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FRA ASSUMPTION REGISTER

Table of Contents
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Page

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 PROJECT INFORMATION .............................................................................................. 8 2.1 Project Title ........................................................................................................... 8 2.2 Definitions.............................................................................................................. 8 2.3 Abbreviations ........................................................................................................ 8 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 FRA ASSUMPTION REGISTER .................................................................................... 13

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Sections Revised in this Issue No. Section Paragraph

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1.
1.1

PROJECT DESCRIPTION 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. 2. 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.

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3. 4. 5.

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.

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.

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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 3C 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 semiautomatic 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.

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2.
2.1

PROJECT INFORMATION 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 CONSULTANT AKZO NOBEL, INDONESIA M/s. Tebodin Consultants and Engineers India Ltd; (TCEI), appointed by the COMPANY (AKZO NOBEL, INDONESIA) to perform PROJECT. The contract between COMPANY (AKZO NOBEL) and CONSULTANT (TCEI) for PROJECT (FRA AND HAC ZONING FOR AKZO NOBEL). FRA AND HAC ZONING FOR AKZO NOBEL Services being provided by TEBODIN as per the CONTRACT for the PROJECT Tebodin Consultants and Engineers India Ltd;

CONTRACT

PROJECT SERVICES TEBODIN

2.3

Abbreviations
AFP API FRA HA HAC HSD IP MTO MTS NFPA OGP PFD PFP PID QC TCEI VCE Active Fire Protection American Petroleum Institute Fire Risk Assessment Hectares Hazardous Area Classification High Speed Disperser Petroleum Institute Made to Order Made to Stock National Fire Protection Association Oil & Gas Producers Process Flow Diagram Passive Fire Protection Piping and Instrumentation Diagram Quality Control Tebodin Consultants and Engineers India Vapour Cloud Explosion

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3.

FRA METHODOLOGY
The methodology adopted for this FRA is presented graphically below:

Figure 2: FRA methodology

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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. 1. 2. 3. 4. 5. 6. 7. FRA Project Scope Atmospheric Conditions Scenarios Process Conditions and Material Composition Release size, Height, Duration and Direction Impact criteria Vulnerability Description

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL FRA Project Scope All Rev.: A Assumption No. Date: 1 08/10/2013

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.

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL FRA Project Scope All Rev.: A Assumption No. Date: 1 08/10/2013

The Tank cleaning area is considered to have minimal amount of hazardous material capable of causing fire/explosion as its 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:

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Atmospheric Condition All Rev.: A Assumption No. Date: 2 08/10/2013

Ambient Conditions [Ref. 1] 1. 2. 3. 4. Average Ambient Temperature Average Barometric Pressure Average Relative Humidity Solar Radiation : 28 C : 1 bar : 64 % : 0.882 kW/m2

The Pasquill Atmospheric Stability Classes Table 1: Pasquill Stability Class Stability Class A B C D E F Definition Very Unstable Unstable Slightly Unstable Neutral Slightly Stable 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: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Atmospheric Condition All Rev.: A Assumption No. Date: 2 08/10/2013

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) N NNE NE ENE E ESE SE SSE S SSW SW WSW W WNW NW NNW Total Surface Roughness The ground characteristics are represented by surface roughness which will be assumed as 0.1m (10cm) Low crops, occasional large obstacles. Weather Class / Wind speed Probability F2 0.059 0.035 0.012 0.010 0.008 0.008 0.008 0.014 0.021 0.021 0.021 0.017 0.013 0.018 0.023 0.041 0.326 C5 0.078 0.049 0.020 0.019 0.019 0.014 0.009 0.019 0.028 0.028 0.029 0.018 0.007 0.013 0.020 0.049 0.416 C/D7 0.024 0.023 0.021 0.024 0.027 0.016 0.004 0.007 0.009 0.015 0.021 0.012 0.003 0.005 0.007 0.015 0.232 D9 0.001 0.003 0.005 0.004 0.003 0.001 0.000 0.000 0.001 0.002 0.003 0.001 0.000 0.000 0.000 0.001 0.025 TOTAL 0.162 0.110 0.058 0.057 0.056 0.038 0.021 0.040 0.059 0.066 0.073 0.047 0.022 0.035 0.049 0.105 1.000

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Atmospheric Condition All Rev.: A Assumption No. Date: 2 08/10/2013

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:

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set: Scenario:

FRA FOR AKZO NOBEL AKZO NOBEL Scenarios All Rev.: A Assumption No. Date: 3 08/10/2013

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

Loss of containment from Diesel Storage Tank Loss of containment from Drums in Raw material storage area Loss of containment from Big Tank Loss of containment from Drums/Tanks Mobile Tank area Loss of containment from Drums in Mixing Room

Loss of containment from Drums in SFG Storage

Loss of containment from Drums in Cold Room Loss of containment from Drums in Transfer Area Loss of containment from Drums in Filling Hardener Area Loss of containment from Drums in Color WareHouse

10

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set: 11

FRA FOR AKZO NOBEL AKZO NOBEL Scenarios All Rev.: A Assumption No. Date: 3 08/10/2013

Loss of containment from Drums in Drum Yard Loss of containment from Drums Outside Drum Yard Loss of containment from Tank in Tank Area Loss of containment WareHouse from Drums/cans in

12

13

14 Reference:

TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

Table 4: Process and Operating Conditions: The following table represents the Process and Operating conditions for this study: Quantity (liters) 2000 Operating Pressure (barg) Amb Operating Temp. o ( C) Amb

Scenario

Description Loss of containment from Diesel Storage Tank Loss of containment from Drums in Raw material storage area1 Loss of containment from Big Tank 2

Phase

Material

Composition*

Liquid

Diesel

N-Undecane Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% Toluene: 60 % n-Butanol: 40 %

Liquid

SETALUX 1160 XS 51

2000

Amb

Amb

Liquid

Dianal DG 4040

3050

Amb

Amb

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Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

Loss of containment from Drums/Tanks Mobile Tank area3

Liquid, Resin

Exxsol DSP 80/100

n-hexane: (15-20)% Heptane & isomers: (3236)% Cyclohexane: (25-27)% Methylcyclohexane: (3-7)% n-hexane: (15-20)% Heptane & isomers: (3236)% Cyclohexane: (25-27)% Methylcyclohexane: (3-7)% n hexane: 25% xylene:25% toluene: 15% cyclohexane:15% pentane:15% heptane:5% n-hexane: (15-20)% Heptane & isomers: (3236)% Cyclohexane: (25-27)%

2000

Amb

Amb

Loss of containment from Drums in Mixing Room 4

Liquid

EXXSOL DSP 80/100

500

Amb

Amb

Loss of containment from 5 Drums in SFG Storage

Liquid

Exxsol D30

10000

Amb

Amb

Loss of containment from 6 Drums in Cold Room

Liquid

EXXSOL DSP 80/100

700

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

Methylcyclohexane: (3-7)% 8 Loss of containment from 7 Drums in Transfer Area Loss of containment from Drums in Filling Hardener Area8 Loss of containment from 9 Drums in Color WareHouse Liquid SETALUX 1160 XS 51 SETALUX 1160 XS 51 SETALUX 1160 XS 51 Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% n hexane: 25% xylene:25% toluene: 15% cyclohexane:15% pentane:15% heptane:5% n-butanol 2500 Amb Amb

Liquid

2500

Amb

Amb

10

Liquid

1700

Amb

Amb

11

Loss of containment from 10 Drums in Drum Yard

Liquid

Exxsol D30

5200

Amb

Amb

12

Loss of containment from Drums Outside Drum Yard 11

Liquid

Butanol Normal

825

Amb

Amb

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run: Assumption/ Rule Set: 13

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

Loss of containment from Tank in Tank Area

Liquid

n-Butyl Acetate

n - Butyl Acetate n hexane: 25% xylene:25% toluene: 15% cyclohexane:15% pentane:15% heptane:5%

1200

Amb

Amb

14

Loss of containment from 12 Drums/cans in WareHouse

Liquid

Exxsol D30

800

Amb

Amb

Note: * - Composition taken up such that it is accepted by DNVs 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 tanks 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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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run:

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

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 Tanks final outlet i.e., 3 tonnes of product is being sent to Transfer Area at one possible time. Hence, Transfer Areas 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

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run:

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

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:

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run: Assumption/ Rule Set: Release Size

FRA FOR AKZO NOBEL AKZO NOBEL Release Size, Height, Duration & Direction All Rev.: A Assumption No. Date: 5 08/10/2013

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:

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Impact Criteria All Rev.: A Assumption No. Date: 6 08/10/2013

The following impact criteria shall be used for this FRA study: Table 5: Impact Criteria [Ref 1] Accident Hazards Criteria 6 Unit kW/m2 Assessment Impairment of escape routes Extreme pain within 20s; movement to shelter is instinctive; fatality if escape is not possible. Outdoors/offshore: 70% lethality Indoors onshore: 30% lethality* 20 Incapacitation, leading to fatality unless rescue is done quickly. Immediate fatality (100% lethality)

12.5 Thermal Flux 20

kW/m2

kW/m

35

kW/m2

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:

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FRA ASSUMPTION REGISTER

Project: Client: Assumption Calculation Run: Assumption/ Rule Set:

FRA FOR AKZO NOBEL AKZO NOBEL Vulnerability All Rev.: A Assumption No. Date: 7 08/10/2013

The following Table represents the Indoor / Outdoor vulnerabilities for this FRA Study: Table 6: Indoor / Outdoor Vulnerabilities Scenario Flash Fire (inside flame envelope) Jet Fire, Pool Fire ( 35 kW/m2) Indoor Vulnerability 0.2 0.2 Outdoor Vulnerability 0.7 0.7

Reference:

TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:

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