Risk Assessment Tank Farm
Risk Assessment Tank Farm
Risk Assessment Tank Farm
AL I S AR I , P H . D . , P. E .
D I R E C T O R , O M E G A A D V A N C E D E N G I N E E R I N G A N D R I S K C O N S U LT I N G , “ O M E G A - R I S K ” , H O U S T O N , T X , U S A
A S S O C . P R O F. , I S T A N B U L T E C H N I C A L U N I V E R S I T Y, I S T A N B U L , T U R K E Y
N AT E C H R I S K M A N A G E M E N T W O R K S H O P 2 0 1 8
10 October 2018 1
Presentation Outline
Objectives
Process and Natural Hazards at Storage Tank Terminals
Risk Calculation Approach
Risk Criteria
Random Variables and Input Data for Risk Study
Frequency Assessment
Structural Consequence Assessment/ Structural Damage
Examples - Hazard Consequence and Individual Risk
Domino Effects
Conclusions
2
Objectives
Risk assessment for a hydrocarbon storage tank terminal requires due consideration of process and
non-process hazards;
To date, there is no a comprehensive approach, or a set of industry guidelines, or technical
publications available that address the risks from hazards such as fire, blast, toxic smoke, tornado,
lightning, earthquake, loss of containment (dike failure, etc.), forest fires and etc.;
A significant gap in the industry that lacks to combine the knowledge of process safety, advanced
structural analysis, and reliability together to accurately and reliably estimate the individual,
environmental and facility damage risks from such hazards.
Lastly, there is a considerable need for inclusion of domino (knock-on) effects in the analysis
whereby multiple failures and catastrophic events are initiated simultaneously or in very close
proximity to each other.
Conclusion: there is a need for a comprehensive, holistic approach for determining risk in and around
the hydrocarbon storage tank terminal accounting for domino effects.
3
Potential Process and Non-Process Hazards
PRIMARY EVENTS ESCALATIONS
(Secondary, Tertiary .. Events)
• Fire (pool fire, rim seal fire, pontoon fire,
Process roof spill fire, tank full surface fire, bund
fire and jet fire) - Boil-over
Hazards • Vapor Cloud Explosion
• Toxic*
- Dyke (Bund) Fire
- Full Surface Fire
(Single or Multiple Tank)
• Lightning
Natural • Seismic Event - Toxic Smoke
• Tornado - Loss of Containment
Hazards • Flooding/Rainstorm/Hurricane
- Forest Fire
- Explosion
• Terrorist Attack
Man – Made • Fire – Fighting /Tank Cooling Activities**
Hazards
4
Potential Hazards at Storage Tank Facilities: Containment Loss
Reasons of Containment Loss:
1.Tank Rupture due to fire, blast, tornado and seismic
2. Rainstorm water
3. Firefighting activities
Containment Loss
The 2017 Arkema plant explosion during Hurricane Harvey
in Crosby, Texas
Risk Assessment Flow Diagram
Tank and Process Information
P&IDs, Flow Diagrams, Fire-Fighting system
Shutdown Systems, Tank Utilization
• Risk due to hazards at a storage tank terminal and its surroundings is composed of summation of all risks
given no escalation (i.e. no domino effects) of undesired events and all risks given an escalation (i.e. domino
effects) of undesired events:
7
Risk Criteria – Major Industrial Accidents Council of Canada (MIACC)
9
Analysis Random Variables
Example Tank Utilization
0.0% 4.0% 8.0% 12.0% 16.0% 20.0% 24.0% 28.0% 32.0% 36.0%
Histogram
40.0% 44.0% 48.0% 52.0% 56.0% 60.0% 64.0% 68.0% 72.0% 76.0% 80.0% 84.0% 88.0% 92.0% 96.0%
100% 100%
Frequency
90% Cumulative F requency
90%
80% 80%
Cumulative Frequency
70% 70%
Frequency
60% 60%
50% 50%
40% 40%
30% 30%
20% 20%
10% 10%
0% 0%
0 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 27
Tank Contents (kbbl)
10
Analysis Input Data – Rain Precipitation
4.8 mm
100 yr
10 yr
3.4 mm
24 hr
Sumas Terminal
5 km
Source for
data collection 11
Seismic Hazard Curves – PGA vs frequency
• Site seismic hazard curves can be developed for a specific site; or
• Can also be obtained from the National Seismic Codes and modified based on local soil characteristics.
http://www.earthquakescanada.nrcan.gc.ca/hazard-alea/interpolat/index_2015-eng.php
12
Tornado Frequency Map
14
Modeling Procedure – Example Steel Cone Roof Tank
Structural Damage due to Blast
Finite element model of the tank includes:
• Tank
• Crude oil inside the tank
• Soil underneath the tank
Tank
1.2
θ=0 θ=10
Crude 1
θ=20 θ=30
θ=40 θ=50
Oil 0.8
θ=60 θ=70
θ=80 θ=90
θ=100 θ=110
P/Pr
0.6
θ=120 θ=130
θ=140 θ=150
0.4
θ=160 θ=170
θ=180
0.2
Soil 0
0 0.1 0.2 0.3 0.4 0.5
-0.2
Time
15
Blast Response of Tank (Example Case)
Deformation response (m): Ps=3.5 psi (24 kPa), td=0.5 sec
16
Structural Damage due to Fire
The modeling procedure includes following steps:
Step 1: Carry out a coupled heat transfer-CFD analysis to quantify the temperature evolution over the fire
exposed side of the tank.
Step 2: Carry out structural analysis to predict the performance of the tank at elevated temperature.
17
Results for Structural Analysis – External Floating Roof
Time to failure (ttf) of open roof tanks based on yield criterion:
1000 Utilization: 25% 1000
Utilization: 50%
Landucci method
Landucci method
FEM
FEM
100 100
10 10
0 50 100 150 200 0 50 100 150 200
Heat flux (kW/m2) Heat flux (kW/m2)
1000
Utilization: 75% Landucci method
FEM_yield
Time to Failure (sec)
100
10
0 50 100 150 200
Heat flux (kW/m2)
18
Fragility Curves for On-grade Steel Tanks with % Full > 50%
Damage States
DS1 No damage to tank or I/O pipes
DS1
DS2 Damage to roof, minor loss of
contents, minor damage to
piping, but no elephant-foot
buckling
DS5
20
Seismic Damage State vs Loss of Containment
Elephant-foot buckling
21
91
Thermal Radiation Contours due to Dike Fire at Tank 85 (10m/s Wind) -
93 95 97
78
Example 76
74
82 84 86 80
14
77
100 72
12 75
50
10
89
0 83 85 71 8 73
6
-50
4
-100
2
-150
-200 -150 -100 -50 0 50 100 150 200
22
Thermal Radiation Contours for Tank Full Surface Fire (Example Case)
Envelop Max. Thermal Radiation from 5 Tanks
Random Variables:
- Wind Speed
- Wind Direction
- Tank Utilization
23
Individual Risk Contours for Tank Full Surface Fire
Random Variables:
- Wind Speed
- Wind Direction
- Tank Utilization
24
Individual Risk Contours without Domino Effects
Red color indicates 1.0E-04; Blue color: 1.0E-12
University and Residence: 1.0E-07 - 1.0E-06
25
Domino Effects
FARID KADRI, E. CHATELET, PATRICK LALLEMENT. THE ASSESSMENT OF RISK CAUSED BY FIRE AND
EXPLOSION
IN CHEMICAL PROCESS INDUSTRY: A DOMINO EFFECT-BASED STUDY. JOURNAL OF RISK ANALYSIS
26
A Dike Fire that leads to Tank Full Surface Fires and Boil-Over- illustration
101 102
Fire Impingement
27
A Dike Fire that leads to Tank Full Surface Fires and Boil-Over
28
Individual Risk Contours with Domino Effects
Red color indicates 1.0E-04; Blue color: 1.0E-12
University and Residence: 1.0E-06 - 1.0E-05
29
Conclusions
A comprehensive, holistic approach is required for determining risk in and around the
hydrocarbon storage tank terminal accounting for domino effects.
A proposed approach in this presentation closes the gap in the industry and combines the
knowledge of process safety, advanced structural analysis, and reliability together to
accurately and reliably estimate the individual, environmental and facility damage risks from
process and non-process hazards.
Analysis results show that domino effect may have a significant impact on the overall
risk calculation such that neglecting this effect can lead to overly low estimation in risk
studies.
30
THANK YOU!
Thank You! Questions??
Contact Details
Dr. Ali Sari, P.E.
Director
“Omega-risk”
E-mail: [email protected]
Potential Fire Scenarios at Tank Terminal
The most severe types are full surface fire and boil-over.
A full surface fire is where the tank roof has lost its buoyancy and some or all of the
surface of liquid in the tank is exposed and then involved in the fire
ARGYROPOULOS, C.D., CHRISTOLIS, M.N., NIVOLIANITOU Z., MARKATOS, N.C. “A HAZARDS ASSESSMENT METHODOLOGY FOR
LARGE LIQUID HYDROCARBON FUEL TANKS”. JOURNAL OF LOSS PREVENTION IN THE PROCESS INDUSTRIES. S.L. : ELSEVIER, 32
MARCH 2012. VOL. 25, 2, PP. 329-335.
Potential Fire Scenarios at Tank Terminal
Potential fire scenarios that can be developed in a tank accident include:
As shown in the diagram, relatively small fires initiated on the roof may lead to full
surface fire on a single tank. A full surface fire, if not extinguished, may lead to a
more severe fire scenarios such as boil-over on the same tank and/or full surface
fire on near-by tanks.
Shaluf, I.M., Abdullah, S.A., “Floating roof storage tank boilover”, Journal of Loss Prevention in the Process Industries, 2001.
33
Past Fire Hazard
https://www.flickr.com/photos/dowgor/2969303992/in/photostream/ http://www.williamsfire.com/libraries/code_red/boilover_sleeping_giant.pdf
• Overfilling
• Leaking from worn-out and corroded containment
• Loss of containment due to pipeline ruptures.
• Generation of combustible vapors that can be formed from the mixtures of
combustible liquids stored in storage tank.
35
Past Explosions
U.S. Chemical Safety and Hazard Investigation Board U.S. Chemical Safety and Hazard Investigation Board
Buncefield Major Incident Investigation Board Buncefield Major Incident Investigation Board
Tank farm fires after Kocaeli Earthquake Sloshing damage to upper shell and roof
(1999) in Turkey of tank during 1999 earthquake in
Turkey
38
Toxic Smoke
39
Toxic Smoke
• The hazard caused by smoke and toxic
gases is characterized by:
o plume dispersion rates
o height elevation
o the ground level concentration of
toxic pollutants.
International Business Times
• The smoke may contain toxic pollutants such as Sulphur dioxide (SO2), carbon
monoxide (CO), polyaromatic hydrocarbons (PAHs), and volatile compounds
(VOCs).
• Highly toxic Hydrogen Sulfide (H2S) could very quickly expose residential areas
to immediately life threatening conditions.
• Smoke containing Sulphur Dioxide (SO2) is potential health concern which could
be felt up to at least a couple of kilometers away.
40
Tolerability of Environmental Risk (Category Definitions) – Loss of Containment
Category Definitions
- Major airborne release with serious off-site effects
- Site shutdown
6 Catastrophic
- Serious contamination of groundwater or water course with extensive loss of
aquatic life
- Evacuation of local populace
- Temporary disabling and hospitalization
5 Major - Serious toxic effect on beneficial or protected species
- Widespread but not persistent damage to land
- Significant fish kill over 5-mile range
- Hospital treatment required
4 Severe - Public warning and off-site emergency plan invoked
- Hazardous substance releases into water course with 1/2-mile effect
- Severe and sustained nuisance, e.g. strong offensive odors or noise
disturbance
3 Significant
- Major breach of permitted emissions limits with possibility of prosecution
- Numerous public complaints
- Noticeable nuisance off-site, e.g. discernible odors
2 Noticeable - Minor breach of permitted emission limits, but no environmental harm
- One or two complaints from the public
- Nuisance on site only (no off-site effects)
1 Minor
- No outside complaint.
UK HSE, “Safety and environmental standards for fuel storage sites”, Process Safety Leadership Group, 2009. 41
Environment Agency for England and Wales, “Integrated Pollution Prevention and Control (IPPC) Environmental Assessment and Appraisal of BAT”, July 2003
Tolerability Criteria of Environmental Risk
6 Catastrophic 1.0E-06 per year 1.0E-04 to 1.0E-06 per year 1.0E-04 per year
5 Major 1.0E-06 per year 1.0E-04 to 1.0E-06 per year 1.0E-04 per year
4 Severe 1.0E-06 per year 1.0E-02 to 1.0E-06 per year 1.0E-02 per year
3 Significant 1.0E-04 per year 1.0E-01 to 1.0E-04 per year 1.0E-01 per year
2 Noticeable 1.0E-02 per year ~1.0E+01 to 1.0E-02 per year ~1.0E+01 per year
All shown as
1 Minor - -
acceptable
Broadly
Acceptable Region
Tolerable if ALARP Intolerable Region
Region
UK HSE, “Safety and environmental standards for fuel storage sites”, Process Safety Leadership Group, 2009. 42
Environment Agency for England and Wales, “Integrated Pollution Prevention and Control (IPPC) Environmental Assessment and Appraisal of BAT”, July 2003
Leak Frequency
Leak Frequency
Type of Tank Type of Release
(per tank year)
Liquid spill outside tank 2.8E-03
Fixed/floating roof
Tank rupture 3.0E-06
43
Event Frequency
Event Frequencies Based on OGP Report No. 434-3
Fixed plus Internal
Floating Roof Tank (per Fixed Roof Tank (per
Event Floating Roof Tank (per
tank year) tank year)
tank year)
CFD CFD
Concentration
45
Tornado Fujita Scale Descriptions
46
Ref: https://en.wikipedia.org/wiki/Fujita_scale
Calculations Methodology for Loss of Containment
• In general, the total volume of liquid to be contained in a secondary
containment is considered to include three portions:
Oil spilled from the tank;
Rain water;
Fire-fighting liquid (in a fire event).
47
General Risk Assessment Scheme Using Monte Carlo Simulations
Total individual risk, including domino effects, can be estimated using Monte Carlo simulations;
Random variables include the wind speed and direction, tank utilization, seismic hazard curves in the
case the primary event is an earthquake, tornado information (intensity, path, width) if the primary
event is a tornado;
Main steps in Monte Carlo simulations are illustrated in figure below:
48
Probability of Fatality using TNO Purple Book
Human Vulnerability – Toxic SO2 Exposure
1
5 min.
0.9 10 min.
30 min.
0.8 60 min.
120 min.
0.7 180 min.
0.6
Probility
0.5
0.4
0.3
0.2
0.1
0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Concentration (ppm)
49
Individual Risk Contours for Toxic Smoke (CO and SO2)
Tank Full Surface Fire
50
Individual Risk Contours for Toxic Smoke (CO and SO2)
Secondary Containment Fire
51
Tornado Impact - Example
• Flipped Empty Oil Tank after Tornado in Edmonton in 1987
Ref: http://www.sherwoodparknews.com/2012/08/03/photographer-recalls-black-friday
52
Terrorist Attacks
• Tank Failure, Baghdad, Iraq in May 2016 that was caused by terrorist attack.
At least 14 people were killed on Sunday in an attack by the militant group at a gas plant near Baghdad,
http://www.newindianexpress.com/world/2016/may/16/14-killed-in-IS-suicide-bombing-at-gas-plant-in-Iraq-904247.html
53
Risk Calculation Given No Escalation
𝑁
𝑃(𝐹𝐼𝐼) = 𝑃 𝐹𝐼 𝐴𝑖 × 𝑃 𝐴𝑖 × 𝑃(𝐼 𝑎𝑡 𝐴𝑖 )
Where, 𝑖
The probability of individual present when an accidental event occurs will be estimated based on the working
schedules of the personnel on site, for example if an individual works 50 hours a week, this probability can be
estimated as 50/(7x24hrs) = 50/168 or 0.30. For the people outside the boundary of the terminals, this
probability will be assumed to 100%, i.e. 100% of the time an individual is present given an accidental event
occurs.
54
Risk Calculation Given Escalation
𝑁
𝑃(𝐹𝐼𝐼|𝐸) = 𝑖 𝑃 𝐼 𝐸𝑖 × 𝑃 𝐴𝑖 × 𝑃 𝐸𝑖 |𝐴𝑖 × 𝑃(𝐹𝐼|𝐸)
Where,
P(FII|E) = probability of an individual experiencing a fatal injury given an escalation;
P(I|Ei) = probability of an individual present given an escalation occurs;
P(Ai) = probability of an accidental event (Ai) occurring;
P(Ei|Ai) = probability of an escalation occurring given an event
P(FI|E) = probability of an FI occurring given an escalation occurs, i.e. human
vulnerability at certain escalation level;
N = number of events in fire, blast, seismic, etc.
55
Loss of Containment – Scenario 1
Area ≈ 50000 m2
56
Loss of Containment – Scenario 1
Thermal Radiation Contours (10 m/s Wind)
Thermal Radiation (kW/m2) contours
1200 14
1100
96 98
12
1000
78
91 93 95 97 76
900 74 10
79
800 88 90 82 84 86 80 77
72
75
700 8
87 81 83 85 89 71 73
600
6
500
10 m/s Wind
400 4
300
2
200