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Job 1
at Dow
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Calculations
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HAZOP
and
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I to 4
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Inspection
Yearly
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Reactive
C hemical
R eviews
NIOSH Data
NIOSH stands for National Institute for
Occupational Safety and Health.
Lookup your chemical on the NIOSH
Pocket Guide to Chemical Hazards.
http://www.cdc.gov/niosh/npg/npg.html
As soon as you know you have a
certain chemical, extract the following
NIOSH data:
NIOSH STEL
Short term exposure limit (STEL) is a
15 minute time weighted average (TWA)
exposure limit that should not be
exceeded at any time during a workday.
NIOSH IDLH
IDLH stands for Immediately dangerous
to life and health.
IDLH represents the maximum
concentration from which, in the case
of respirator failure, one could escape
within 30 minutes without a respirator
and without experiencing any escapeimpairing or irreversible effects.
NIOSH Flammability
LEL = Lower Explosive Limit aka LFL
for Lower Flammable Limit in vol% in
air at room temperature.
UEL = Upper Explosive Limit aka UFL
for Upper flammable Limit in vol% in air
at room temperature.
Flash Point (Fl.P.) using either closed
cup (cc) or open cup (op) methods.
NIOSH Incompatibilities
NIOSH give the important hazardous
incompatibilities or reactivities of each
substance.
This is where I would look for
polymerization potential and the need
to take special preventative action
should a polymerization reaction start
to generate high heat of reaction.
OSHA Classification of
Flammables
Class 1A flammable liquid. Fl.P. below
73F and BP below 100F.
Class 1B flammable liquid. Fl.P. below
73F and BP above 100F.
Class 1C flammable liquid. Fl.P. at or
above 73F and below 100F.
MSDS Information
MSDS stands for Material Safety Data Sheets.
A repeat of NIOSH data.
Most large companies publish their MSDS on
the internet.
Often six different MSDS sets of one
chemical are compared and a consensus is
taken to resolve differences in toxic and
flammability data particularly auto ignition.
(NH3 as an example).
Log10(P) =A +B/(t+C)
Basis
P1 =
P2 =
P3 =
C=
B=
B=
Diff =
Ethylene Oxide
EO
C2H4O
MW =
44
P in psia and t in C
psia
psia
psia
t1 =
t2 =
t3 =
4.44
32.22
60.00
C
C
C
LEL =
Atm Press =
14.696
psia
F
40
90
140
Vapor Pressure of EO
80.00
70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
0.00
20.00
40.00
Temperature, C
60.00
80.00
MIACC or RMP?
Check to see if your chemical is listed
on the Major Industrial Accident
Coordinating Committee List.
Check to see if your chemical is listed
on the U.S. Risk Management Plan List.
These lists tell you whether or not you
need to take toxic or flammable
preventative measures in your design.
U.S. RMP
The U.S. RMP method is now favored in
Canada over the CDN MIACC method.
If your chemical is on the list and if your
quantity exceeds the specified threshold
quantity, you must run the RMP program to
determine the environmental impact on the
public and file the results with the EPA.
The EPA will approve your plant design if you
have developed a suitable emergency
response plan with the public.
Fire Protection
National Fire protection Association (NFPA)
No. 30 Flammable & Combustible Liquids
Code
No. 58 Liquified Petroleum Gases, Stg &
Hdlg.
No. 59 Liquified Petroleum Gases at Utility
Gas Plants.
PSV Design NFPA 30
PSV Design API-520 & API-521
Drainage
NFPA 30 - 2-3.3 Control Of Spillage From
Aboveground Tanks (see PSV Size & Cost
V3.7)
Dyking
Dyke Dimensions on CD-ROM
Dyke L =
S
18.87
61.38
58.73
2.65
Dia
S
21
18.87
Ht = 21
2.11
above grade, h
H Ab Hole = 9.89
Hole Ht, h = 9.00
18.89
18.89
slope
S = 18.87
EO Storage
Sizing PV Contd
Select Corrosion Allowance ca,
usually 1/16 inch for inside.
May have to allow 1/16 inch for outside
corrosive atmospheres near Cl2
plant.
Select materials from data base.
Select Joint Efficiency, E, = 0.85 or 1.0
Select flange rating = 150 lb, 300 lb or ?
Flange Data
PRESSURE - TEMPERATURE RATINGS FOR STEEL PIPE FLANGES AND FLANGED FITTINGS
American National Standard ANSI B16.5 - 1977
Class
Hydro TP, psig
Temp, Deg F
-20 TO 100
200
300
400
500
600
650
700
750
800
850
900
950
1000
150 lb
300 lb
400 lb
600 lb
900 lb
1500 lb
450
1125
1500
2225
3350
5575
MAXIMUM ALLAOWABLE NON-SHOCK PRESSURE, PSIG
285
740
990
1480
2220
3705
260
675
900
1350
2025
3375
230
655
875
1315
1970
3280
200
635
845
1270
1900
3170
170
600
800
1200
1795
2995
140
550
730
1095
1640
2735
125
535
715
1075
1610
2685
110
535
710
1065
1600
2665
95
505
670
1010
1510
2520
80
410
550
825
1235
2060
65
270
355
535
805
1340
50
170
230
345
515
860
35
105
140
205
310
515
20
50
70
105
155
260
2500 lb
9275
6170
5625
5470
5280
4990
4560
4475
4440
4200
3430
2230
1430
860
430
Sizing Contd
Cylindrical Shell thickness = t where
t = (P)(R) / [(S)(E) - (0.6)(P)]
P = Design Pressure, psig, aka MAWP for
Maximum allowable Working pressure.
R = Vessel radius, inches
S = Stress value of material, lb/sq. inch
E = Joint Efficiency = 0.85 or 1.0
P = (S)(E)(t) / [R + (0.6)(t)]
Sizing Cond
2:1 Ellipsoidal head
t = (P)(D) / [(2)(S)(E) - (0.2)(P)]
Final tf = [t + ca] rounded to next
thickness
P = (2)(S)(E)(tf) / [(D) + (0.2)(tf)] where P
is now the back-calculated Design
Pressure
Units same as above.
Results Contd
Tp rounded, in. =
Twind, in. =
Tgirth, in. =
Tb =Tw+Tg =
Tb rounded, in. =
Tb final, in. =
Top Thk+CA, in.
Btm Thk+CA, in.
Avg thk top to btm
Wt Shell, lb =
Cs Max, FOB Vendor
Cs, Avg, FOB Vendor=
Cs Min., FOB Vendor
Internals Cost
Total Est'd Cost
Act Cost FOB Vendor
Actual Freight
Actual Cost =
0.25000
0.00584
0.11214
0.11798
0.18750
0.25000
0.25000
0.25000
0.25000
2,140
$34,550
$31,444
$28,337
$1,044
$32,487
$0
$0
$0
Min. Thk =
0.18750
Special Cost
Est'd Cost
Factor
Range
1.00
$34,550
1.00
$31,444
1.00
$28,337
Shop Installed Demister
1.0000
End of Presentation
Good luck with your storage tank
designs.
Any questions?
If you have questions later, email me at
richardhaw@sympatico.ca