F&EI Calculation Workbook

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Explanation of the Dow Fire and Explosion Index.

The Fire and Explosion Index (F&E!) calculation is a tool to help determine the areas of greatest loss potential in a also enables one to predict the physical damage that would occur in the event of an incident.

The first step in making the F&EI calculation requires using an efficient and logical procedure to determine which be studied. A process unit is defined as any major item of process equipment. The following process units co typical plant. Unloading facility Storage tank

Explanation of the Dow Fire and Explosion Index.

The Fire and Explosion Index (F&E!) calculation is a tool to help determine the areas of greatest loss potential in a also enables one to predict the physical damage that would occur in the event of an incident.

The first step in making the F&EI calculation requires using an efficient and logical procedure to determine which be studied. A process unit is defined as any major item of process equipment. The following process units co typical plant. Unloading facility Storage tank Reactor Distillation Column Quench Vessel Storage Vessel Loading facility

A designation of the Process Unit must be entered in the appropriate space on the F&EI form. The designation must also be entered on the F&EI form. A Manufacturing Unit is the entire productio chemical processes, mechanical processes, warehouse, packaging lines, etc.

It is quite clear that most manufacturing units have many process units. To calculate the Fire and Explosion process units that could have an impact from a loss prevention standpoint should be evaluated. These are known Units. Important factors for selecting Pertinent Process Units include: a. Chemical energy potential (Material Factor) b. Quantity of hazardous material in the Process Unit c. Process pressure and process temperature d. Units critical to plant operation, e.g. Reactor Important Considerations A.

The Fire and Explosion Index system assumes that a process unit handles a minimum of 2,500 kg of a flamm reactive material. If less material is involved, generally the risk will be overstated. However, F&EI cal meaningful results for pilot plants if they handle at least 500 kg) of combustible or reactive material.

B.

Careful consideration is needed when equipment is arranged in series and the items are not effectively isol An example would be a reaction train without an intermediate pump. In such situations, the type of proces several vessels or just a single vessel should be considered as the Process Unit.

It should rarely be necessary to calculate the F&EI for more than three or four Process Units in a sing Manufacturing Unit. The number of Process Units will vary according to the type of process and the Manufacturing Unit. A separate F&EI form must be completed for each process unit evaluated.

C.

It is also important to give careful consideration to the state or point in time of the operation. By their natur as startup, steady-state operation, shutdown, filling, emptying, adding catalyst, etc., often create unique impact on the F&EI. Generally, good judgment will enable selection of the point in time of operation calculation. Occasionally more than one point in time will have to be studied to determine the significant risk

C.

It is also important to give careful consideration to the state or point in time of the operation. By their natur as startup, steady-state operation, shutdown, filling, emptying, adding catalyst, etc., often create unique impact on the F&EI. Generally, good judgment will enable selection of the point in time of operation calculation. Occasionally more than one point in time will have to be studied to determine the significant risk

areas of greatest loss potential in a particular process. It an incident.

gical procedure to determine which process units should t. The following process units could be identified in a

areas of greatest loss potential in a particular process. It an incident.

gical procedure to determine which process units should t. The following process units could be identified in a

pace on the F&EI form. The Manufacturing Unit ng Unit is the entire production facility including c.

calculate the Fire and Explosion Index, however, only uld be evaluated. These are known as Pertinent Process

a minimum of 2,500 kg of a flammable, combustible or overstated. However, F&EI calculations can provide tible or reactive material.

d the items are not effectively isolated from each other. such situations, the type of process determines whether Unit.

e or four Process Units in a single process area of a g to the type of process and the configuration of the

me of the operation. By their nature, such normal stages atalyst, etc., often create unique conditions having an of the point in time of operation to perform the F&EI ed to determine the significant risk.

me of the operation. By their nature, such normal stages atalyst, etc., often create unique conditions having an of the point in time of operation to perform the F&EI ed to determine the significant risk.

PLANT NAME Sheet i.d. Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8 Unit 9 Unit 10 Unit Description Butadiene Unloading Finishing tower 0 0 0 0 0 Xylene storage LPG Store Solids pesticides warehouse

Material Butadiene Ethylene Oxide 0 0 0 0 0 P Xylene 0 0

F&EI

103.34 145.14 0.00 0.00 0.00 0.00 0.00 56.38 114.16 41.78

Material factors for unlisted materials can be estimated by table at the bottom of this screen

MATERIAL1,1,1-Trichloroethane 1,1-Ethylidene Dichloride 1,2,3-Trichloropropane 1,2,4-Trichlorobenzene 1,2-Dichloroethylene 1,2-Dinitrobenzene 1,3-Butadiene 1,3-Dichloropropene 1,3-Propanediamine 1,4-Dioxane 1-Butanol (Butyl alcohol) 1-Butene 1-Chloro 1-Nitroethane 2,2-Dimethyl-1-Propanol 2,3-Butylene Oxide 2,3-Dichloropropene 2,4-Dinitro Phenol 2-Chloropropane 2-Ethylhezanal 2-Hydroxyethyl Acrylate 2-Methylpropenal 2-Picoline 3,5-Dichloro Salicylic Acid 4-Vinyl Cyclohexene Acetaldehyde Acetic Acid Acetic Anhydride Acetone Acetone Cyanohydrin Acetonitrile Acetyl Chloride Acetyl Ethanolamine Acetyl Peroxide Acetyl Salicylic Acid [7] Acetylene Acrolein

MF4 16 10 4 24 40 24 16 16 16 16 21 29 16 24 16 40 21 14 24 24 10 24 24 24 14 14 16 24 16 24 14 40 16 29 29

Hc BTU/LB x 1033.1 4.5 4.3 6.2 6.9 7.2 19.2 6.0 13.6 10.5 14.3 19.5 3.5 14.8 14.3 5.9 6.1 10.1 16.2 8.9 15.4 15.0 5.3 19.0 10.5 5.6 7.1 12.3 11.2 12.6 2.5 9.4 6.4 8.9 20.7 11.8

Hc Kcal/Kg x 1031.7 2.5 2.4 3.4 3.8 4.0 10.7 3.3 7.6 5.8 7.9 10.8 2.0 8.2 7.9 3.3 3.4 5.6 9.0 4.9 8.6 8.3 2.9 10.6 5.8 3.1 3.9 6.8 6.2 7.0 1.4 5.2 3.6 4.9 11.5 6.6

NhHealth 2 2 3 2 2 3 2 3 2 2 1 1 3 2 2 2 3 2 2 2 3 2 0 0 3 3 3 1 4 3 3 1 1 1 0 4

Acrylamide Acrylic Acid Acrylonitrile Allyl Alcohol Allyl Bromide Allyl Chloride Allyl Ether Allylamine Aluminum Chloride Ammonia Ammonium Nitrate Amyl Acetate Amyl Nitrate Aniline Barium Chlorate Barium Stearate Benzaldehyde Benzene Benzoic Acid Benzyl Acetate Benzyl Alcohol Benzyl Chloride Benzyl Peroxide Bisphenol A Bromine Bromobenzene Butane Butyl Acetate Butyl Acrylate Butyl Bromide Butyl Chloride Butyl Ether Butyl Nitrate Calcium Carbide Calcium Stearate [6] Carbon Disulfide Carbon Monoxide Chlorine Chlorine Dioxide Chloro Methyl Ethyl Ether

24 24 24 16 16 16 24 16 24 4 29 16 10 10 14 4 10 16 14 4 4 14 40 14 1 10 21 16 24 16 16 16 29 24 4 21 21 1 40 14

9.5 7.6 13.7 13.7 5.9 9.7 16.0 15.4 [2] 8.0 12.4 14.6 11.5 15.0 [2] 8.9 13.7 17.3 11.0 12.3 13.8 12.6 12.0 14.1 0.0 8.1 19.7 12.2 14.2 7.6 11.4 16.3 11.1 9.1 6.1 4.3 0.0 0.7 5.7

5.3 4.2 7.6 7.6 3.3 5.4 8.9 8.6 #VALUE! 4.4 6.9 8.1 6.4 8.3 #VALUE! 4.9 7.6 9.6 6.1 6.8 7.7 7.0 6.7 7.8 0.0 4.5 10.9 6.8 7.9 4.2 6.3 9.1 6.2 5.1 #VALUE! 3.4 2.4 0.0 0.4 3.2

3 3 4 4 3 3 3 4 3 3 0 1 2 3 2 0 2 2 2 1 2 2 1 2 3 2 1 1 2 2 2 2 1 3 0 3 3 4 3 2

Chloroacetyl Chloride Chlorobenzene Chloroform Chloropicrin Chlorostyrene Coumarin Cumene Cumene Hydroperoxide Cyanamide Cyclobutane Cyclohexane Cyclohexanol Cyclopropane DER* 331 Di-tert-butyl Peroxide Dichlorobenzene Dichlorostyrene Dicumyl Peroxide Dicyclopentadiene Diesel Fuel Diethanolamine Diethyl Carbonate Diethyl Ether Diethyl Peroxide Diethylamine Diethylene Glycol Diisobutylene Diisopropyl Benzene Dimethylamine Diphenyl Oxide Dipropylene Glycol Divinyl Acetylene Divinyl Ether Divinylbenzene DOWANOL* DM DOWANOL* EB DOWANOL* PM DOWANOL* PnB DOWFROST* DOWFROST* HD

14 16 1 29 24 24 16 40 29 21 16 10 21 14 40 10 24 29 16 10 4 16 21 40 16 4 16 10 21 4 4 29 24 24 10 10 16 10 4 1

2.5 10.9 1.5 5.8 12.5 12.0 18.0 13.7 7.0 19.1 18.7 15.0 21.3 13.7 14.5 8.1 9.3 15.4 17.9 18.7 10.0 9.1 14.5 12.2 16.5 8.7 19.0 17.9 15.2 14.9 10.8 18.2 14.5 17.4 10.0 12.9 11.1 9.1

1.4 6.1 0.8 3.2 6.9 6.7 10.0 7.6 3.9 10.6 10.4 8.3 11.8 7.6 8.1 4.5 5.2 8.6 9.9 10.4 5.6 5.1 8.1 6.8 9.2 4.8 10.6 9.9 8.4 8.3 6.0 10.1 8.1 9.7 5.6 7.2 6.2 #VALUE! 5.1 #VALUE!

3 2 2 4 2 2 2 1 4 1 1 1 1 1 3 2 2 0 1 0 1 2 2 3 1 1 0 3 1 0 2 1 2 1 1 1 1 0

DOWFROTH* 250 DOWICIL* 200 DOWICIL* 200 DOWICIL* 75 DOWTHERM* 4000 DOWTHERM* A DOWTHERM* G DOWTHERM* HT DOWTHERM* J DOWTHERM* LF DOWTHERM* Q DOWTHERM* SR-1 DURSBAN* Epichlorohydrin Ethane Ethanolamine Ethyl Acetate Ethyl Acrylate Ethyl Alcohol Ethyl Benzene Ethyl Benzoate Ethyl Bromide Ethyl Butylcarbonate Ethyl Butyrate Ethyl Chloride Ethyl Chloroformate Ethyl Ether Ethyl Formate Ethyl Mercaptan Ethyl Nitrate Ethyl Propyl Ether Ethylamine Ethylbutylamine Ethylene Ethylene Carbonate Ethylene Dichloride Ethylene Glycol Ethylene Glycol Dimethyl Ether Ethylene Glycol Monoacetate Ethylene Oxide

1 24 24 24 4 4 4 4 10 4 4 4 14 24 21 10 16