Dow's Chemical Exposure Index Guide, First Edition

by AIChE technical manual

Copyright 1994 American Institute of Chemical Engineers

APPENDIX 3
EXAMPLE CEI CALCULATIONS
~

CHLORINE VAPOR RELEASE

The 3/4 inch vapor connection on a 1 ton chlorine cylinder stored at ambient temperature (30 "C or 86 "F)
has broken.

Needed information:

US/Brit
114.3 psig
129.0 psia
70.91
86 OF
0.75 in

SI

788.1 P a gauge
889.5 kPa
70.9 1
30 "C
19 mm

Pressure inside the cylinder, Pg

Absolute Pressure, Pa
Molecular Weight, MW
Storage Temperature, T
Diameter of Hole, D

Determine Airborne Quantity.

USIBrit Units (Equation I B)

SI Units (Equation IA)

AQ=4.751~10 D Pa
-6

MW
d(T+273)

AQ=4.751 x 104(19)2(889.5)

AQ=3.751D2Pa

-i

gE
/

AQ = 3.751 (.75)2(129.0)
9)::!8:(
AQ = 98.2 lb I min

AQ = 0.74 kg / see

Calculate the CEI.

USIBrit Units (Equation I OB)

SI Units (Equation I OA)

whereERpG-2 = 9mg/m3

where ERPG-2 = 3 PPM

CEI = 655.1

CEI = 281.8

&z
J-F

CEI=655.1

CEI = 281.8

CEI = 188

/=
/-

CEI = 191

Differences in CEI values result from rounding the EFWG values when converting between PPM and
mghn3.

27

Calculate Hazard Distances.

SI Units (Equation I IA)

USIBrit Units (Equation I I B)

For ERPG-2 = 9 mdm3

ForERPG-2 = 3PPM

/2zi
1-

J
Z'
,/?

HD=6551

HD = 9243

HD = 655 1 0.74

HD = 9243

HD = 1,878 meters

HD = 6,280 feet

For ERPG-1 = 3 mg/m3

ForERPG-1 = 1 PPM

/-

HD = 6 5 5 0.74
1 G

HD = 9243

HD = 3,254 meters

HD = 10,878feet

;/,

For ERPG-3 = 58 mdm3

ForERPG-3 = 20PPM

HD = 655 1 0.74
HD = 740 meters

HD = 2,432 feet

Differences in HD values result from rounding the ERPG values when converting between PPM and
mghn3.

28

AMMONIA LIQUID RELEASE

Ammonia is stored in a 12 ft diameter by 72 ft long horizontal vessel under its own vapor pressure at
ambient temperature (30 "C or 86 OF). The largest liquid line out of the vessel is 2 inch diameter (50.8

mm).

Needed infomation:

US/Brit
154.5 psig
86 OF
-28 O F
37.1 w f t 3
2.23 E-03
12 ft
2.0 in
17.03

SI

1G64 kPa gauge

30 OC
-33.4 "C
594.5 kdm3
4.01 E-03
3.66 m
50.8 mm
17.03

Pressure inside vessel, P,

Temperature inside vessel, T
Normal boiling point
Liquid density in vessel, p1
Ratio Cp/Hv
Height of liquid in tank,Ah
Diameter of hole, D
Molecular weight, MW

Estimate liquid released.

USIBnt Units (Equation 2B)

SI Units (Equation 2A)

L = 9.44 x 10-7D2 p

lo0oP
l ,

+/9.8 Ah
F

J+9.8(3.66)

L = 9.44 x 10-7(50.8)2(594.5)

L = 2.234(2.0)2 (37.1)

L = 61.9 kg / s e ~

L = 8,200 Ib /min

Estimate flash fraction.

USIBnt Units (Equation 4B)

SI Units (Equation 4A)

r-

F~=-E(T,-T~)
HV

Fv =-(T,-Tb)
LP
HV

Fv= 0. oo401(30-(-33.4))

Fv= 0.00223(86-(-28))

Fv = 0.254

Fv = 0.254

Sine F,, > 0.2

Since Fv > 0.2

AQ = L

AQ = L

AQ = 8,2001b/min

AQ = 61.9 kg/sec

29

Calculate CEI.
USIBnt Units (Equation I OB)

SI Units (Equation I OA)

whereERPG-2 = 200PPM

where ERPG-2 = 139 mg/m3

CEI = 655.1i E 2 2

CEI = 6 5 5 . 1 E

CEI = 281.8

CEI = 437

CEI = 437

/z&

Calculate the Hazard Distances.

SI Units (Equation I I A )

USlBrit Units (Equation IIB)

For ERPG-2 = 139 mg/m3

For ERPG-2 = 200 PPM

HD = 655 1 , / g

HD = 6 5 5 1 E

HD = 9243 0
3
?):2
:

HD = 4,372 meters

HD = 14,342 feet

For ERPG-I = 17 mg/m3

For ERPG-I = 25 PPM

Jzz

HD = 6 5 5 1 E

HD = 9243

HD = 12,500 meters

HD = 40,564 feet

ForERPG-3 = 696mg/m3

For ERPG-3 = 1000 PPM

Jzz3)

d6Qg69

HDz6551

HD = 9243

HD = 6,414 feet

HD = 1,953meters

30

STYRENE U Q U I D RELEASE

Styrene is stored in a 40 ft x 40 ft API tank at ambient temperature (25 "C or 77 OF). The tank has a
closed vent system but is essentially at ambient pressure. The outlet is a 6-inch Schedule 40 nozzle.
Needed information:

SI
0.0 Wa
25 OC
145.2 "C
0.841 kPa
901.6 kg/m3
12.2 m
104.15

Pressure inside the tank, P,

Temperature inside the tank,T
Normal boiling point
Vapor pressure, ambient temperature
Liquid density, pi
Height of liquid, Ah
Molecular weight, M W

USBrit
0.0 psig
77 O F
293.4 OF
0.122 psi
56.3 lb/ft3
40.0 ft
104.15

Scenario selection -For greater than 4-inch diameter, use 20% of the cross sectional area (CSA).
For 6-inch Schedule 40,CSA = 28.89 in2
0.20(28.89)=5.78 in2

=fi
=

= 2.71 in or 68.9 mm

Estimate liquid released.

USIBrit Units (Equation 2B)

SI Units (Equation 2A)

L = 9.44 x 10-7D2 p

lo0oP
1

L = 2.234D2

-4

L=9.44 x 10-7(68.9)2(901.6)

L = 2.234(2.71)2(56.3)

L = 44.2 kg /sec

L = 5,842 lb / min

+ Ah

JF

Compare operating temperature to normal boiling point:

77 OF < 293.4 OF

25 OC < 145 OC

Therefore, Flash Fraction = 0

Estimate pool size.

USIBrit Units (Equation 3B)

SI Units (Equation 3A)

'
w

W T = 15(L)

=m ( L )

WT= 39,800 kg = wp

WT =87,6001b=Wp
31

USlBnt Units (Equation 7B)

SI Units (Equation 7A)

A, = 30.5-WP
PI

A, = 100-WP
PI
A, =100-

39800
901.6

A, = 30.5-

A, = 4,410 m2

87600
56.3

A, = 47,460 ft2

Assume no dike.

SI Units (Equation 8A)

USIBnt Units (Equation 8B)

AQ, =9.OxlO4(A, 0.95) (Mw)pv

T+273

AQ, = 0.154(A, 0.95) ( M w )pv

T+459

Characteristic pool temperature equals ambient

AQ, =9.0x1O4(4410

0.95 104.15(0.841)

0.95

AQ, = 0.154(47460

25+273

AQ, =0.767kg/se~

(0.122)
) 104.15
77+459

AQ, =lOllb/min

SI Units (Equation 9A)

USIBrit Units (Equation 9B)

AQ= AQf + AQ,

AQ= AQf + AQ,

AQ = 0 + 0.767

AQ = 0 + 101

AQ = 0.729 kg 1sec

AQ = 101lb / min

Calculate CEP.

SI Units (Equation I OA)

USIBrit Units (Equation 1OB)

where E R E - 2 = 1065 mg/m3

,/"

CEI = 655.1

whereERPG-2 = 250PPM

EFWG-2

,/%

CEI = 655.1 0.767

CEI = 281.8

CEI=18

CEI=18

32

,/z

Calculate the Hazard Distances.

SI Units (Equation I IA)

USIBrit Units (Equation 1I B)

For ERPG-2 = 1065 mg/m3

ForERPG-2 = 250PPM

/ = '

J""
EFWG

HD = 6551

HD = 9243

J25o:pd1.15)

HD=6551

HD = 9243

HD = 576 feet

HD = 176 meters

/zz

ForERPG-I = SOPPM

ForERPG-1 = 213mg/m3

HD = 9243
HD = 393 meters

HD = 1,287feet

ForERPG-3 = 4259mg/m3

HD=6551

ForERPG-3 = 1OOOPPM

JizL

J
Z

HD = 9243

HD = 87.9 meters

HD = 288 feet

33

CHLORINE LIQUID RELEASE

Chlorine is stored in a sphere at 5 OC (41 OF). A 2-inch nozzle fails on the bottom of the vessel allowing
liquid to escape.
Needed information:

UsBrits
48.2 psig
70.9 1
41 O F
9 1.01 lb/ft2
19.7 ft
2 in
2.5 x 106 lb

SI
332 kPa gauge
70.91
5 "C
1458 kg/m3
6m
50.8 mm
1.134 x 106 kg

Pressure inside the cylinder, P,

Molecular weight, M W
Storage temperature, T
Liquid density, p1
Height of liquid in the sphere, Ah
Diameter of hole, D
Capacity of sphere

Estimate liquid released.

SI Units (Equation 2A)

USfBrit Units (Equation 2B)

+ 9.8 Ah

JF

L = 2.234(2)291.01
L = 60.1 kg / sec

L = 7,967 lb/min

Determine the total liquid released.

For 15 minutes (900 seconds), the total liquid leaving the tank is:
W, = 900(60.1) = 54,090 kg

WT = 15(7,967) = 119,505lb

The capacity of the tank when full is 1.134 x 106 kg. Since LT = 54090 kg is less than the capacity of the

tank.

W, =54,090 kg

WT = 119,505lb

Calculate the flash fraction.

Needed information:
Normal boiling point temperature = -34 OC
Normal boiling point temperature = -29.2 O F
Heat of vaporization = 275,030 J/kg
Heat capacity of liquid (at average temperature) = 943.8 J/kgJ'C

34

A technically correct solution for evaluating the flash fraction q u i r e s the heat capacity (C,) to be
evaluated at the average temperature (storage and boiling point) and the heat of vaporization at the boiling
point. For example:
C, (@ -15 OC or 5 OF) = 943.8J/kg/OC = 0.2254 BTU/lbPF
and

H, (BP) = 285,457J/kg = 122.72BTU/lb

USlBrit Units (Equation4B)

SI Units (Equation4A)

F, = 943* (5 -(-34.0))

F, =-0'2254(41-(-29.2))

F, = 0.129

Fv= 0.129

122.72

285,457

Calculate vapor source strength from the flash.

AQf=5(Fv)(L)=5(0.129)(6O.1)=38.8 kg / s e ~

(SI)

AQf=5(Fv)(L)=5(0.129)(7967)=5,l39lb/min

(UsBrit)

Calculate the total liquid entering the pool.

wp=w~(~-~F,)=54,~0(1-(5)(0.129))=19,202
kg

(SI)

wp= WT(1-5FV) = 1 19,505(1 - (5)(0.129)) = 42,424lb

(USIBrits)

Liquid density of chlorine at its boiling point = 1,562kghn3

USIBnt Units (Equation7B)

SI Units (Equation 7A)

A, =30.5-wP

A, = 100-wP

P1

P1

A, =100-

42424
A, = 30.597.5

19202
1562

A, =13,271ft2

A, = 1,229m2

35

Calculate the vapor flow rate from the pool.

Since chlorine is boiling in the pool, P, = 101.3 kPa = 14.70 psi

Molecular weight of chlorine = 70.91

USlBrit Units (Equation 8B)

SI Units (Equation 8A)

AQ,

AQ, = 0.154(AP0.95) ( M w )pv

T +459

= ~ . O X ~ O ~ ( A0.95)
,
(Mw)pv

T+273

AQ, =9.Ox1O4(1229

) (-29.2)+459

0.95 70.91(14.70)

) (-34.0)+273

0.95 70.9 l(101.3)

AQ, =0.154(13271

AQ, = 3,083lb 1min

AQ, = 23.3 kg I sec

Calculate source strength of release.

USIBrit Units (Equation 9B)

SI Units (Equation 9A)

AQ = AQf + AQp

AQ = AQf + AQp

AQ=38.8+23.3

AQ = 5139 + 3083

AQ =62.1 kg Isec

AQ=8,222lb/min

Compare to the liquid release: 62.1 kdsec is greater than 60.1 kg/sec and 8,222 lblmin is greater than
7,967 lb/min:
AQ = 7,967 lb 1min

AQ = 60.1 kg 1sec

Calculate the CEI.

USIBrit Units (Equation I OB)

SI Units (Equation I OA)

where ERPG-2 = 3 PPM

whereERFG-2 = 9mg/m3

i2z

CEI = 655.1

CEI = 6 5 5 . 1 E

CEI = 281.8JT3(70.9 1)

CEI = 1,963

CEI = 1.725

This is greater than 1OOO; thus

CEI = 1,ooO

This is greater than 1OOO; thus

CEI = 1.000

36

Calculate the Hazard Distances.

SI Units (EquationI I A )

USIBnt Units (Equation I I B)

ForERPG-2 = 9mg/m3

ForERPG-2 = 3PPM

HD = 6551/* EFWG

J-

HD = 6 5 5 1 E

HD = 9243

HD = 16,929meters

HD = 56,525 feet

HD is greater than 10,ooO meters, thus

HD is greater than 32,800 feet, thus

HD = 10,OOOmeters

HD = 32,800 feet

For ERPG-I = 1 PPM

For ERPG-I = 3 mgIm3

J-

HD = 6 5 5 1 E

HD = 9243

HD = 29,321 meters

HD = 97,973 feet

HD is greater than 10,ooO meters, thus

HD is greater than 32,800 feet, thus

HD = 10,OOOmeters

HD = 32.800 feet

ForERPG-3 = 58mg/m3

ForERPG-3 = 20PPM

J-

HD = 6 5 5 1 c

HD = 9243

HD = 6,668 meters

HD = 21,907 feet

37