consequence and risk assessment case study of an ammonia storage facility

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Consequence and risk assessment: Case study of an ammonia storage facility

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Consequence Modelling and Risk Assessment for Hazardous Substance Release in Fertilizer Plant Using Aloha

• Conference paper
• First Online: 16 June 2022
• Cite this conference paper

• Bikarama Prasad Yadav 6 ,
• Nikhil Verma 6 ,
• Umang Kumar Yadav 6 ,
• Akshay Kant Mishra 6 &
• Anand K. Jayan 6  

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Fertilizer production industries are considered to be primarily based on production of 75% to 90% of ammonia which is utilized for making fertilizer and 50% of world’s food production is met through the use of ammonia-based fertilizers. Ammonia is produced; stored; and transported in extremely large quantities; hence, it possibly poses high risk to the population and environment. The release of any chemical may lead to toxic effect, fire and explosion and it makes the activity critical for which safety systems to be made efficient and adequate enough to mitigate the haphazard in case of emergency. This study focuses more on the ammonia production as hazards are more in this process than the urea production process. In the proposed work, the Risk Assessment and consequence modelling are carried out by taking consideration of all major toxic release, fire and explosion possible in ammonia plant for any fertilizer industry with the help of ALOHA (Areal location of hazardous atmosphere) and MARPLOT (Mapping, Application for Response, Planning and Local Operational Tasks). The scenarios are analysed based on the HAZOP and ETA. With profit function calculations for estimation of fatalities also, the individual risk is calculated which includes the nature of injury to the individual, similarly societal risk which is the measure of risk to the group of people and its expression into frequency (F) versus number of fatality (N) curve for different scenario considered are carried out. Meteorological data is taken as per the geological data and same is used for modelling and mapping. Also, with the help of ALOHA and MARPLOT, the extent of level of exposure with its dosage is determined. This work will help the industry to prepare and mitigate the consequences of any hazardous situation arising which has impact on population of both onsite and offsite areas.

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University of Petroleum & Energy Studies, Bidholi, Dehradun, India

Bikarama Prasad Yadav, Nikhil Verma, Umang Kumar Yadav, Akshay Kant Mishra & Anand K. Jayan

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Health Safety, Environment and Civil Engineering, University of Petroleum and Energy Studies, Dehradun, Uttarakhand, India

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MKO Process Safety Centre, College Station, TX, USA

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University of Petroleum and Energy Studies, Dehradun, Uttarakhand, India

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Emirates National Oil Company Limited, Dubai, United Arab Emirates

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Yadav, B.P., Verma, N., Yadav, U.K., Mishra, A.K., Jayan, A.K. (2022). Consequence Modelling and Risk Assessment for Hazardous Substance Release in Fertilizer Plant Using Aloha. In: Siddiqui, N.A., Khan, F., Tauseef, S.M., Ghanem, W.S., Garaniya, V. (eds) Advances in Behavioral Based Safety. Springer, Singapore. https://doi.org/10.1007/978-981-16-8270-4_24

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DOI : https://doi.org/10.1007/978-981-16-8270-4_24

Published : 16 June 2022

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Ammonia Risk Assessments – How advanced consequence modelling can improve safety management

Written by: UK FLACS-CFD Technical Lead & Senior Engineer

Pablo Giacopinelli

Ammonia has been for many years the refrigerant of choice for businesses with a need for process cooling, temperature-controlled storage and distribution, food and drink manufacturing, and many other applications.

The benefits of using ammonia include high energy efficiency and a reduced global warming potential depending on the fuel mix used to generate electricity.

Even though it is a natural refrigerant there are some challenges to using ammonia which may pose additional risks to a facility and personnel if not stored or handled correctly.

Ammonia hazards

Ammonia is classed as a highly poisonous gas when exposed to high levels, however with its distinctive smell detectable at low levels, and leaks naturally rising and dissipating into the atmosphere due to its lighter than air density, these two factors alone could mitigate the hazards of exposure to dangerous levels in occupied areas. 

Whilst fires and explosions may not be the greatest hazard relating to ammonia, its occasional classification as a ‘non-flammable’ gas has lead emergency responders to the dangerous assumption that there is no risk of igniting a flammable atmosphere. However, Ammonia in the air at concentrations of 15% to 25% volume is flammable and will burn or can explode, particularly if the gas/air mixture is present in a confined space.

When ammonia is mixed with combustible materials such as lubricating oils, its flammability range widens, and because ammonia is commonly stored as a liquid under pressure, boiling liquid expanding vapour explosions (BLEVEs) are theoretically a hazard. For such reasons, precautions against fire and explosions still have to be taken especially for unoccupied parts of the installation.

Risk assessment and safety mangement

All refrigeration systems require risk assessment and ammonia systems are no exception. The regulatory requirement is different based on the location of the facility and whether it falls under the ATEX Directive or Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).

Risk of leakage and over pressurisation of the refrigerator system need to be handled with a strict and robust safety inspection and the appropriate hazardous atmosphere assessments being completed, this includes studies like HAZMAT, HAZOP, SIL and LOPA assessments, which typically include and review operational faults, process control, cause and effects.

The HSE has in the past identified common failures in the understanding of ammonia refrigeration technology applicable to some designers, installers, contractors and site staff. These include, among others, “failure(s) to identify through assessment the likely sources of gas escape so that appropriate plant modifications may be made or appropriate plant checks instituted to detect likely sources of leakage at an early enough stage.” 

While locating the plant in a separate building from the main store or workroom is recommended, this may be difficult to implement by building designers. Machinery rooms should be provided with sufficient permanent ventilation during normal operation to mitigate the build-up of toxic concentrations of ammonia from any small operational releases.

Often this can be achieved by mechanical ventilation, inlet louvers or air bricks in external walls fitted at low level with vents at high level to facilitate natural circulation, unfortunately on many occasions it has been observed that installers fail to guarantee the minimum required levels of ventilation.

Advanced CFD (computational fluid dynamic) modelling by means of FLACS-CFD can help in improving ventilation/dilution levels in enclosed/open areas and improved detection times from common leaks, as well as gaining insight into the expected dispersion of ammonia upon accidental releases to the atmosphere. 

To learn more about the use of consequence modelling techniques to support your risk and safety management please click on the link below.

A more detailed presentation on this topic will be delivered by Pablo Giacopinelli at this month’s UK District Energy Association event entitled ‘Practical Application of Heat Pumps within District Energy Networks’ , which will be held on Wednesday 17th November 2021.

To find out more and to register, please visit our events page

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