consist of fire alarm systems for control room, MCC room and cable alleys.
Portable extinguishers at strategic locations in the plant will be provided. Risk Control Measures Suggested
1. As per OISD 129, ensure that regular internal inspection along with ultrasonic thickness survey for storage tanks to be done in intervals of every ten years and external inspection for storage tanks to be done in intervals of every three years.
2. Provide concrete blocks of 355 mm thickness or of R.C.C. of 200 mm thickness shall be constructed between 11Kv transformer yard transformers, WBL tank and furnace oil storage tanks.
3. Onsite Emergency Response & Disaster Management Plan should be developed for the facility.
4. Ensure that bunds provided at the tank farm have proper drainage system. 5. Ensure that all the storage tanks are to be earthed separately as per IS 3043-1966. 6. Ensure that fire extinguisher and its components are inspected at regular intervals. 7. Ensure that fire alarms are tested at least once in a week. 8. Ensure that spill Management Kits are available and it should be maintained
properly. 9. To carry out adequacy check of fire water system for the upgraded facility.
QRA Study for Seshasayee Paper and Boards Limited, Erode Page 18 of 18
ANNEXURE – 1: EVENT TREE ANALYSIS
Leak of furnace oil storage tank
Initiating Event
Frequency
Probability of
Immediate Ignition
Probability of Delayed
Ignition
Explosion Probabilit
y
Outcome Frequenc
y Event Outcome
Yes 0.01 1.00E-06 Immediate Pool Fire Explosion
1.00E-04 0.4 2.77E-05 Explosion Yes 0.7 No
0.99 0.6 4.16E-05 Flash Fire/ Late Pool Fire
No 0.3 2.97E-05 No Ignition
Rupture of furnace oil storage tank
Initiating Event
Frequency
Probability of
Immediate Ignition
Probability of Delayed
Ignition
Explosion Probabilit
y
Outcome Frequenc
y Event Outcome
Yes 0.01 5.00E-08 Immediate Pool Fire Explosion
5.00E-06 0.4 1.39E-06 Explosion Yes 0.7 No
0.99 0.6 2.08E-06 Flash Fire/ Late Pool Fire
No 0.3 1.49E-06 No Ignition