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Transcript of 67053- FRA Assumption Register
FRA ASSUMPTION REGISTER
DOC. NO.: 3415001 REV. A Page # 2 of 30
Z:\Dept - HSE\INDONESIA - AKZO NOBEL
Table of Contents Page
1. PROJECT DESCRIPTION ............................................................................................... 4
1.1 Introduction............................................................................................................ 4
1.2 Project Objective ................................................................................................... 4
1.3 TEBODIN Scope of Services ................................................................................ 4
1.4 Areas/Facilities covered under FRA study ........................................................... 5
1.5 Purpose of the Document ..................................................................................... 7
2. PROJECT INFORMATION .............................................................................................. 8
2.1 Project Title ........................................................................................................... 8
2.2 Definitions .............................................................................................................. 8
2.3 Abbreviations ........................................................................................................ 8
3. FRA METHODOLOGY ..................................................................................................... 9
3.1 Hazard Identification ........................................................................................... 10
3.2 Inventory Analysis ............................................................................................... 10
3.3 Consequence Analysis ....................................................................................... 11
3.4 Fire Risk Assessment ......................................................................................... 11
3.5 Escalation Analysis and Assessment Criteria .................................................... 11
3.6 Passive Fire Protection (PFP) ............................................................................ 12
3.7 Active Fire Protection (AFP) ............................................................................... 12
4. FRA ASSUMPTION REGISTER .................................................................................... 13
FRA ASSUMPTION REGISTER
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Sections Revised in this Issue
No. Section Paragraph
FRA ASSUMPTION REGISTER
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1. PROJECT DESCRIPTION
1.1 Introduction
The plant was constructed in 1979 in the East of Jakarta and is a well established site within the
Pulogadung Industrial Estate. It occupies an area of 1.4 HA and is presently surrounded by many factories.
The plant works on 5 days per week and 3 shift per day. It currently produces a capacity of 26 KL per day
with around 78 production employees.
The plant manufactures a full range of solvent based paints and intermediates for Car Refinishes market
under brands: Sickens, Leona, Miluz and Wanda. All the products were classified under 10 supply family:
1. Putty
2. Primer
3. Pearls & Metallics
4. Clearcoats
5. Thinner
6. Hardener
7. Top/Basecoat Bulk
8. Top/Basecoat Color
9. Top/Basecoat White
10. Top/Basecoat Black
1.2 Project Objective
The objective of this Fire Risk Assessment (FRA) study is to assess the potential fire hazards in the facilities.
1.3 TEBODIN Scope of Services
The scope of services consists of the following activities:
1. Site survey and Data collection.
2. Review of collected data and present a list of assumptions in the form of FRA assumption register
which shall be reviewed and approved.
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3. Perform the modelling for the identified potential hazards.
4. Draft report will be provided to AKZO NOBEL.
5. Final FRA report will be submitted to AKZO NOBEL.
1.4 Areas/Facilities covered under FRA study
The product was streamlined based on different flow of process:
Production Stream 1: Putty, Primer, Pearls & Metallics
Putty & Primer consist of high powder materials with process flow starting from dispersion at High speed
dissolver, continued to bead-milling (unless 2000 putty was used without milling) and let down followed by
filling and packing. Pearls and metallics are produced by mixing process without milling. After QC
inspection is carried out, it is sent for filling and packing.
Production Stream 2: Thinner, Clear coats and Hardener
Clear coats, Thinner and Hardener are solution products (non-powder products) processed mostly in the
big tank by mixing process where all raw materials are pumped into the tank, unless they are small batches
produced under mobile tank.
Production Stream 3 : Top/Basecoat Bulk, Colour, White and Black.
Top/Basecoat Bulk is an imported toner product either in drums or pails. The product is repacked in small
packs of sizes 1L or 3.75L. Before repacking, stirring is required to make the product homogenous. QC
inspection is carried out before continuing to filling and packing. Top Basecoat Color, White and Black is
dispersion products required high speed dissolver continue to milling process to get a specified particells
size distribution, let down, filling and packing.
The products produced from this site would cater to the local demands as well as to countries in Asia
Pacific region. These would comprise of Made to Stock products (MTS) and Made To Order products
(MTO).
Production of a batch of paints takes place when a batch ticket (order to manufacture) along with the raw
materials pick list is issued by the Production Planning Officer under the Purchasing Planning department.
This batch initially requires all raw materials accurately weighted and prepared. Then, it is followed by a
sequence of activities such as premixing, milling, Let down, color matching, adjustments, quality control
tests and filling into containers.
FRA ASSUMPTION REGISTER
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RAW MATERIALS PREPARATION
Upon receiving a raw materials pick list, the raw materials handler prepares and weighs the required
materials and places them on a wooden pallet. All pigments and powdery materials are prepared and
weighed in a powder weighing booth provided with a dust collector. All solvents are weighed and prepared
at the solvent dispensing area while the additives are prepared at the semi finish weighing area. All along,
the hand pallet lorry and the explosion proof type of forklift truck are used to move the palletized raw
materials and portable tanks containing the products in the production area.
DISPERSION - PREMIXING
All manufacturing recipes would be based on two routes: namely the HSD (High Speed Disperser) - Bead
Mill route wherever secondary dispersion is required or the only HSD / Let down Mixing route otherwise.
There are 4 units of HSD capable of dispersing products in portables tanks with capacities ranging from
500 up to 2,000 L. These units are installed in a closed ventilated room and the room is equipped with a
dust collector. In this stage, solvent, dispersant additive, pigment and resin are slowly added into portables
tanks and are stirred from low to high speed to achieve homogeneity of the products. The dust collector
extracts the dust generated from the loading of pigment and other powdery raw materials.
DISPERSION - BEADMILLING
Once the intermediate from the above premixing stage is QC passed, it is then taken out from the Premix
room to the bead milling area. In this stage the intermediate is run through a bead milling machine for
several passes until the fineness of the product is achieved. In normal run, one pass goes for around 4
hours. The intermediates output from this stage is called mill base. There are 5 units of horizontal bead
milling machines ranging from 5 up to 45 L grinding chambers. The grinding chamber is cooled with a
chilled water of 3°C to reduce the generated heat. The bead milling machines are dedicated to certain
products based on mutual compatibility and to avoid cross contamination.
LET DOWN
Once the mill base is QC passed, it then must right away be processed in the next process stage called Let
Down. The portable tank containing the mill base is transferred to the Letdown area. In here, the mill base
is added with more resin and additives to stabilize the mill base to prevent the pigment from agglomerating
again. It is then mixed well at a low speed to give a homogeneity product. Through color matching,
adjustment and quality control test, the product is QC passed and is now ready to be filled into containers.
A fume extraction unit is installed in all production area to tap off the released vapor.
FILLING
The portable tank containing the product is then transferred to the filling area for filling. From the filling
batch ticket, the required packaging such as empty cans, labels, boxes and lids are prepared by the raw
materials handler and issued to production. During the filling, the product is pumped through a pump filter
set then goes into the hopper of the filling machine. There are 7 filling machines of type manual and semi-
automatic available plus putty press filling machine. Three of them are manual and weight based type
(gravity based). Four of them are of semi-automatic type and volumetric based. The filling machines are
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dedicated to certain products to avoid cross contamination. Upon finishing the filling, the packed product is
then the next batch of paints. A portable tank cleaning unit is currently being ordered to eliminate the
manual cleaning transferred to the Distribution Center for delivery to customers. The empty portable tank is
then brought to the tank cleaning area for cleaning prior to be used for the tank. The cleaning solvent is
recycled until several uses then collected in 200L drums as a dirty solvent which later on is sent to the
legalized third party recycler.
Fig 1: Process Flow
1.5 Purpose of the Document
This report presents the register of agreement between AKZO NOBEL and Tebodin on the assumptions
necessary to be made prior to the commencement of “FRA AND HAC ZONING FOR AKZO NOBEL”.
This document lists the assumptions made prior to starting the FRA study. Any further assumptions that are
necessary to be made in order to develop the study will be clearly presented in the study report.
FRA ASSUMPTION REGISTER
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2. PROJECT INFORMATION
2.1 Project Title
The official title of the PROJECT is “FRA AND HAC ZONING FOR AKZO NOBEL”. This title shall be used
on all the deliverables.
2.2 Definitions
COMPANY AKZO NOBEL, INDONESIA
CONSULTANT M/s. Tebodin Consultants and Engineers India Ltd; (TCEI), appointed by the
COMPANY (AKZO NOBEL, INDONESIA) to perform PROJECT.
CONTRACT The contract between COMPANY (AKZO NOBEL) and CONSULTANT (TCEI) for
PROJECT (“FRA AND HAC ZONING FOR AKZO NOBEL”).
PROJECT FRA AND HAC ZONING FOR AKZO NOBEL
SERVICES Services being provided by TEBODIN as per the CONTRACT for the PROJECT
TEBODIN Tebodin Consultants and Engineers India Ltd;
2.3 Abbreviations
AFP Active Fire Protection
API American Petroleum Institute
FRA Fire Risk Assessment
HA Hectares
HAC Hazardous Area Classification
HSD High Speed Disperser
IP Petroleum Institute
MTO Made to Order
MTS Made to Stock
NFPA National Fire Protection Association
OGP Oil & Gas Producers
PFD Process Flow Diagram
PFP Passive Fire Protection
PID Piping and Instrumentation Diagram
QC Quality Control
TCEI Tebodin Consultants and Engineers India
VCE Vapour Cloud Explosion
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3. FRA METHODOLOGY
The methodology adopted for this FRA is presented graphically below:
Figure 2: FRA methodology
FRA ASSUMPTION REGISTER
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In summary, the FRA study will involve the following key steps:
� Identification of the hazardous material inventory applicable to the project includes flow rate, pressure,
temperature, composition etc.
� Modelling of physical effects based upon the process conditions of the hazardous material inventories,
and assumptions regarding release hole sizes
� Investigate the effect of flame impingement between equipment.
� Recommend additional requirements for Fire Protection Systems (AFP/PFP).
� The risk contribution that arises from this project will be calculated and this will be compared against
OGP risk acceptance criteria.
3.1 Hazard Identification
Identify the potential hazards related to the fire scenarios. FRA study excludes the analysis of toxic impact
as its purpose is to assess the impact of fire events onto assets.
3.2 Inventory Analysis
The first step in evaluating the FRA is the identification of fuel sources and their location. This includes
information relating to the fuel itself, and the inventories stored or processed, together with the process
conditions. Inventory analysis involves the following:
• Identification of scenarios based on one Process/Storage Unit to another Process/Storage Unit
within the process units.
• Calculation of volume hold-up for different scenarios with respect to gas or liquid within the
equipment.
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3.3 Consequence Analysis
The Fire Hazard Information enables the likely fire scenario to be developed based on a consideration of
the events that follow a release of material. For Example, a release of gas that undergoes immediate
ignition will result in jet fire.
This stage of the fire analysis involves determination of the impact of each of the identified hazardous
outcomes from various release events (e.g. gas jet, flashing liquid jet, liquid pool).
The consequence modelling is performed using the latest version of PHAST v 6.7 software. The outcome of
the modelling will be reported in terms of the extent of thermal effects distances.
3.4 Fire Risk Assessment
The FRA study includes:
• Assessment of the credible release from leak hole size.
• Investigate the effect of flame impingement between equipment.
• Recommend additional requirements for Fire Protection Systems (AFP / PFP).
3.5 Escalation Analysis and Assessment Criteria
The potential of escalation is identified based on the fire must have sufficient duration to still impinge onto
the target surface at the time to failure. Consideration is given to the vulnerability of the equipment (for
example the possible presence of a liquid to facilitate heat removal from the system), and the impact of
failure due to fire impingement.
The criteria for determining the potential of escalation are based on the following:
� 35 kW/m2 thermal radiations or jet flame length whichever higher may still impinge on the
equipment.
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3.6 Passive Fire Protection (PFP)
The requirement of passive fire protection will be assessed for:
• Vessels
• Pipework between vessels
• Manual valves*
• Vessel and pipework supports.
Note*: All valves used are assumed to be Manual Valves.
3.7 Active Fire Protection (AFP)
The Active Fire Protection has been shown to be effective in a pool fire but uncertainties remain regarding
the degree of protection afforded in a jet fire. Hence, AFP is given credit for pool fire scenarios only.
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4. FRA ASSUMPTION REGISTER
The Assumptions are presented in the format of assumption sheets, as follows:
Assumption No. Description
1. FRA Project Scope
2. Atmospheric Conditions
3. Scenarios
4. Process Conditions and Material Composition
5. Release size, Height, Duration and Direction
6. Impact criteria
7. Vulnerability
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption FRA Project Scope Assumption No. 1
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Tebodin scope of work is to perform Fire Risk Assessment for the Production Process which covers;
• Diesel Storage
• Production Area which covers:
� Big Tank
� Mobile Tank Area
� Mixing Room
� Raw Material
� Filling Hardener Area
� SFG Storage
� Transfer Area
• Drum Yard
• Warehouse
• Tank Area (Tanks 1 and 2 storing Xylene and Butyl Acetate)
• Color Warehouse
To perform this FRA, Tebodin scope of services consist of following activities;
• Site survey and Data collection.
• Review of collected data and present a list of assumptions in the form of FRA assumption
register which shall be reviewed and approved.
• Perform the modelling for the identified potential hazards.
• Draft report will be provided to AKZO NOBEL.
• Final FRA report will be submitted to AKZO NOBEL.
Exclusions: [Ref 1]
• The battery charger area is not likely to hold up hazardous material. Hence it has not been
included in the hazard study.
• The QC lab will be holding up a minimal amount of hazardous material. Hence it has not
been included in the hazard study.
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption FRA Project Scope Assumption No. 1
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
• The Tank cleaning area is considered to have minimal amount of hazardous material
capable of causing fire/explosion as it’s not used periodically. Hence it has not been included in the
hazard study.
• The Labelling area is not considered to have very high amount of hazardous material
capable of causing fire/explosion. Hence it has not been included in the hazard study.
• The Packaging Ware House area is considered to have minimal amount of hazardous
material capable of causing fire/explosion. Hence it has not been included in the hazard study.
• Ruang Bonded Ware House is considered to have minimal amount of hazardous material
capable of causing fire/explosion. Hence it has not been included in the hazard study.
Reference: 1. Site Visit Data
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments:
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Atmospheric Condition Assumption No.
2
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Ambient Conditions [Ref. 1]
1. Average Ambient Temperature : 28 ºC
2. Average Barometric Pressure : 1 bar
3. Average Relative Humidity : 64 %
4. Solar Radiation : 0.882 kW/m2
The Pasquill Atmospheric Stability Classes
Table 1: Pasquill Stability Class
Stability Class Definition
A Very Unstable
B Unstable
C Slightly Unstable
D Neutral
E Slightly Stable
F Stable
Based on the Table 1, following stability / wind-speed categories shall be used in the study for two weather
conditions representing day and night:
• D Stability, 5 m/s wind speed
• F Stability, 2 m/s wind speed
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Atmospheric Condition Assumption No.
2
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Table 2: Wind Direction Probability by Wind Speed [Ref 2]
The meteorological data for the Jakarta, Indonesia airport for the years 2001 to 2010 as follows:
(Wind direction coming from) Weather Class / Wind speed Probability
F2 C5 C/D7 D9 TOTAL
N 0.059 0.078 0.024 0.001 0.162
NNE 0.035 0.049 0.023 0.003 0.110
NE 0.012 0.020 0.021 0.005 0.058
ENE 0.010 0.019 0.024 0.004 0.057
E 0.008 0.019 0.027 0.003 0.056
ESE 0.008 0.014 0.016 0.001 0.038
SE 0.008 0.009 0.004 0.000 0.021
SSE 0.014 0.019 0.007 0.000 0.040
S 0.021 0.028 0.009 0.001 0.059
SSW 0.021 0.028 0.015 0.002 0.066
SW 0.021 0.029 0.021 0.003 0.073
WSW 0.017 0.018 0.012 0.001 0.047
W 0.013 0.007 0.003 0.000 0.022
WNW 0.018 0.013 0.005 0.000 0.035
NW 0.023 0.020 0.007 0.000 0.049
NNW 0.041 0.049 0.015 0.001 0.105
Total 0.326 0.416 0.232 0.025 1.000
Surface Roughness
The ground characteristics are represented by surface roughness which will be assumed as 0.1m (10cm) –
Low crops, occasional large obstacles.
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Atmospheric Condition Assumption No.
2
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Reference: 1. Atmospheric measurement Data provided by Client
2. Typical Weather Data for Jakarta from Internet (www.solarshine.com)
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments:
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Scenarios Assumption No. 3
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Scenario:
Basis for Scenario: Each possible different section is considered to hold hazardous material capable of
causing fire/explosion, at one possible time, within the plant facility.
The following table represents the Scenarios that were considered for this study;
Table 3: Scenarios :
Scenario Number Description
1 Loss of containment from Diesel Storage Tank
2 Loss of containment from Drums in Raw material
storage area
3 Loss of containment from Big Tank
4 Loss of containment from Drums/Tanks Mobile
Tank area
5 Loss of containment from Drums in Mixing Room
6 Loss of containment from Drums in SFG Storage
7 Loss of containment from Drums in Cold Room
8 Loss of containment from Drums in Transfer
Area
9 Loss of containment from Drums in Filling
Hardener Area
10 Loss of containment from Drums in Color
WareHouse
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Scenarios Assumption No. 3
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
11 Loss of containment from Drums in Drum Yard
12 Loss of containment from Drums Outside Drum
Yard
13 Loss of containment from Tank in Tank Area
14 Loss of containment from Drums/cans in
WareHouse
Reference:
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments:
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Table 4: Process and Operating Conditions:
The following table represents the Process and Operating conditions for this study:
Scenario Description Phase Material Composition* Quantity (liters)
Operating Pressure
(barg)
Operating Temp.
(oC)
1 Loss of containment from
Diesel Storage Tank Liquid Diesel N-Undecane 2000 Amb Amb
2 Loss of containment from
Drums in Raw material
storage area1
Liquid SETALUX 1160 XS -
51
Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14%
2000 Amb Amb
3 Loss of containment from
Big Tank 2
Liquid Dianal DG 4040 Toluene: 60 %
n-Butanol: 40 % 3050 Amb Amb
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C:\Users\62016029\Desktop\FRA Assumption Register - Revised.Docx
Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
4 Loss of containment from
Drums/Tanks Mobile Tank
area3
Liquid, Resin
Exxsol DSP 80/100
n-hexane: (15-20)% Heptane & isomers: (32-
36)% Cyclohexane: (25-27)%
Methylcyclohexane: (3-7)%
2000 Amb Amb
5 Loss of containment from
Drums in Mixing Room 4
Liquid EXXSOL DSP 80/100
n-hexane: (15-20)% Heptane & isomers: (32-
36)% Cyclohexane: (25-27)%
Methylcyclohexane: (3-7)%
500 Amb Amb
6 Loss of containment from
Drums in SFG Storage5
Liquid Exxsol D30
n hexane: 25% xylene:25%
toluene: 15% cyclohexane:15%
pentane:15% heptane:5%
10000 Amb Amb
7 Loss of containment from
Drums in Cold Room 6
Liquid EXXSOL DSP 80/100
n-hexane: (15-20)% Heptane & isomers: (32-
36)% Cyclohexane: (25-27)%
700 - -
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Methylcyclohexane: (3-7)%
8 Loss of containment from
Drums in Transfer Area 7
Liquid SETALUX 1160 XS -
51
Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14%
2500 Amb Amb
9 Loss of containment from
Drums in Filling Hardener
Area8
Liquid SETALUX 1160 XS -
51
Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14%
2500 Amb Amb
10 Loss of containment from
Drums in Color WareHouse 9
Liquid SETALUX 1160 XS -
51
Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14%
1700 Amb Amb
11 Loss of containment from
Drums in Drum Yard 10
Liquid Exxsol D30
n hexane: 25% xylene:25%
toluene: 15% cyclohexane:15%
pentane:15% heptane:5%
5200 Amb Amb
12 Loss of containment from
Drums Outside Drum Yard 11
Liquid Butanol Normal n-butanol 825 Amb Amb
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
13 Loss of containment from
Tank in Tank Area Liquid n-Butyl Acetate n - Butyl Acetate 1200 Amb Amb
14 Loss of containment from
Drums/cans in WareHouse 12
Liquid Exxsol D30
n hexane: 25% xylene:25%
toluene: 15% cyclohexane:15%
pentane:15% heptane:5%
800 Amb Amb
Note:
• * - Composition taken up such that it is accepted by DNV’s PHAST 6.7 software used for modelling.
1. Raw material storage is assumed to have Talc & Resin to a total quantity of 398.4 (498 <pallets>*4<drums>*200kg<weightage of each drum>) tonnes. Since it
may have substances ranging in different flashpoints, we assume that it may have a total number of 55 different resins & 120 different Talc of equal Quantity i.e.,
2.34 tonnes of each material roughly.
2. Big Tank Area consists of 12 Tanks. Each tank’s processing capacity is given as 3000kg. Dianal DG 4040 is considered for this area.
3. Mobile Tank Area is assumed to have minimal processing capacity. Assuming it has processing capacity of 25 drums with each drum weightage of 200 kg, the
quantity of hazardous material present is 5000 kg. Since it may have resins and solvents, we consider Exxsol DSP 80/100 to be at 2000 l for this study.
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
4. Mixing Room has pigment, dispersant, additive & solvent. Assuming the maximum capacity of 2000 l, EXXSOL DSP 80/100 with a flashpoint of -15 °C is assumed
to have 500 l at one possible time.
5. SFG storage area is assumed to have solvents to a total quantity of 412.8 (516 <pallets>*4<drums>*200kg<weightage of each drum>) tonnes. Since it may have
solvents ranging in different flashpoints, we assume it to have a total of 50 different solvents of equal Quantity i.e., 8 tonnes of each material roughly.
6. EXXSOL DSP 80/100 with a flash point of – 15 °C is considered for this area. Cold Room is assumed to store substances with flashpoints ranging from – 15 to 10
°C. Assuming it has 11 different substances, the volume of EXXSOL DSP 80/100 is taken as 700 l.
7. Assuming Big Tank’s final outlet i.e., 3 tonnes of product is being sent to Transfer Area at one possible time. Hence, Transfer Area’s capacity at one possible time
is assumed to be 3 tonnes. Assuming the product to flash point above 10 °C, SETALUX 1160 XS – 51 or a material having a similar flash point is assumed for this
study.
8. Filling Hardener Area is assumed to have 3 tonnes of capacity at one possible time.
9. Colour Ware House is assumed to have 5 different products. The total capacity is 50 drums with each drum having a capacity of 200 kg, at one possible time.
10. Drum Yard is assumed to have solvents with a total quantity of 202.4 (253 <pallets>*4<drums>*200kg<weightage of each drum>) tonnes. Since it may have
solvents ranging in different flashpoints, we assume it to have a total of 50 different solvents of equal Quantity i.e., 4 tonnes of each material roughly.
11. Outside Drum Yard facility that extends upto area outside Packaging Warehouse, Ruang Bonded Warehouse & Loading area is assumed to have solvents to a
total quantity of 33 ([112+32+32] <pallets>) tonnes. Since it may have solvents ranging in different flashpoints, we assume it to have a total of 50 different solvents
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
of equal Quantity i.e., 660 kg of each material roughly. Butanol Normal is assumed for this study.
12. Ware House is assumed to have a total of 25 different products of equal quantity stored in 20 litres can/drum. Ware House is assumed to have storage capacity of
1000 numbers at one possible time.
Reference: 1. Data provided by Client.
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments:
FRA ASSUMPTION REGISTER
DOC. NO.: 3415001 REV. A Page # 27 of 30
C:\Users\62016029\Desktop\FRA Assumption Register - Revised.Docx
Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Process Condition & Material Composition Assumption No. 4
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
FRA ASSUMPTION REGISTER
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Release Size, Height, Duration & Direction Assumption No. 5
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
Release Size
The Following Leak Sizes are to be considered for this FRA study:[Ref 1]
• 10 mm
• 25 mm
• 50 mm
Since most of the storage is in Drums, leak sizes 25mm and above are the most suitable for this study.
Release height
The release height shall be assumed as 1 m.
Release Duration
The release duration shall be assumed as 30 minutes (1800 Seconds) or inventory depletion whichever is earlier.
Release Direction
The release direction is assumed as Horizontal.
Reference:
1. OGP Risk Assessment Data Directory, Report No. 434 – 1.
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments:
FRA ASSUMPTION REGISTER
DOC. NO.: 3415001 REV. A Page # 29 of 30
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Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Impact Criteria Assumption No. 6
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
The following impact criteria shall be used for this FRA study:
Table 5: Impact Criteria [Ref 1]
Accident Hazards Criteria Unit Assessment
Thermal Flux
6 kW/m2
Impairment of escape routes
12.5 kW/m2
Extreme pain within 20s; movement to shelter is instinctive; fatality if escape is not possible.
Outdoors/offshore: 70% lethality Indoors onshore: 30% lethality*
20 kW/m2
20 Incapacitation, leading to fatality unless rescue is done quickly.
35 kW/m2
Immediate fatality (100% lethality)
Reference: 1. OGP Risk Assessment Data Directory Report No: 434 – 14.1
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments:
FRA ASSUMPTION REGISTER
DOC. NO.: 3415001 REV. A Page # 30 of 30
Z:\Dept - HSE\INDONESIA - AKZO NOBEL
Project: FRA FOR AKZO NOBEL
Client: AKZO NOBEL
Assumption Vulnerability Assumption No. 7
Calculation Run: All Rev.: A Date: 08/10/2013
Assumption/ Rule Set:
The following Table represents the Indoor / Outdoor vulnerabilities for this FRA Study:
Table 6: Indoor / Outdoor Vulnerabilities
Scenario Indoor Vulnerability Outdoor Vulnerability
Flash Fire (inside flame envelope) 0.2 0.7
Jet Fire, Pool Fire (≥ 35 kW/m2) 0.2 0.7
Reference:
TEBODIN – Assumption Initiated by (sign):
TEBODIN – Assumption Verified by (sign):
AKZO NOBEL – Assumption Agreed Upon (sign):
Comments: