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Dow Fire and Explosion Index (FEI) Dick Hawrelak Presented to ES317Y in 2001 at UWO

5.10 Dow Fire and Explosion Index

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Page 1: 5.10 Dow Fire and Explosion Index

Dow Fire and Explosion Index (FEI)

Dick Hawrelak

Presented to ES317Y in 2001 at UWO

Page 2: 5.10 Dow Fire and Explosion Index

Introduction V1.0 was first Issued in 1964 By Bill Braise

(RIP). V7.0 was last issued in 1994 and is now

marketed by the AIChE ($50/copy). FEI is widely used outside of Dow. FEI is the leading hazard index methodology

recognized by the chemical industry. V7.0 is available on my CD in Folder (9) as

Dow FEI V1.3.

Page 3: 5.10 Dow Fire and Explosion Index

What is the Dow FEI? The Dow FEI is a ranking system

that gives a relative index to the risk of individual process units due to potential fires and explosions.

Page 4: 5.10 Dow Fire and Explosion Index

What is the Primary Purpose of the Dow FEI?

It serves as a guide for the selection of fire and explosion protection methods.

It assists in determining the spacing between adjacent process units within the ISBL.

It is a guide for insurance agencies to set insurance rates.

It ranks individual process units where special safety attention can be focused.

Page 5: 5.10 Dow Fire and Explosion Index

When should one perform an FEI?

Late in Phase III Engineering after: P&IDs have been completed, Equipment has been sized, A trial equipment layout has been done, A DFC estimate has been completed.

Page 6: 5.10 Dow Fire and Explosion Index

Who Usually Performs the FEI? Generally a senior process engineer, who

is acquainted with the details of the project, is assigned the task.

Occasionally, different groups tackle the assignment and results are compared for consensus building.

Page 7: 5.10 Dow Fire and Explosion Index

What Does the FEI Consider?

Six general process hazards. Twelve special process hazards. Nine process control credit factors. Four material isolation credit factors. Nine fire protection credit factors.

Page 8: 5.10 Dow Fire and Explosion Index

General Process Hazards Exothermic reactions. Endothermic processes. Material handling and transfer Enclosed or indoor process units. Access. Drainage and spill control.

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Special Process Hazards

Toxic materials. Sub-atmospheric pressure (<500 mmHg). Operating in or near flammable range.

Tank farm storage flammable liquids. Process upset or purge failure. Always in flammable range.

Dust explosion. Pressure.

Page 10: 5.10 Dow Fire and Explosion Index

Special Hazards Cont’d

Low temperature. Quantity of flammable/unstable

material. Liquids or gases in process. Liquids or gases in storage. Combustible solids in storage.

Corrosion and erosion.

Page 11: 5.10 Dow Fire and Explosion Index

Special Hazards Cont’d

Leakage – joints and packing. Use of fired equipment. Hot oil heat exchanger system. Rotating equipment.

Page 12: 5.10 Dow Fire and Explosion Index

Process Control Credit Factors

Emergency power. Cooling. Explosion control. Emergency shutdown. Computer control.

Page 13: 5.10 Dow Fire and Explosion Index

Process Control Factors Cont’d

Inert gas. Operating instruction procedures. Reactive chemical review. Process hazard analysis.

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Material isolation Credit Factors Remote control valves. Dump or blow down control. Drainage. Interlocks.

Page 15: 5.10 Dow Fire and Explosion Index

Fire Protection Credit Factors Leak detection. Structural steel . Fire water supply. Special systems. Sprinkler systems. Water curtains. Foam. Hand extinguishers. Cable protection.

Page 16: 5.10 Dow Fire and Explosion Index

FEI Example

DOW FIRE AND EXPLOSION INDEX 7th Edition, J anuary, 1994 dB No. = 1 (1,6,16)

Area / Country Division: WC Location DateSite Mnfg Unit: LHC#1 Process Unit C2 SplitterPrepared By Appr'd By BuildingReviewed By Mgt Review By: TC Review By: S&LPMaterials In Process EthyleneState Of Operation Design Startup Norm Opn ShutdownBasic Materials For Material Factor EthyleneMaterial Factor (See Table 1 or Appendix A or B) Note temperature requirements when unit temperatures over 140 °F = 24

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General Process Hazards

Penalty Penalty1 General Process Hazards Factor Factor

Range UsedBase Factor 1.00 1.00

p-16 A Exothermic Chemical Reactions Type = None 0.3 - 1.25 0.00p-17 B Endothermic Processes Type = None 0.2 - 0.4 0.00p-17 C Material Handling & Transfer (Table 1) Type = None 0.25 - 1.05 0.00p-17 D Enclosed or Indoor Process Units Type = Open 0.25 - 0.9 0.00p-18 E Access Type = Two Sides 0.2 - 0.35 0.00p-18 F Drainage and Spill Control Notes Meets NFPA 30? No USG = 1.73E+05 0.25 - 0.5 0.50

General Process Hazards Factor (F1) = 1.50

Page 18: 5.10 Dow Fire and Explosion Index

Special Process Hazards2 Special Process Hazards

Base Factor = 1.00 1.00p-20 A Toxic Material(s), Use (0.2)(Nh) Nh = 1.00 Note 0.2 - 0.8 0.20p-20 B Sub-Atmospheric Pressure (< 500 mm Hg) Possible vacuum? No Penalty 0.50 0.00p-21 C Operation Near In or Near Flammable Range Padding? None Penaltiesp-21 1 Tank Farms Storage Flammable Liquids Note C1: 0.50 0.00p-21 2 Process Upset or Purge Failure Note C2: 0.30 0.00p-21 3 Always in Flammable Range Note C3: 0.80 0.00p-21 D Dust Explosion (See Table 3) Type = None Micron Sz = 0 Inerted? No 0.25 - 2.0 0.00p-22 E Pressure (See Fig. 2) Operating Psig = 58.4 Relief Set psig = 125 0.16 - 1.5 0.24p-25 F Lowest Temperature = -155 °F Material Suitable ? = Yes 0.2 - 0.3 0.00p-25 G Quantity of Flammables / Unstable Material lb = 217,000 Heat Comb BTU/lb = 20,800p-26 1 Liquids or Gases In Process (See Fig. 3) Penalty = 2.18 2.18p-28 2 Liquids or Gases in Storage (See Fig. 4) Type = A Penalty = 0.96 0.00p-30 3 Combustible Solids in Stg (See Fig. 5) lbs = 0 Density = 0 0.00p-32 H Corrosion and Erosion Rates = 0.00 mil / Yr. Penalty = 0.00 0.1 - 0.75 0.00p-33 I Leakage - J oints and Packing Type = Minor Penalty 0.1 - 1.50 0.10p-33 J Use of Fired Equipment (See Fig. 6) Dist = 600 ft. Penalty Curve A-2 0.10p-35 K Hot Oil Heat Exchange System (See Table 5) Volume = 0.00 Penalty 0.15 - 1.15 0.00p-36 L Rotating Equipment Type = Comp Penalty 0.50 0.50

Special Process Hazards Factor (F2) 4.32Process Unit Hazards Factor (F1 x F2) = F3 = 6.47

Fire and Explosion Index (F3 x MF = FEI) = 155.36

Fire and Explosion Class (See Table 6) = FEI Range = 128 - 158 Heavy

Page 19: 5.10 Dow Fire and Explosion Index

Fig 8: Damage FactorFigure 8 - Damage Factor

0.000

0.200

0.400

0.600

0.800

1.000

1.200

0 5 10 15 20 25 30 35 40 45

Material Factor (MF)

Dam

age

Fact

or

F3 = 1F3 = 2F3 = 3F3 = 4F3 = 5F3 = 6F3 = 7F3 = 8Case Pt.

Page 20: 5.10 Dow Fire and Explosion Index

Process Control Credit Factors1. Process Control (C1)a) Emergency Power 0.98 .98b) Cooling .97 - .99c) Explosion Control .84 - .98d) Emergency Shutdown .96 - .99e) Computer Control .93 - .99 .93f) Inert Gas .94 - .96g) Operating Instruct/Proc .91 - .99 .91h) Reactive Chemical Review .91 - .98 .91

C1 = .75

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Material Isolation Factors2. Material Isolation (C2)a) Remote Control Valves .96 - .98 .96b) Dump / Blowdown .96 - .98 .96c) Drainage .91 - .97 .95d) Interlock 0.98

C2 = .88

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Fire Protection Credit Factors3. Fire Protection (C3)a) Leak Detection .94 - .98 .98b) Structural Steel .95 - .98 .97c) Buried Tanks .84 - .91d) Water Supply .94 - .97 .94e) Special Systems 0.91f) Sprinkler Systems .74 - .97 .97g) Water Curtains .97 - .98h) Foam .92 - .97i) Hand Extngshrs / Mntrs .95 - .98 .97j) Cable Protection .94 - .98 .94

C3 = .79

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Credit Factor Summary Process Control, C1 =0.75 Material isolation, C2 = 0.88 Fire Protection, C3 = 0.79 C1xC2xC3 = (0.75)(0.88)(0.79) = 0.52

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Process Unit Risk Analysis Summary

UNIT ANALYSIS SUMMARY

Credit Factor = C1 X C2 X C3 = .52

A-1. F & E I 152.05A-2. Radius of Exposure 127.7 ft Radius of Exposure = 0.84*FEIA-3. Value of Area of Exposure 19.16 $MMB. Damage Factor (Fig 8) 0.85 Fr Special Fig 8 Interp'n RoutineC. Base MPPD ( A-3 X B ) 16.19 $MMD. Credit Factor 0.52E. Actual MPPD ( C X D ) 8.46 $MMF. Days Outage ( MPDO ) 74 Days Outage = EXP(3.0489+0.58925*LN(H30))G. Bus. Interruptn Loss (BI) $MM

Page 25: 5.10 Dow Fire and Explosion Index

Plot Plan Summary

Page 26: 5.10 Dow Fire and Explosion Index

Features Not Used In V7.0Dow Separation Distance vs FE Index - 4th Edition (1979)

1

10

100

0 20 40 60 80 100 120 140

F&E Index

Sepa

ratio

n D

ista

nce,

Ft.

VCM

EO

Best Fit

Page 27: 5.10 Dow Fire and Explosion Index

Limitations of Dow FEI No scientific basis for many of the

features can be found in Dow records. Fig 8 is an example. (RAH study – 1993).

Does not correlate well with known plant disasters (Flixborough, Phillips, Norco).

While explosion damage is fairly advanced (Flixborough – 1974), fire damage alone is more difficult to predict.

Not scenario driven as in recent QRA work in Holland and the U.K.

Page 28: 5.10 Dow Fire and Explosion Index

Recent Trends Insurance companies are looking at

Maximum Foreseeable Loss, (MFL), based on Baker‘s- 1994 blast technology for Detonations and Deflagrations as applied to plant equipment layout.

There is a trend toward higher insurance premiums as insurance companies adjust their actuarial data.

Many chemical companies may follow Exxon’s trend to insure themselves.

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End Of Show Your Department should have a

copy of the 7th Edition available for further examination and application to your projects.