Guidelines for Evaluating Plant Buildings for Fire Explosion and Toxic Releases
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Transcript of Guidelines for Evaluating Plant Buildings for Fire Explosion and Toxic Releases
Global Congress on Process Safety - 2012
__________________________________________________________________________
Guidelines for Evaluating Plant Buildings for Fire, Explosion, and
Toxic Releases—2nd Edition
R. Wayne Garland,
Eastman Chemical Company; [email protected] (for correspondence)
Adrian L. Sepeda,
CCPS Staff Consultant; [email protected] (for correspondence)
Quentin A. Baker Baker Engineering and Risk Consultants, Inc.; [email protected] (for correspondence)
Raymond H. Bennett, Ph.D.
Baker Engineering and Risk Consultants, Inc.; [email protected] (for correspondence)
Michael D. Moosemiller
Baker Engineering and Risk Consultants, Inc.; [email protected] (for
correspondence)
Prepared for Presentation at
8th
Global Congress on Process Safety
Houston, TX
April 1-4, 2012
UNPUBLISHED
AIChE shall not be responsible for statements or opinions contained
in papers or printed in its publications
Global Congress on Process Safety - 2012
__________________________________________________________________________
Note: Do not add page numbers. Do not refer to page numbers when referencing different portions of the
paper
Guidelines for Evaluating Plant Buildings for Fire,
Explosion, and Toxic Releases—2nd Edition
R. Wayne Garland,
Eastman Chemical Company; [email protected] (for correspondence)
Adrian L. Sepeda,
CCPS Staff Consultant; [email protected] (for correspondence)
Quentin A. Baker Baker Engineering and Risk Consultants, Inc.; [email protected] (for correspondence)
Raymond H. Bennett, Ph.D.
Baker Engineering and Risk Consultants, Inc.; [email protected] (for correspondence)
Michael D. Moosemiller
Baker Engineering and Risk Consultants, Inc.; [email protected] (for
correspondence)
The Center for Chemical Process Safety (CCPS) of the American Institute of Chemical
Engineers has completed a project to update the book, “Guidelines for Evaluating Process Plant
Buildings for External Fires, Explosions, and Toxic Releases.” The first edition of the guidelines
book was published in 1996, based on the existing edition of API RP 752 at that time. This new
second edition of the Guidelines book brings it in line with state of the art by addressing the
newest version of API RP 752 [1], addressing portable buildings under API RP 753 [2], adding
sections on toxic releases, and including recent technology and management system
developments. Major changes to API RP 752 include the elimination of occupancy screening,
requirements for more extensive documentation, and the requirement to address a Maximum
Credible Event (MCE). The second edition of the book provides an up-to-date comprehensive
and valuable resource to process safety professionals needing an understanding of how to
evaluate and address building siting situations. A summary of the project objectives, status, and
changes to API RP 752 that are addressed in the second edition of the book are presented here.
INTRODUCTION AND BACKGROUND The Center for Chemical Process Safety (CCPS) of the American Institute of Chemical
Engineers has completed a project to update the first edition of the book ―Guidelines for
Evaluating Process Plant Buildings for External Fires, Explosions, and Toxic Releases.‖ The
second edition captures new requirements from the latest version of American Petroleum
Institute API RP 752 ―Management of Hazards Associated with Location of Process Plant
Buildings‖ (2009-Third Edition) and adds those of API RP 753 ―Management of Hazards
Associated with Location of Process Plant Portable Buildings‖ (First Edition, June 2007).
Global Congress on Process Safety - 2012
__________________________________________________________________________
Project oversight was provided by the CCPS Process Plant Building subcommittee. BakerRisk
was the contractor for development of the second edition.
The intended audience for the second edition of the book ranges from corporate level managers
to Process Safety Subject Matter Experts (SMEs) involved in building siting evaluations of
buildings intended for occupancy. We also expect the second edition of the book to be used as a
reference by regulators. The broad uses necessitated a technically neutral discussion to
alternative approaches.
The first edition of the guidelines book was published in 1996 and was based on the then current
First Edition of API RP 752, and thus it did not include a section on toxic releases. The second
edition brings it in line with state of the art by addressing the new requirements in the Third
Edition of API RP 752 and adding API RP 753 requirements, including allowing the use of
either consequence or risk-based approaches for all of the hazards addressed. It also expands
upon recent technology and management system developments.
The second edition of the book also directs EH&S site leaders involved in building siting
discussions to other CCPS books that will remain the primary technical references in such areas
as explosion modeling and risk assessment.
PROJECT OBJECTIVES AND GUIDING CONCEPTS The first edition of the book is slightly less than 200 pages. Because the new second edition of
the book has an increased scope, it is longer—approximately 300 pages. The new book
represents a significant expansion of the first edition due to the complete revamping of API RP
752, the addition of API RP 753, inclusion of toxic releases and risk, a better understanding of
expectations from regulatory agencies and end users, and other developments in the state of the
art. To the extent possible, the second edition of the book provides the owners and operators of
facilities the information required to develop a consistent philosophy for siting buildings.
To maximize the value of the second edition to the target audiences, it focuses on the integration
of various activities associated with building siting utilizing API RP 752 and API RP 753.
Various analysis techniques are discussed for consequence and risk analyses. Considering that
explosion, fire and toxic hazards are addressed as well as consequences for building damage and
occupant vulnerability and risk to occupants, the scope of technical content is very broad. This
broad scope created overlap with other CCPS Guideline books, some of which are regarded as
authoritative texts on specific subjects. The CCPS subcommittee decided to avoid overlap and
potential duplication with other books by identifying other authoritative texts and referring
readers to those references. Thus, the second edition of the book does not duplicate analysis
methods that are covered in Guidelines for Vapor Cloud Explosion, Pressure Vessel Burst,
BLEVE, and Flash Fire Hazards; Guidelines for Chemical Process Quantitative Risk Analysis;
or other authoritative references such as the Design of Blast Resistant Buildings in Petrochemical
Facilities [3]. Terminology used in the second edition follows CCPS standards and is to the
extent possible consistent with other CCPS books.
The second edition includes an introduction to blast resistant design. Since publication of the
first edition the structural engineering community has developed several key references that
Global Congress on Process Safety - 2012
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make the quantitative information in the first edition obsolete. The quantitative information from
the first edition was deleted. The new edition introduces concepts and direct readers to other
current sources for technical details.
The arrangement of the second edition of the book follows the sequential work process for
completing a building siting evaluation. This may be different than the flow of information in
the 2009 version of API RP 752. However, the pertinent sections of API RP 752 are cited so that
they can be cross-referenced as necessary.
SECOND EDITION CONTENT The second edition of the book includes a management overview that addresses the overall
building siting evaluation process with particular emphasis on the management activities that are
required. A major change in API RP 752 from the previous editions is that building siting is now
identified as a process and on-going activity rather than a one-time event. Thus, there are
multiple actions that must be performed by the owner or operator management team.
Management activities include the selection of approach, selection of acceptance criteria,
documentation of the building siting process, and risk mitigation plan and schedule (required by
API RP 752). Since managers are typically not practitioners of consequence and risk analysis,
this section does not include technical details.
The majority of the second edition of the book focuses on the technical aspects of the various
consequence and risk analyses as well as the administrative aspects of managing the building
siting process. New features are described in the following sections.
Determining the Scope of Buildings to Evaluate This discussion includes the requirements for selecting the relevant buildings to be included in
the assessment. A major change to API RP 752 is that the use of occupancy screening criteria in
the previous editions is specifically prohibited. Buildings must be addressed in the siting study if
they are ―intended for occupancy,‖ a term initially introduced in API RP 753. This change is
likely to result in many owners having to address buildings that had been screened out under the
previous versions of API RP 752.
“Maximum Credible Event (MCE)”
The revised API RP 752 requires sites to determine the MCEs that affect each occupied building
when performing consequence-based analyses. The second edition of the book provides
assistance to owners in selecting appropriate scenarios for MCEs for their individual buildings
based upon their operations. The determination of the MCEs is one of the most important steps
of the consequence-based approach under API RP 752. The MCE is defined as:
A hypothetical explosion, fire, or toxic material release event that has the potential
maximum consequence to the occupants of the building under consideration from among
the major scenarios evaluated. The major scenarios are realistic and have a reasonable
probability of occurrence considering the chemicals, inventories, equipment and piping
design, operating conditions, fuel reactivity, process unit geometry, industry incident
history, and other factors. Each building may have its own set of MCEs for potential
explosion, fire, or toxic release impacts.
Global Congress on Process Safety - 2012
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The second edition of the book provides examples of what may (or may not) constitute an MCE,
a selection of which is reproduced below.
Selected Examples of Credible and Non-Credible Situations for Building Siting Evaluations*
―Credible‖ Rupture of small bore piping
Gasket failure
Loading/unloading hose rupture
Process upsets such as overfilling a vessel or tank
May or May
Not Be
―Credible‖
Rupture of large bore piping or vessel/tank
Reaction runaway that exceeds the pressure relief system
capacity
Vehicle impact to exposed process equipment and piping
Alternate case US EPA RMP scenario
―Non-Credible‖ Events that are not physically possible (e.g., inventory of
flammable material is insufficient to generate the scenario)
Multiple domino events when each event has a low likelihood
*reproduced here from Table 3.1, second edition of the book
Building Siting Evaluation Criteria The Third Edition of API RP 752 does not provide any quantitative criteria for use in a building
siting evaluation. Each owner/operator is allowed to set the criteria based on their own risk
circumstances but must be prepared to support the basis for their selection. The second edition
of the book introduces the different types of criteria that can be selected and the advantages and
disadvantages of each. The criteria may be consequence-based, risk-based, or spacing table-
based (for fires only). Different types of criteria may be set for different types of hazards. For
example, an owner/operator may choose to evaluate bursting pressure vessel explosion exposures
on a consequence basis (since the magnitude of the explosion is limited by the bursting pressure
and volume of the vessel). The same site may choose to evaluate vapor cloud explosions on a
risk basis, since in that case the strategy may be to provide various prevention measures that
reduce the frequency of the event. It is also permitted for sites to initially evaluate a hazard on a
consequence basis and later refine the analysis using a risk-based evaluation.
It is important for owner/operators to recognize that a principle of the hazard management
process is that the criteria for building siting are defined prior to an evaluation, in order to avoid
the perception that sites are revising criteria to fit their analysis results. Therefore, the criteria
used should be well thought-out and reviewed with management before final implementation of
a program, or completion of individual studies.
Consequence Assessment The sections for explosions and fires have been extensively revised to comply with the
requirements of API RP 752. Much of the anecdotal information in the first edition of the book
has been removed and replaced with discussions of concepts and principles as well as references
to other CCPS books and professional guidance documents. The chapter on toxic hazards is
entirely new.
Global Congress on Process Safety - 2012
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The new version of API RP 752 accepts by name certain types of methodologies that are
allowed, or not allowed, for the assessment of explosion and fire consequences. Examples
include but are not limited to the following:
Fires (Acceptable Methods) – Standard industry spacing tables, Dow Fire & Explosion
Index
Vapor Cloud Explosions (Acceptable Methods) – Blast Curve Techniques (such as the
Baker-Strehlow-Tang method, TNO multi-energy method, Congested Assessment
Method (CAM) and Advanced Blast Simulation Techniques (commonly referred to as
Computational Fluid Dynamics)
Vapor Cloud Explosions (Unacceptable) – TNT Equivalency Method
The second edition of the book provides a roadmap to references for additional information on
blast prediction methods and their application.
Frequency/Probability Assessment API RP 752 allows for the use of Quantitative Risk Assessment, but has specific requirements
regarding how frequencies may be established. This section provides a link between the second
edition book and other existing CCPS books on risk analysis. Areas of special interest include
guidance on the development of frequency information, potential sources of the information, and
guidelines for determining the applicability of the data to specific processes.
Risk Assessment It will often be the case that a risk analysis will consider events that are both greater and lesser
than an MCE for a given building. Thus, some events that may be considered ―non-credible‖ for
the purposes of an MCE may be evaluated in a risk assessment by quantifying their likelihood of
occurring.
API RP 752 does not provide risk acceptance criteria and neither does the CCPS book.
However, the RP does require the evaluation of aggregate risk to all personnel within a building,
whereas previously, some owner/operators only evaluated individual risk. The second edition of
the book serves as a roadmap to assist the user in implementing risk-based strategies, and
identify other resources available to assist in the development of risk acceptance criteria and
performing risk calculations.
The second edition of the book introduces new risk measures that are designed specifically for
the purposes of building siting risk assessment, and puts them in perspective with the ‗classic‘
ways of reporting risk. The second edition of the book also defines which types of risk are in the
scope of a building siting review, and which are not.
Risk Management The Third Edition of API RP 752 recommends specific actions for owner/operators to manage
risk upon completion of a building siting evaluation. Among these requirements are:
Global Congress on Process Safety - 2012
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The active management of building occupancy (e.g., to ensure buildings not intended for
occupancy do not become occupied).
Implementation of Management of Change (MOC) procedures to ensure that the assumptions
used in the development of the building siting evaluation remain appropriate and to identify
the changes in conditions that would trigger a reassessment of the evaluation. The second
edition of the book does not specifically define MOC procedures but identifies the types of
activities the procedures need to address.
Development of mitigation plans for buildings that do not meet the owner‘s siting criteria.
The mitigation plans may address relocation of personnel, minimizing the probability of
occurrence, or strengthening of the buildings. The plans must include a schedule for the
mitigation activities.
SUMMARY
The updated API RP 752 is more prescriptive in some ways, yet provides greater evaluation
options than before. As a result, it is expected that building siting evaluation methodologies will
become more standardized (and accurate) than was required previously. In addition, it is likely
that more owner/operators will migrate to risk-based approaches in order to be able to evaluate,
and take credit for the many mitigation measures that are typically in place in chemical
processing facilities.
The updated API RP 752 also requires operators to treat building siting as an ongoing process of
continuous improvement rather than simply a one-off technical evaluation. The second edition
book will help guide owner/operators through this process. This will help ensure the long-term
safety of the occupants of process plant buildings.
LITERATURE CITED
1. API (American Petroleum Institute), Management of Hazards Associated with Location of Process Plant
Permanent Buildings, API Recommended Practice 752, 3rd Edition, Washington, D.C., December 2009.
2. API (American Petroleum Institute), Management of Hazards Associated with Location of Process Plant Portable
Buildings,” API Recommended Practice 753, First Edition, Washington, D.C., June 2007.
3. ASCE, Design of Blast Resistant Buildings in Petrochemical Facilities, Second edition, Task Committee on Blast
Resistant Design, American Society of Civil Engineering, Reston, Virginia, 2010.