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Process Safety Formula Sheet

The document provides formulas and guidelines for calculating evaporation rates, vapor concentrations, risk matrices, and more. It includes Raoult's law for calculating partial vapor pressures, Dalton's law for total pressure of a vapor mixture, and equations for lower and upper flammability limits accounting for temperature and pressure. Guidelines are given for calculating minimum oxygen content, vapor concentration in enclosures, hood flowrates, and non-ideal mixing factors. A 5x5 risk matrix is defined using likelihood and severity ratings to determine risk priority numbers.

Uploaded by

Kumaravel Padmaroopa
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
124 views

Process Safety Formula Sheet

The document provides formulas and guidelines for calculating evaporation rates, vapor concentrations, risk matrices, and more. It includes Raoult's law for calculating partial vapor pressures, Dalton's law for total pressure of a vapor mixture, and equations for lower and upper flammability limits accounting for temperature and pressure. Guidelines are given for calculating minimum oxygen content, vapor concentration in enclosures, hood flowrates, and non-ideal mixing factors. A 5x5 risk matrix is defined using likelihood and severity ratings to determine risk priority numbers.

Uploaded by

Kumaravel Padmaroopa
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Formula Sheet

Raoults Law

Pi = Pi* xi

• Pi is the partial pressure of component i in the vapour mixture above the liquid
mixture
• Pi* is the equilibrium vapour pressure of pure component i
• xi is the liquid mole fraction of component i in the liquid mixture

Dalton’s Law

𝑃𝑃𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = ∑𝑛𝑛𝑖𝑖=1 𝑃𝑃𝑖𝑖

• Pi is the partial pressure of component i in the vapour mixture above the liquid
mixture

LFL and UFL of gas/vapour mixture:


1
𝐿𝐿𝐿𝐿𝐿𝐿𝑚𝑚𝑚𝑚𝑚𝑚 = 𝑦𝑦𝑖𝑖
∑𝑛𝑛
𝑖𝑖=1 𝐿𝐿𝐿𝐿𝐿𝐿𝑖𝑖

1
𝑈𝑈𝑈𝑈𝑈𝑈𝑚𝑚𝑚𝑚𝑚𝑚 = 𝑦𝑦𝑖𝑖
∑𝑛𝑛
𝑖𝑖=1𝑈𝑈𝑈𝑈𝑈𝑈
𝑖𝑖

Temperature correction for LFL & UFL of gas/vapour mixture:

𝑇𝑇 − 25
𝐿𝐿𝐿𝐿𝐿𝐿 𝑇𝑇 = 𝐿𝐿𝐿𝐿𝐿𝐿25 �1 − 0.75( )�
∆𝐻𝐻𝑐𝑐

𝑇𝑇 − 25
𝑈𝑈𝑈𝑈𝑈𝑈 𝑇𝑇 = 𝑈𝑈𝑈𝑈𝑈𝑈25 �1 + 0.75( )�
∆𝐻𝐻𝑐𝑐
 ΔHc is heat of combustion for component in kcal/mol
 T is in °C
Pressure correction for UFL of gas/vapour mixture:

𝑈𝑈𝑈𝑈𝑈𝑈𝑝𝑝 = 𝑈𝑈𝑈𝑈𝑈𝑈 + 20.6(𝐿𝐿𝐿𝐿𝐿𝐿10 𝑃𝑃 + 1)

 P is in MPa absolute
 1 atm = 0.101 MPa

Minimum Oxygen Content (MOC)

Mole O
MOC = LFL % 2

Mole Fuel

Evaporation rate of a liquid:

𝑀𝑀𝑀𝑀𝑀𝑀𝑃𝑃 𝑠𝑠𝑠𝑠𝑠𝑠
Qm =
R𝑇𝑇𝐿𝐿

1
18 3 𝑓𝑓𝑓𝑓
where K= 1.634 � �
𝑀𝑀 min

• Qm is the evaporation rate, lb/min


• M is the molecular weight of the volatile substance, lb/lbmol
• Psat is the saturation vapour pressure of the pure liquid volatile at temperature
of the liquid, atm
• K is mass transfer coefficient (length/time) for an area A, ft/min
• A is the evaporating area of the volatile substance, ft2
𝑓𝑓𝑡𝑡 3 ∙atm
• R is the universal gas constant,
lbmole∙°R
• TL is the absolute temperature of the liquid, oR
Concentration of volatile vapour in enclosures with ventilation:

× 106
Qm RT
𝐶𝐶𝑝𝑝𝑝𝑝𝑝𝑝 =
kQv PM

or

KAP sat
𝐶𝐶𝑝𝑝𝑝𝑝𝑝𝑝 = × 106
kQ v P

or

P sat
𝐶𝐶𝑝𝑝𝑝𝑝𝑝𝑝 = (∅𝐹𝐹 + 𝐾𝐾𝐾𝐾) × 106
kQvP

• Cppm is the vapour concentration of the volatile substance in the enclosure, ppm

• Qm is the evaporation rate, lb/min


𝑓𝑓𝑓𝑓 3 ∙atm
• R is the universal gas constant,
lbmole∙°R
• T is the absolute ambient temperature, oR
• P is the absolute pressure, atm
• M is the molecular weight of the volatile substance
• k is the non-ideal mixing factor varies from 0.1 to 0.5
• Qv is the ventilation rate of the enclosure (ft3/min)
• Psat is the saturation vapour pressure of the pure liquid volatile at temperature of
the liquid, atm
• K is mass transfer coefficient for an area A, ft/min
• F is the filling rate, ft3/min
• A is the evaporating area of the volatile substance, ft2
• For splash filling; ∅ = 1.0
• For subsurface filling; ∅ = 0.5

Hood Calculations

Qv = LWū

• Qv is the volumetric flowrate of the fumehood, ft3/min


• L is the length of the fumehood, ft
• W is the width of the fumehood, ft
• Ū is the required control velocity (face velocity) of the fumehood, ft/min
Non-ideal mixing factor k for various dilution ventilation condition:

Vapour Mixing Factor (k) for mixing condtion


Concentration Poor Average Good Excellent
(ppm)
Over 500 1/7 1/4 1/3 1/2
101 to 500 1/8 1/5 1/4 1/3
0 to 100 1/11 1/8 1/7 1/6

5 x 5 Risk Matrix

Likelihood Rare Remote Occasional Frequent Almost


Severity (1) (2) (3) (4) Certain (5)

Catastrophic (5) 5 10 15 20 25
Major (4) 4 8 12 16 20
Moderate (3) 3 6 9 12 15
Minor (2) 2 4 6 8 10
Negligible (1) 1 2 3 4 5

RPN: 1 to 3 (Low Risk)


RPN: 4 to 12 (Medium Risk)
RPN: 15 to 25 (High Risk)

Likelihood Rating

Level Likelihood Description


1 Rare Not expected to occur but still possible.
2 Remote Not likely to occur under normal circumstances.
3 Occasional Possible or known to occur.
4 Frequent Common occurrence.
5 Almost Certain Continual or repeating experience.

Severity Rating
Level Severity Description
5 Catastrophic Death, fatal diseases, multiple major injuries.
4 Major Serious injuries or life-threatening occupational diseases
(includes amputations, major fractures, multiple injuries,
occupational cancers, acute poisoning, disabilities & deafness).
3 Moderate Injury or ill-health requiring medical treatment (includes
lacerations, burns, sprains, minor fractures, dermatitis, and work-
related upper limbs disorder).
2 Minor Injury or ill-health requiring first aid only (includes minor cuts and
bruises, irritation, ill-health with temporary discomfort).
1 Negligible Negligible injury.

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