DOW FIRE & EXPLOSION

INDEX
BY
NARAYANA PILLAI.P.N

DOW CHEMICAL COMPANY

DOW FIRE &

Explosion index
method developed
by Dow chemicals
is extensively used
to evaluate plant
hazard at design
stage
This index is a
number indicates
the fire and
explosion hazard of
a unit

DOW Fire & Explosion Index

Summary
Originated due to poor loss (accident) record in
1966
One of the first chemical plant hazard
analysis systems
Unique Features
Maximum Probable Property Damage
Maximum Probable Days Outage
Continues to be upgraded in use and
application
Fill out like a Tax Form

Principle and Techniques

PLANT SECTIONS ARE ANALYSED TO LIST: RAW MATERIALS
INTERMEDIATE PRODUCTS
MAIN PRODUCTS
CATALYSTS

SUB-DIVISION OF THE INSTALLATION

PLANT SUB DEVIDED INTO LOGICAL
INDIPEPENDENT ELEMENTS
OR UNITS
WHETHER SEPARATED BY WALLS OR
NOT

EXAMPLES

FEED SECTION
HEATING/COOLING SECTION
COMPRESSION SECTION
DISTILLATION SECTION
WASH SECTION
FILTRATION SECTION
FLARE
BLOWDOWN

EXPLOSION INDEX F &Toxicity Index

T
F=MF x(1+GPH

tot +

1+SPH

tot

MF=Material Factor=a measure of potential energy of

dangerous chemicals as per NFPA
GPH tot=measure of hazard from process condition
SPH tot =special process hazards

Toxicity T = Th+Ts (1+GPHtot+SPHtot)

100
Th= Toxicity factor NFPA
Ts= suppliment for MAC- value(Maximum Allowable
Concentration)
F,T MUST BE DETERMINED FOR EACH SUBSTANCE

DETERMINATION OF MF
MF- is denoted by a number from 0
to 40 higher number indicates
greater energy available
Determined by flammability and
reactivity

Determination of General Process

Hazards

1.EXOTHERMIC REACTIONS
i)combustion: 0.2 penalty
Ii)following reactions require0.3 penalty
Hydogenation
Hydrolisis
Alkalination
Sulfonation
Neutralisation

 iii)Esterification : penalty0.5
Where acid is
highly reactive
or reacting
substance is
unstable penalty
will be
0.7 or1.25
iv) Oxidation :
penalty 0.5

 Vi) Condensation :penalty 0.5

Vii) Halogenation: penalty 1.0
Viii) Nitration

: penalty1.25

2.Endothermic Reactions
Receive a 0.2
penalty(calcination,electrolisis,
cracking etc)
If combustion process is used
penalty will be 0,4

 3. HANDLING AND TRANSFER OF

MATERIAL
i) Loading /unloading dangerous
materials ,
road tanker,tank cars,ships:
penalty0.5
ii) Storage in drums,cylinders,tanks
---materials with(process)
temperature below
the atmospheric boiling point

4.proces unit within a

building

--flammable liquids above flash point

but
below atmospheric boiling point
penalty 0.3
--flammable liquids or LPG above

 5. miscellaneous
--Packing ,filling of drums,sacks or
boxes with
dangerous goods,use of
centrifuges, mixing
of batches in open apparatus
penalty0.5

Determination of special process

hazards

1.process temperature
--above flash point: penalty 0.25
--above atmospheric boiling point: penalty 0.6
-- materials that can be ignited in hot steam
line : 0.75

 2. Less Pressure
-- No penalty for process that operate at
atmospheric pressure or such atmospheric
pressure provided air leakage in to the system
will not create a hazard
--when air leakage could create a hazard :penalty
0.5
-- vacuum distillation at less than 0.67 bar:
penalty 0.75

 3.operation near flammable range: i) Flammable storage(outdoors): penalty 0.5

Ii) Process close to flammable limits:
penalty0.75
Iii) Process in flammable range: penalty 1.0

4. operating pressures: -- above atmospheric pressure: 0.435log P

(P=Absolute pressure at which relief valve is
set)

 5.low temperature: --for process that operate below 0 cand30c:

penalty 0.3
-- process that operate below -30 c
:penalty 0.5

Loss of Material due to

Corrosion

Apply the following

penalties
i) corrosion rate less than0.5mm/year
with
risk of pitting or local errosion0.10
ii)corrosion rate over o.5mm/year
and less
than 1.0mmyear 0.20
iii)corrosion rate over 1.0mmyear

Leakage of Joints and

Packings
i) leaks from pump glands: 0.10
ii) Regular leaks from pump
flanges:0.20
iii) Process fluids penetrating in
nature,
abrasive slurries: 0.40
iv) Leaks in sight
glases,bellows,expansion
joints 1.5

Determination of toxicity
index T
This is primarily based on index
figures of hazards established by the
NFPA .For a number of materials
these figure vary from 0 to 4

Relation between NFPA hazard figures and Toxicity Factor (Th)

NFPA INDEX FIGURES

Toxicity Factor (Th )

50

125

250

325

 In addition ,the toxicity factor has to

be corrected for the MAC-value of
the toxic substance by adding to it a
penalty TS which is given below in
table
MAC- PPM
PENALTY TS

<Or=5
5-50
>50

125
75
50

Toxicity Index (T )

Is now calculated as follows:T =

Th +Ts
(1+GPHtot+SPHtot)
100

Classification in hazard
categories

Categories of plant element

Fire &explosion index(F)-Toxicity
index (T)
CATEGORY I
CATEGORY II
CATEGORY III

F 65

T6

65 F 95

6 T 10

F 95

T 10

More Detailed Classification by Dow

Fire and Explosion Index
RANGE OF DOW
&EXPLOSION INDEX

OVER ALL HAZARD

0 -20

MILD

20-40

LIGHT

40-60
60-75
75-90

MODERATE
MODERATELY HEAVY
HEAVY

90-115

EXTREME

115-150

VERY EXTREME

150-200
OVER 200

POTENTIALLY
CATASTROPHIC
HIGHLY CATASTROPHIC

Minimum Distance in Metres of unit A

to unit B reduced to DOW FEI
Uint A

UNIT B
MILD LIG
HT

MODE
RATE

MODE
RATEL
Y
HEAV
Y

MILD

10

12

LIGHT

10

12

15

MODERAT
E

10

12

15

17

MODERAT 8
ELY HEAVY

10

12

15

17

20

HEAVY

10

12

15

17

20

25

EXTREME

12

15

17

20

25

30

HEAV
Y

EXTRE
ME

Minimum distance in Metres

to:DOW FEI
WORKS
PLANT
OFFICE
BOUNDARY

BOUNDARY

AMENITIES
CONTROL
ROOMS

MILD

20

15

10

LIGHT

25

20

12

MODERATE

30

30

20

MODERATELY
HEAVY

40

30

20

35

30

HEAVY
EXTREME

50
75

50

45

 THANK
YOU