Methodology: We mapped out leakage scenario frequencies using historical process databases and simulated vapor cloud dispersion, jet fires, and pool fires using PHAST consequence software. We integrated these results into individual risk (IRPA) contours and societal risk curves.

Result: Identified that jet fire radiation from a potential loading arm release crossed the facility fence line. We proposed a revised layout relocating the loading manifold 30 meters inward and adding active deluge barriers, ensuring full regulatory compliance and safety approval.

100% Regulatory Clearance

30m Layout Optimization

Methodology: The terminal process was divided into 18 nodes, covering bulk tank storage, nitrogen blanketing loops, transfer pump headers, and drumming machines. Deviaitons (e.g. High Pressure, High Flow, Reverse Flow) were analyzed by our multidisciplinary panel.

Result: Identified 12 critical scenarios lacking adequate independent protection layers (IPLs). We recommended independent high-level shutoff loops and localized toxic gas detectors interlocked with transfer pumps, preventing potential environmental release incidents.

18 Nodes Evaluated

12 New Safeguards Proposed

Methodology: We defined safety target reliability parameters using Layer of Protection Analysis (LOPA). We then modeled the probability of failure on demand (PFDavg) of the shutdown loop design (comprising pressure transmitters, safety logic PLC, and ESD valves).

Result: Discovered that 3 critical high-pressure shutdown loops failed to satisfy SIL 2 requirements due to poor proof-testing intervals. We recommended a revised proof-testing schedule and changed valve logic configuration from 1oo1 to 1oo2, achieving SIL 2 compliance.

99.9% Loop Reliability

SIL 2 Verification Compliance