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API RP 752 Management of Hazards Associated With Location of Process Plant Buildings, 2nd Edition
standard by American Petroleum Institute, 11/01/2003
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API RECOMMENDED PRACTICE 752 SECOND EDITION, NOVEMBER 2003
API RECOMMENDED PRACTICE 752 SECOND EDITION, NOVEMBER 2003
API publications necessarily address problems of a general nature. With respect to particu- lar circumstances, local, state, and federal laws and regulations should be reviewed.
API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws.
Information concerning safety and health risks and proper precautions with respect to par- ticular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.
Nothing contained in any API publication is to be construed as granting any right, by impli- cation or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.
Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect five years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Standards department telephone (202) 682- 8000. A catalog of API publications, programs and services is published annually and updated biannually by API, and available through Global Engineering Documents, 15 Inverness Way East, M/S C303B, Englewood, CO 80112-5776.
This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API stan- dard. Questions concerning the interpretation of the content of this standard or comments and questions concerning the procedures under which this standard was developed should be directed in writing to the Director of the Standards department, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Requests for permission to reproduce or trans- late all or any part of the material published herein should be addressed to the Director, Busi- ness Services.
API standards are published to facilitate the broad availability of proven, sound engineering and operating practices. These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices.
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All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher,
API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005.
Copyright © 2003 American Petroleum Institute
This publication is intended to assist management in identifying issues related to location of process plant buildings which might be of potential concern, understanding associated hazards, and managing risk. Among hazards that potentially could affect occupants of pro- cess plant buildings are: fire, explosion, and toxic releases. This publication provides a meth- odology for assessing and evaluating the hazards associated with location of process plant buildings. It is not an engineering guide for the design of blast-resistant buildings.
Serious accidental releases of toxic material or explosions that impact occupied process plant buildings are not frequent events. Preventing incidents in process plants is a better safety investment than providing mitigation systems or redesigning process plant buildings. The implementation of process safety management, as described in API’s historical Recom- mended Practice 750, publications of the AIChE CCPS and OSHA 1910.119 is intended to improve industry's safety performance. Risk management involves cost-effective applica- tions of risk-reduction alternatives.
Because this publication affects many existing buildings within processing facilities, a substantial effort may be required for full implementation of the recommended practice. This could include identifying buildings of concern, conducting building evaluations, and, if appropriate, performing building upgrades or modifications. It is recognized that a substan- tial period of time may be required for complete application of the recommended practice, due to the scope and magnitude of the endeavor.
This second edition of API RP 752 Management of Hazards Associated with Location of Process Plant Buildings recognizes that available information, publications and relevant ref- erences concerning specific PSM activities constitute a growing body of knowledge. A num- ber of resource publications are specifically referenced in the body of this standard while others are listed in Appendix A.
API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict.
Suggested revisions are invited and should be submitted to the standardization manager, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.
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Page
GENERAL 1
Purpose 1
Scope 1
Definitions 1
Referenced Publications 2
MANAGEMENT OVERVIEW 2
Hazards to Occupants of Process Plant Buildings 2
Process Plant Building Issues of Concern 3
Overview of Analysis Process 4
Using This Recommended Practice 4
Occupancy and Emergency Role Criteria 5
EXPLOSION ANALYSIS 7
Stage 1—Building and Hazard Identification 7
Stage 2—Building Evaluations 8
Risk Management 11
FIRES 14
Materials of Concern 14
Building Occupancy 14
Spacing 14
Mitigation and Emergency Response 14
Risk Reduction for Fire 16
TOXIC MATERIALS 16
Toxic Material of Concern 16
Building Occupancy 16
Site Conditions 16
Mitigation and Emergency Response 16
Risk Reduction for Toxic Release 18
BUILDING CHECKLIST 18
PROCESS SAFETY MANAGEMENT DILIGENCE 18
APPENDIX A BIBLIOGRAPHY FOR ADDITIONAL READING 19
APPENDIX B EXPLOSION, FIRE, AND TOXIC RELEASE PHENOMENA, AND HAZARDS TO THE OCCUPANTS OF PROCESS
PLANT BUILDINGS 21
APPENDIX C DAMAGE CATEGORIZATION FOR BUILDINGS AND VULNERABILITY OF OCCUPANTS TO EXPLOSION OVERPRESSURE 23
APPENDIX D PROCESS PLANT BUILDING CHECKLIST 27
APPENDIX E EXAMPLES 29
Figures
Stages for Explosion Risk Analysis 4
An Analysis Process for an Explosion 6
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Page
Sample Risk Matrix 12
An Analysis Process for a Fire 15
An Analysis Process for a Toxic Release 17
C-1 Sample Overpressure Versus Vulnerability 24
Tables
Examples of Process Safety Information Needs by Stage 7
Summary of Possible Explosion Effects on Buildings 9
Overpressure Effects on Various Building Components 10
Overpressure on Various Building Types 10
Typical Overpressure Effects on Unprotected People 11
Sample Risk-ranking Categories 13
C-1 Generic Frequencies of Major Explosions 25
vii
Management of Hazards Associated with Location of Process Plant Buildings
This publication provides guidance for identifying hazards that may affect process plant buildings and for managing risks related to those hazards. An analysis process set forth in this Recommended Practice provides a structured approach that can improve worker safety by the following:
Continuing to improve the understanding of identified hazards.
Continuing to focus on accident prevention and addressing identified hazards.
Managing risk.
The methodology recommended in this document will help provide the user with an understanding of the relative risk of each building studied. This relative risk should be considered in long-range planning and projects that involve building changes (such as control building consolidation, office build- ing replacements, and so forth).
This publication was developed for refineries, petrochemical and chemical operations, natural gas liquids extraction plants, and other facilities covered by the OSHA Process Management Standard, 29 CFR 1910.119. This publication does not apply to production facilities surrounded by navigable waters, such as offshore platforms or to storage tanks, wastewater tanks and similar facilities. Such facilities have unique siting issues which are addressed by other recommended practices, such as RP 14J for off-shore facilities.
Additionally, this publication is not intended for use in designing and locating safe refuge from the effects of fires, explosions, and toxic releases.
OSHA 29 Code of Federal Regulations (CFR) 1910.119, “Process Safety Management of Highly Hazardous Chemi- cals (PSM),” includes requirements for addressing facility sit- ing as part of a process hazards analysis (PHA).
This publication is intended to assist in identifying the sit- ing issues for process plant buildings, understanding the asso- ciated hazards, and managing the risk. Hence, this publication provides a framework that can be used to address facility sit- ing within the PHA requirements of OSHA 29 CFR 1910.119 as applied to buildings.
The PHA as required by OSHA 29 CFR 1910.119 is intended to identify scenarios that could lead to serious release of toxic or flammable materials or an explosion. Those parts of this publication intended to assist in the PHA process are iden- tified on the flowcharts (see Figures 2, 4, and 5) by a dashed- line box labeled “PHA.” The remaining parts are intended to serve as management aids in resolving issues that arise when evaluating the location of process plant buildings.
For the purpose of this publication, the following defini- tions apply:
1