API RP 581 - 3rd Ed.2016 - Add.2-2020 - Risk-Based Inspection Methodology
CONTENTS1 SCOPE .................................................................................................................................................... 12 REFERENCES ........................................................................................................................................ 12.1 Normative ....................................................................................................................................... 12.2 Informative ..................................................................................................................................... 13 GENERAL ............................................................................................................................................... 33.1 Overview ......................................................................................................................................... 33.2 Consequence Categories ............................................................................................................. 33.3 Collateral Damage ......................................................................................................................... 43.4 Overview of COF Methodology .................................................................................................... 43.4.1 General ................................................................................................................................... 43.4.2 Level 1 Consequence Analysis ............................................................................................ 43.4.3 Level 2 Consequence Analysis ............................................................................................ 43.5 COF Methodology for AST Bottoms and Shell Courses ........................................................... 53.6 COF Methodology .......................................................................................................................... 53.7 Area- and Financial-based COF ................................................................................................... 53.8 Use of Atmospheric Dispersion Modeling .................................................................................. 53.9 Tables ............................................................................................................................................. 63.10 Figures ............................................................................................................................................ 84 COF—LEVEL 1 ....................................................................................................................................... 94.1 Determine the Representative Fluid and Associated Properties ............................................. 94.1.1 Representative Fluids ........................................................................................................... 94.1.2 Fluid Properties ..................................................................................................................... 94.1.3 Choice of Representative Fluids for Acids and Caustic Fluids ........................................ 94.1.4 Estimation of Ideal Gas Specific Heat Capacity Ratio ....................................................... 104.1.5 Flammable Fluid Types ......................................................................................................... 104.1.6 Release Phase ........................................................................................................................ 104.1.7 Calculation of Release Phase ............................................................................................... 104.2 Release Hole Size Selection ......................................................................................................... 114.2.1 General ................................................................................................................................... 114.2.2 Calculation of Release Hole Sizes ....................................................................................... 114.3 Release Rate Calculation .............................................................................................................. 114.3.1 Overview ................................................................................................................................. 114.3.2 Liquid Release Rate Calculation .......................................................................................... 124.3.3 Vapor Release Rate Equations ............................................................................................. 124.3.4 Calculation of Release Rate ................................................................................................. 134.4 Estimate the Fluid Inventory Available for Release ................................................................... 134.4.1 Overview ................................................................................................................................. 134.4.2 Maximum Mass Available for Release (Available Mass) ................................................... 134.4.3 Calculation of Inventory Mass .............................................................................................. 144.5 Determine the Release Type (Continuous or Instantaneous) ................................................... 154.5.1 Release Type—Instantaneous or Continuous .................................................................... 154.5.2 Calculation of Release Type ................................................................................................. 154.6 Estimate the Impact of Detection and Isolation Systems on Release Magnitude .................. 154.6.1 Overview ................................................................................................................................. 154.6.2 Assessing Detection and Isolation Systems ...................................................................... 154.6.3 Impact on Release Magnitude .............................................................................................. 164.6.4 Impact on Release Duration ................................................................................................. 16
4.6.5 Releases to the Environment ............................................................................................... 164.6.6 Calculation for Detection and Isolation ............................................................................... 164.7 Determine the Release Rate and Mass for COF ......................................................................... 164.7.1 Continuous Release Rate ..................................................................................................... 174.7.2 Instantaneous Release Mass ................................................................................................ 174.7.3 Calculation of Release Rate and Mass ................................................................................ 174.8 Determine Flammable and Explosive Consequence ................................................................. 174.8.1 Overview ................................................................................................................................. 174.8.2 Consequence Area Equations .............................................................................................. 184.8.3 Adjustment of Consequence Areas to Account for Mitigation Systems ......................... 194.8.4 Adjustment of Consequence Areas for Energy Efficiencies ............................................. 194.8.5 Blending of Results Based on Release Type ...................................................................... 194.8.6 Blending of Results Based on AIT ....................................................................................... 204.8.7 Determination of Final Flammable Consequence Areas ................................................... 204.8.8 Calculation of Consequence Area ....................................................................................... 214.9 Determine Toxic Consequence .................................................................................................... 254.9.1 General .................................................................................................................................... 254.9.2 Common Refining Toxic Materials ....................................................................................... 254.9.3 Common Chemical Industry Toxic Materials ...................................................................... 254.9.4 Representative Fluids for Toxic Mixtures ........................................................................... 254.9.5 Determination of the Toxic Release Rate and Mass .......................................................... 264.9.6 Estimation of Toxic Consequence Area for HF Acid and H 2S ........................................... 264.9.7 Estimation of Toxic Consequence Area for Ammonia and Chlorine ............................... 274.9.8 Estimation of Toxic Consequence Area for Additional Common Chemicals.................. 274.9.9 Material Concentration Cut-off ............................................................................................. 284.9.10 Release Duration .................................................................................................................... 284.9.11 Toxic Outcome Probabilities ................................................................................................ 284.9.12 Consequence of Releases Containing Multiple Toxic Chemicals .................................... 294.9.13 Effects of Mitigation Measures on Toxic Releases ............................................................ 294.9.14 Determination of Final Toxic Consequence Areas ............................................................. 294.9.15 Calculation of Toxic Consequence Areas ........................................................................... 294.10 Determine Nonflammable, Nontoxic Consequence ................................................................... 304.10.1 General .................................................................................................................................... 304.10.2 Consequence of Steam Leaks .............................................................................................. 304.10.3 Consequences of Acid and Caustic Leaks ......................................................................... 314.10.4 Blending of Results Based on Release Type ...................................................................... 314.10.5 Determination of Final Nonflammable, Nontoxic Consequence Areas ............................ 314.10.6 Calculation of Nonflammable, Nontoxic Consequence Areas .......................................... 324.11 Determine the Component Damage and Personnel Injury Consequence Areas .................... 324.11.1 Overview ................................................................................................................................. 324.11.2 Final Component Damage Consequence Area ................................................................... 324.11.3 Final Personnel Injury Consequence Area ......................................................................... 334.11.4 Final Consequence Area ....................................................................................................... 334.11.5 Calculation of Final Consequence Area .............................................................................. 334.12 Determine the FC ........................................................................................................................... 334.12.1 Overview ................................................................................................................................. 334.12.2 Component Damage Cost ..................................................................................................... 344.12.3 Damage Costs to Surrounding Equipment in Affected Area ............................................ 344.12.4 Business Interruption Costs ................................................................................................. 354.12.5 Potential Injury Costs ............................................................................................................ 354.12.6 Environmental Cleanup Costs .............................................................................................. 364.12.7 Calculation of FC ................................................................................................................... 374.13 Nomenclature ................................................................................................................................. 38
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CONTENTS
1 SCOPE .................................................................................................................................................... 1
2 REFERENCES ........................................................................................................................................ 1
2.1 Normative ....................................................................................................................................... 1
2.2 Informative ..................................................................................................................................... 1
3 GENERAL ............................................................................................................................................... 3
3.1 Overview ......................................................................................................................................... 3
3.2 Consequence Categories ............................................................................................................. 3
3.3 Collateral Damage ......................................................................................................................... 4
3.4 Overview of COF Methodology .................................................................................................... 4
3.4.1 General ................................................................................................................................... 4
3.4.2 Level 1 Consequence Analysis ............................................................................................ 4
3.4.3 Level 2 Consequence Analysis ............................................................................................ 4
3.5 COF Methodology for AST Bottoms and Shell Courses ........................................................... 5
3.6 COF Methodology .......................................................................................................................... 5
3.7 Area- and Financial-based COF ................................................................................................... 5
3.8 Use of Atmospheric Dispersion Modeling .................................................................................. 5
3.9 Tables ............................................................................................................................................. 6
3.10 Figures ............................................................................................................................................ 8
4 COF—LEVEL 1 ....................................................................................................................................... 9
4.1 Determine the Representative Fluid and Associated Properties ............................................. 9
4.1.1 Representative Fluids ........................................................................................................... 9
4.1.2 Fluid Properties ..................................................................................................................... 9
4.1.3 Choice of Representative Fluids for Acids and Caustic Fluids ........................................ 9
4.1.4 Estimation of Ideal Gas Specific Heat Capacity Ratio ....................................................... 10
4.1.5 Flammable Fluid Types ......................................................................................................... 10
4.1.6 Release Phase ........................................................................................................................ 10
4.1.7 Calculation of Release Phase ............................................................................................... 10
4.2 Release Hole Size Selection ......................................................................................................... 11
4.2.1 General ................................................................................................................................... 11
4.2.2 Calculation of Release Hole Sizes ....................................................................................... 11
4.3 Release Rate Calculation .............................................................................................................. 11
4.3.1 Overview ................................................................................................................................. 11
4.3.2 Liquid Release Rate Calculation .......................................................................................... 12
4.3.3 Vapor Release Rate Equations ............................................................................................. 12
4.3.4 Calculation of Release Rate ................................................................................................. 13
4.4 Estimate the Fluid Inventory Available for Release ................................................................... 13
4.4.1 Overview ................................................................................................................................. 13
4.4.2 Maximum Mass Available for Release (Available Mass) ................................................... 13
4.4.3 Calculation of Inventory Mass .............................................................................................. 14
4.5 Determine the Release Type (Continuous or Instantaneous) ................................................... 15
4.5.1 Release Type—Instantaneous or Continuous .................................................................... 15
4.5.2 Calculation of Release Type ................................................................................................. 15
4.6 Estimate the Impact of Detection and Isolation Systems on Release Magnitude .................. 15
4.6.1 Overview ................................................................................................................................. 15
4.6.2 Assessing Detection and Isolation Systems ...................................................................... 15
4.6.3 Impact on Release Magnitude .............................................................................................. 16
4.6.4 Impact on Release Duration ................................................................................................. 16