guideline domino

36
July 1998 Guidelines for the application of the methodology for studying domino effects page 1/36 Major Risk Research Centre Faculté Polytechnique de Mons DOMINO 98 GUIDELINES FOR THE APPLICATION OF THE METHODOLOGY FOR STUDYING DOMINO EFFECTS I. INTRODUCTION ................................................................................................................ 2 II. PRELIMINARY PHASE: GATHER NECESSARY INFORMATION FOR THE DOMINO STUDY .................................................................................................................... 3 III. FIRST STEP: LOCATE DANGEROUS EQUIPMENT ............................................... 4 III.1. Followed method.........................................................................................................................4 III.1.1. First point: "Locate sections on the establishments plan" ..................................................6 III.1.2. Second point: "Draw up a list of the equipment being part of the sections" .......................7 III.1.3. Third point: "Equipment selection" .....................................................................................9 III.1.4. Fourth point : "Selected equipment classification" ...........................................................15 III.1.5. Fifth point : "Regroup equipment in equipment zones".....................................................17 III.1.6. Sixth point: "note pipes linking equipment zones or feeding the flare". ............................20 III.1.7. Seventh point : "Meet the safety manager and visit the establishment". ...........................20 III.1.8. Eighth point : "Fill in the equipment data sheets" ............................................................21 III.1.9. Ninth point : "Final definition of the equipment zones" ....................................................21 III.2. Processing of the results ............................................................................................................21 IV. STEP 2: SELECTION OF PRIMARY EQUIPMENT ITEMS OR EQUIPMENT ZONES - PRIMARY ACCIDENTS, ASSOCIATED EFFECTS AND EPICENTRES .. 26 IV.1. Primary accidents, associated effects and epicentre location....................................................26 IV.1.1. Solid products storage equipment ......................................................................................26 IV.1.2. Pressure storage equipment ...............................................................................................27 IV.1.3. Atmospheric or cryogenic storage equipment ...................................................................27 IV.1.4. Small conditionings equipment ..........................................................................................27 IV.1.5. Loading / unloading equipment .........................................................................................27 IV.1.6. Process equipment .............................................................................................................28 IV.1.7. Pipe networks .....................................................................................................................28 IV.2. Coupling equipment and accident scenario ..............................................................................28 IV.2.1. Fire: ...................................................................................................................................28 IV.2.2. Explosion and dust explosion: ...........................................................................................28 IV.2.3. Pool fire: ............................................................................................................................29 IV.2.4. Jetfire: ................................................................................................................................29 IV.2.5. BLEVE: ..............................................................................................................................29 IV.2.6. VCE:...................................................................................................................................29 IV.2.7. Tank fire:............................................................................................................................33 IV.2.8. Boilover: ............................................................................................................................33 IV.3. Processing of the results ...........................................................................................................33 V. STEP 3: SECONDARY EQUIPMENT DETERMINATION ....................................... 34 V.1. Determination of effect distances ...............................................................................................34 V.2. Processing of the results .............................................................................................................34 VI. STEP 4: DETAILED ANALYSIS OF PAIRS RETAINED DURING THE THIRD STEP AS LIKELY TO BE INVOLVED IN A DOMINO EFFECT ................................. 35 VII. BIBLIOGRAPHY .......................................................................................................... 36

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  • July 1998 Guidelines for the application of the methodology for studying domino effects

    page 1/36

    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    GUIDELINES FOR THE APPLICATION OF THE METHODOLOGY FOR STUDYING DOMINO EFFECTS

    I. INTRODUCTION ................................................................................................................ 2

    II. PRELIMINARY PHASE: GATHER NECESSARY INFORMATION FOR THE DOMINO STUDY .................................................................................................................... 3

    III. FIRST STEP: LOCATE DANGEROUS EQUIPMENT ............................................... 4 III.1. Followed method ......................................................................................................................... 4

    III.1.1. First point: "Locate sections on the establishments plan" .................................................. 6 III.1.2. Second point: "Draw up a list of the equipment being part of the sections" ....................... 7 III.1.3. Third point: "Equipment selection" ..................................................................................... 9 III.1.4. Fourth point : "Selected equipment classification" ........................................................... 15 III.1.5. Fifth point : "Regroup equipment in equipment zones" ..................................................... 17 III.1.6. Sixth point: "note pipes linking equipment zones or feeding the flare". ............................ 20 III.1.7. Seventh point : "Meet the safety manager and visit the establishment". ........................... 20 III.1.8. Eighth point : "Fill in the equipment data sheets" ............................................................ 21 III.1.9. Ninth point : "Final definition of the equipment zones" .................................................... 21

    III.2. Processing of the results ............................................................................................................ 21

    IV. STEP 2: SELECTION OF PRIMARY EQUIPMENT ITEMS OR EQUIPMENT ZONES - PRIMARY ACCIDENTS, ASSOCIATED EFFECTS AND EPICENTRES .. 26

    IV.1. Primary accidents, associated effects and epicentre location .................................................... 26 IV.1.1. Solid products storage equipment ...................................................................................... 26 IV.1.2. Pressure storage equipment ............................................................................................... 27 IV.1.3. Atmospheric or cryogenic storage equipment ................................................................... 27 IV.1.4. Small conditionings equipment .......................................................................................... 27 IV.1.5. Loading / unloading equipment ......................................................................................... 27 IV.1.6. Process equipment ............................................................................................................. 28 IV.1.7. Pipe networks ..................................................................................................................... 28

    IV.2. Coupling equipment and accident scenario .............................................................................. 28 IV.2.1. Fire: ................................................................................................................................... 28 IV.2.2. Explosion and dust explosion: ........................................................................................... 28 IV.2.3. Pool fire: ............................................................................................................................ 29 IV.2.4. Jetfire: ................................................................................................................................ 29 IV.2.5. BLEVE: .............................................................................................................................. 29 IV.2.6. VCE:................................................................................................................................... 29 IV.2.7. Tank fire: ............................................................................................................................ 33 IV.2.8. Boilover: ............................................................................................................................ 33

    IV.3. Processing of the results ........................................................................................................... 33

    V. STEP 3: SECONDARY EQUIPMENT DETERMINATION ....................................... 34 V.1. Determination of effect distances ............................................................................................... 34 V.2. Processing of the results ............................................................................................................. 34

    VI. STEP 4: DETAILED ANALYSIS OF PAIRS RETAINED DURING THE THIRD STEP AS LIKELY TO BE INVOLVED IN A DOMINO EFFECT ................................. 35

    VII. BIBLIOGRAPHY .......................................................................................................... 36

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    GUIDELINES FOR THE APPLICATION OF THE METHODOLOGY FOR STUDYING DOMINO EFFECTS

    I. INTRODUCTION This document constitutes a practical guide for the application of the methodology for studying domino effects [1]. The user must thus imperatively be acquainted with the contents of this methodology and with the terms used. Moreover, this guide is supplemented by a Technical Appendix [2]. The four steps methodology permits to locate and characterize quickly hazardous equipment items in dangerous establishments, as well as sequences of accidents likely to form a domino effect (figure 1). These four steps are preceded by a preliminary phase in order to gather information.

    Locate dangerous equipment

    relevant data

    Specific accidents forms

    Step 1

    Selection of primary equipment, accidents

    and effects

    Determination of secondary equipment,

    domino effects

    Detailed analysis of domino effects

    Step 2

    Step 3

    Step 4

    historical analysis and selection rules

    method for calculating effect distances and selection rules

    Simulation tools or experimentation

    Preliminary phase

    methodology description

    needed data, equipment forms

    establishment visit

    Gather information

    selection rules

    contact safety officers

    Potential domino effects

    figure 1: a methodology for studying domino effects

    In order to help the user of the methodology, a set of decision diagrams were developed. These decision diagrams are presented and commented in the continuation of the text.

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    II. PRELIMINARY PHASE: GATHER NECESSARY INFORMATION FOR THE DOMINO STUDY Various information about the studied establishments are needed before the domino study can begin. The needed information for each establishment are presented in the document describing the methodology [1]. From the very beginning of the preliminary phase, the document summarizing the principles of the methodology must be given to the concerned establishments, so that they understand what is expected from them. Equipment forms are joined to this document and will be used later in order to obtain detailed information about some hazardous equipment items (see at the end of the first step). After receipt of these information, it is useful that the user of the methodology visits the concerned establishments and meets the safety managers. The aims of the meeting with the safety manager are: To check that the methodology process has been well understood by the safety manager of

    the studied establishment; To check that the information at the methodology user disposal is complete enough to

    realize the study. During this meeting, it is especially advisable to: examine the establishment plan in order to understand what are and for what are used the

    elements appearing on the plan; ask the safety manager to specify the location and the nature of the hazardous equipment

    items; check the presence of possible underground pipes; specify the location of all loading/unloading equipment (watch especially road

    loading/unloading facilities which can be scattered in the establishment whereas rail and river facilities are more easy to locate on a plan);

    specify the location of compressors, pumps and other utilities; specify the location of eventual boilers; specify the location of an eventual gas expansion facility; examine the neighbourhood of the establishment: are there other companies covered by the

    Directive in the vicinity of the establishment considered ? If so, these establishments must be integrated into the domino study.

    The visit of the site helps to be aware of the real volume and configuration of the equipment items, their layout on the site, the position of pipes... During the visit, it is necessary to pay attention to:

    the presence of roads close to the different equipment items (risk of traffic accident involving an equipment item, risk of hitting a pipe ...);

    the presence of temporary parkings (for example rail or road tank cars waiting for loading or unloading) and their location with respect to the different equipment items;

    the congestion of the different zones of the establishment (the congestion is important in order to evaluate vapour cloud explosion hazards), and the average height of the equipment items (in order to determine the volume of an eventual vapour cloud present

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    in the congested zone. Detailed calculation is explained in the Technical Appendix [2]);

    the presence and the layout of bunds and safe away spill containment; the presence of hot spots (furnaces, boilers, engines, flares ...) likely to be an ignition

    source for a vapour cloud; the presence of safety systems.

    III. FIRST STEP: LOCATE DANGEROUS EQUIPMENT The purpose of the first step is to catalogue, categorize and locate dangerous equipment items or equipment zones in every concerned establishment. III.1. FOLLOWED METHOD The logical way of drawing up the list of equipment zones to be retained in the domino study is specified in decision flowcharts. These flowcharts are presented in the text below. It concerns the following decision flowcharts:

    flowchart 1.1: Summary of the first step; flowchart 1.2: List of equipment items being part of a section; flowchart 1.3: Selection criteria for equipment items belonging to storage or loading /

    unloading sections; flowchart 1.4: Selection criteria for equipment items belonging to process sections; flowchart 1.5: Selection criteria based on the nature of the substances and the quantities

    involved; flowchart 1.6: Determination of a category for the storage equipment; flowchart 1.7: Regroup storage equipment, loading / unloading equipment and pipe

    network in equipment zones. The first step includes 9 points which are listed below.

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    Flowchart 1.1: Summary of the first step

    1. Locate sections on the establishment plan

    2. Draw up a list with the equipment being part of the sections (flowchart 1.2)

    3. Apply selection criteria for each equipment item (flowchart 1.3, 1.4, 1.5)

    Were all theequipment listed in the second

    point examinated?

    The list of equipment items involved in the domino study is determined

    4. Classify selected equipment (equipment categories) (flowchart 1.6)

    5. Group equipment in equipment zones (flowcharts 1.7, 1.8)

    yes

    yes

    no

    Are all the elementsof the plan included

    in a section ?

    no

    (List DOMINO98-L1)

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    6. Not pipes linking equipment zones (flowchart 1.5) and pipe network feeding the flare.

    The list of equipment zones involved in the domino study is determined

    7. Meet the safety manager and visit the establishment.Choose equipment requiring an equipment data sheet to be filled in.

    8. Fill in equipment data sheets (safety manager).

    9. Final definition of the equipment zones.

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    III.1.1. First point: "Locate sections on the establishments plan" a) Definitions Establishment: the whole area under the control of an operator where dangerous substances

    are present in one or more installations, including common or related infrastructures or activities (article 3, paragraph 1 of the European Directive 96/82/EC of 9 December 1996 [3]).

    Section: part of an establishment forming a logical set, geographically separated from the other parts of the establishment (for example by a wall or an open space). The following sections are considered: storage, loading and unloading, process and buildings.

    Storage section: section used for the storage of raw materials, intermediate goods, manufactured products or waste products. These sections are only used for storage (not for the processing of substances).

    Loading / unloading section: section used for inlet and outlet of substances in the establishment, involving transport equipment (rail or road tank car, barge ...)

    Process section: section used for the processing of the substances or for the production of the energy used in the establishment. The process section can be a "power", "classic" or "miscellaneous " one.

    "Power" process section: process section specifically designed for the production and the supply of energy to the establishment (e.g.: section including furnaces, boilers, ...).

    "Classic" process section: process section specifically designed for the processing or the physical or chemical separation of substances (e.g.: reaction, distillation, purification zone, secondary products or effluents treatment zone, ...)

    "Miscellaneous" process section: process section which does not include any of the above quoted elements but which handles dangerous substances (e.g.: set of pumps, compressors, gas expansion facility, ...).

    "Buildings" section: section made up of buildings (administrative, technical, ... ones). b) Comments The plan of the establishment must be used in order to define sections, by means of simple logical and geographical criteria (open spaces, walls, buildings, roads, ...)

    These sections are:

    storage sections (raw materials, intermediate goods, manufactured products, waste products, ...);

    loading / unloading sections for in and out goods; process sections (products processing, energy production, ...) buildings.

    At the end of this first point, the user of the methodology must draw up the list DOMINO98-L1

    of all the sections identified in the studied establishments (see "processing of the results" in paragraph III.III.2.).

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    III.1.2. Second point: "Draw up a list of the equipment being part of the sections" a) Definitions Equipment: elementary constitutive parts of a section (for example: storage tank, reactor,

    distillation column, boiler, heat exchanger, rail tank car, ...) "Slender" equipment: equipment item which is higher than 20 m and which height/diameter

    ratio is higher than 4. Intermediate storage equipment: container used in a process in order to stock substances

    temporarily. This container is located in the corresponding process section. Dangerous substances [3]: substances which toxicity, flammability, unstability or explosivity

    may induce hazard for people or equipment. The used hazard characteristics are based on the hazard classes of the 'Guide des Pompiers de Genve' [4]. The following classes are selected:

    toxic substances: classes 2, 3 and 4; flammable substances: classes 1, 2, 3 and 4; unstable substances: classes 3 and 4; explosive substances: classes 3 and 4.

    The hazard classes of the main substances handled in industry are given in the Technical Appendix [2].

    Quantity: a quantity is the mass of substance being used. This quantity can be a static mass

    (mass in a vessel) or a dynamic mass (maximum flow rate multiplied by a period of time given in the methodology, for example half an hour).

    b) Comments For every section defined in the first point, the constituent equipment items should be listed. This is performed in accordance with flowchart 1.2. With regard to the "Buildings", one must make sure that they are not used for the storage of dangerous substances, for a process section (pilot unit, ... ) or for a loading / unloading section. If it is not the case, the 'building' section is no longer considered. In the opposite case, this section should be classified and treated as a storage, process or loading / unloading section. At the end of this second point, all the equipment items constituting the above defined sections must have been listed by the user. The set of these equipment items must be listed in the list DOMINO98-L2 (see "processing of the results", paragraph III.III.2.).

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    Flowchart 1.2: list of equipment items being part of a section

    loading /unloadingsection ?

    yes

    Draw up a list with : the mean of transport type (lorry, rail tank car, barge, ... ) the nature of the substance contained in each equipment item the mass or the volume of substance contained in each equipment

    item, as well as the flow rates during transfer operations

    no

    "power"process

    section ?

    processsection ?

    "classic"process

    section ?

    yes

    yes

    Draw up a list with : boilers and furnaces equipment items using thermal oil at high temperature the energy used (gas flow rate or quantity of stored

    fuel)END

    no

    yes

    Draw up a list with: columns, "slender" equipment items, reactors intermediate storage equipment equipment working at a pressure higher than 30 bar equipment working with thermal oil at high temperature for each equipment item, note down the handled

    substance (nature, quantity and/or flow rate)

    no

    Note down the main handled substances and their quantityand/or flow rate

    storagesection ?

    yes

    Draw up a list with: the identification codes of the storage equipment items. the nature and quantity of the substances contained in each

    equipment item

    ENDno

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    (List DOMINO98-L2)

    no

    Building ?

    Do the buildinghouse a storage, process

    or loading/unloadingsection ?

    yes

    Classify this section as a storage, process orloading/unloading one.

    The section is no longerconsidered in the continuation of

    the domino study

    Impossible ! The section must be a storage, process,loading/unloading or building one.

    Go back to the beginning of the flowchart 1.2

    END

    yes

    no

    no

    END

    END

    END

    "miscellaneous"processsection

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    III.1.3. Third point: "Equipment selection" a) Definitions Runaway hazard: hazard of uncontrolled acceleration of a reaction in a reactor or a tank

    (often intermediate storage tank in a process), generating a high overpressure endangering the integrity of the vessel.

    Internal explosion: explosion of a closed vessel, often due to the accumulation of explosive

    substances (vapour, gas or dust) under the tank roof. b) Comments Each equipment item listed in the second point must be examined by means of selection criteria given in decision flowcharts 1.3, 1.4 and 1.5, in order to select or not the equipment item for the continuation of the domino study.

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    Flowchart 1.3: selection criteria for equipment items belonging to storage orloading - unloading sections

    Is the substancecontained in the equipment

    item a dangerous one ?Do not select the equipment item END

    yes

    Storage equipment (solid, underpressure, atmospheric, smallconditionnings) or loading -

    unloading equipment

    no

    Is the substancequantity known ?

    Get information about the substance quantity

    no

    Is thesubstance quantity

    higher than5 tonnes ? See flowchart 1.5.

    no

    END

    yes

    yes

    SELECT the equipment item END

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    Flowchart 1.4: Selection criteria for equipment items belonging toprocess sections

    "power"process ?

    no

    process section

    Select automatically: boilers furnaces burning gas fuel tanks if the stored quantity is higher than 5

    tons equipment items using thermal oil at high

    temperature

    END

    yes

    "classic"process ?

    Select automatically : columns "slender" equipment items equipment items working at pressure higher

    than 30 bar equipment items using thermal oil at high

    temperature

    yes

    Select: reactors and intermediate storage equipment

    IF risk of runaway or IF risk of internal explosion all equipment items containing or handling

    dangerous substances in sufficient quantity(see flowchart 1.5)

    Select equipment items containing or handlingdangerous substances in sufficient quantity(see flowchart 1.5)

    no

    END

    "miscellaneous"process ?

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    Flowchart 1.5: Selection criteria based on the nature of thesubstances and the quantities involved

    Dangeroussubstance ?

    no

    DO NOT SELECT END

    yes

    Quantityhigher than

    5 tons ?

    yes

    no

    Work at atemperature nearthe flash point ?

    Flammablesubstance ?

    (1,2,3,4)*yes

    no

    SELECT END

    Fire durationlonger than 10 to 15

    minutes ?

    no yes

    SELECT END

    Substance ofclass 1 ?

    yes

    yes

    SELECT END

    no

    no

    *: hazard classes of the "guide orange des sapeurs-pompiers genevois"

    page 1/3

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    Flowchart 1.5.

    page 2/3

    Explosivesubstance ?

    (3,4)*

    yes

    Is thesubstance reactivity

    high ?

    SELECT

    yes

    Quantityhigher than 100

    kg ?

    yesno

    SELECT

    END

    yes

    Quantityhigher than 500

    kg ?

    yesno

    SELECT

    Quantityhigher than 1000

    kg ?

    yes

    no

    no

    no

    END

    END

    no

    The storedor handled substance

    is gaseous or liquid at a temperaturehigher than its boiling

    temperature at atmosphericpressure ?

    yes

    no

    Is thesubstance reactivity

    average ?

    The substancereactivity

    is low.

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    The substance issolid

    Is the vaporpressure at 20Cbetween 0.5 and

    1 bar ?

    yes

    Flowchart 1.5.page 3/3

    Is the substancereactivity high ?

    no

    yes

    Possible poolsurface higherthan 200 m ?

    no

    SELECT

    END

    no

    yes

    Toxicsubstance ?

    (2,3,4)*yes

    Substance ofclass 4 ?

    noSELECT

    yes

    END

    SELECT

    Substance ofclass 3 ?

    yes

    Quantityhigher than

    ?

    yesno

    END

    SELECT

    Substance ofclass 2 ?

    Quantityhigher than

    ?

    yes

    ENDUnstable

    substance ?(2,3,4)*

    The substanceis liquid at atmospheric

    pressure ?

    yes

    selection criteria remainto be defined

    selection criteriaremain to be defined

    *: hazard class of the "guide orange des sapeurs-pompiers genevois"

    no

    no

    no

    yes

    no

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    Major Risk Research Centre Facult Polytechnique de Mons DOMINO 98

    Decision flowcharts 1.3 and 1.4 give respectively selection criteria for, on the one hand, equipment of storage sections (four types) or loading/unloading sections and for, on the other hand, equipment of process sections. The decision flowchart 1.5 must only be used if the user is referred to it by the flowcharts 1.3 or 1.4 (or for selection criteria related to pipes, see point 6). Some remarks can be made about these decision flowcharts:

    Once an equipment item is selected on any criterion, the other selection criteria do not need to be examined. The association between an equipment item and the other accident scenarios will be made in the second step.

    In the decision flowcharts 1.3 and 1.4, if the quantity of dangerous substance handled or stored is higher than 5 tons, the equipment item will automatically be taken into consideration in the continuation of the study. In most accident cases, this quantity is considered as sufficient to cause significant effects in the sense of domino effects.

    In the decision flowchart 1.4, it can be noted that only furnaces burning gas are selected, and will be coupled with a gas release scenario. Furnaces burning fuel oil or other liquid fuel will not be selected for themselves, but the corresponding fuel tank will be selected (if the quantity is higher than 5 tons).

    In the decision flowchart 1.4, reactors and intermediate storage tanks are systematically selected if a risk of runaway or internal explosion is present.

    In the decision flowchart 1.5, the selection of an equipment item containing or handling a flammable substance depends on the duration of the possible fire. An easy method for the computation of pool fires duration is proposed in the Technical Appendix [2].

    In the decision flowchart 1.5, with regard to the selection of equipment items containing liquid explosive substances, only the case of highly reactive substances is taken into account, as far as these substances have a vapour pressure between 0.5 and 1 bar and are likely to form a pool whose surface is larger than 200 m (a method for calculating the pool surface is given in the Technical Appendix [2]). For equipment containing substances with other reactivity or other vapour pressure, a quantity higher than 5 tons is necessary for creating a severe risk of explosion. Therefore, either these equipment items are already selected, either they must not be retained.

    III.1.4. Fourth point : "Selected equipment classification" a) Definitions Equipment category: the seven equipment categories permit to classify the equipment items

    according to their characteristics. The equipment categories are the following ones:

    solid products storage equipment pressure storage equipment atmospheric or cryogenic equipment small conditionings storage equipment loading / unloading equipment process equipment pipe networks

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    (1) solid products storage equipment It concerns storage of solid substances in the form of powder or pellets. These substances must be stored in bulk (solid products storage in form of bags are not taken into account).

    (2) pressure storage equipment Pressure storage tanks shall mean storage tanks working at a pressure above 2 bar (pressure exerted by the substance or by an inert). These tanks are used to store pressure liquefied gases as chlorine, LPG, vinyl chloride monomer, ammonia, ... that is to say substances with a vapour pressure largely higher than the atmospheric pressure. Refrigerated pressure storage are also classified among pressure storage equipment, as far as the pressure is higher than 2 bar. Even if other equipment is likely to work above atmospheric pressure (for example some reactors), only storage tanks are included in this category. (3) atmospheric storage equipment This category concerns only storage tanks. The different types of atmospheric storage (with floating roof, with fixed roof, without roof) are included in this category. Cryogenic storage are in the same category as atmospheric storage, since they work generally at atmospheric pressure or at low pressure. (4) small conditioning storage equipment Small conditionings shall mean low capacity storage as carboys, drums and all storage tanks which individual volume is smaller than 1 m. Considered alone, they can probably not cause a major accident. Nevertheless, they are sometimes stockpiled in a limited space and the extent of the stored volume of substances represents a potential cause of accident.

    (5) loading / unloading equipment Loading and unloading equipment is necessary to the establishment operations. The equipment can be road tank cars, rail tank cars or boats. They are potentially dangerous because they imply frequent handling. (6) process equipment This category includes: equipment designed for the processing or the physical or chemical separation of

    substances (reactor, distillation column, absorption column, liquid-liquid extraction, centrifuge, ... );

    intermediate storage equipment integrated into the process; utility facilities (pumps, heat exchangers, compressors, gas expansion facility, ...); equipment designed for energy production and supply (furnaces, boilers, ...); all the pipes pertaining to the above quoted equipment are included in the process

    equipment. (7) pipes networks Piping linking different equipment zones are considered as "pipes networks" (for example a pipe linking an unloading facility and a storage area, or linking a storage area and a process area), as well as pipes feeding the flare.

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    Are not considered as "pipes networks" Small pipes pertaining to an equipment item (for instance drain off pipe or sampling

    pipe ...). Those are considered to belong to the equipment item with which they are connected.

    Pipes pertaining to a process. Those are studied with the process equipment. b) Comments The classification into categories is obvious for process, loading/unloading equipment and pipes networks. On the other hand, for storage equipment, the decision flowchart 1.6 can help the user in order to classify storage equipment in the above defined categories. The selection of pipes will be explained in point 6 hereunder. III.1.5. Fifth point : "Regroup equipment in equipment zones" a) Definitions Equipment zone: set of equipment items belonging to a same category (among the seven

    categories quoted above), logically grouped and behaving, in principle, identically in case of accident. In an equipment zone, in order to calculate effect distances, only primary accidents related to the most dangerous equipment item (for example the larger one) will be studied. An equipment zone can be constituted by a single equipment item.

    b) Comments The decision flowchart 1.7 can be used in order to group most equipment items selected in the previous point in equipment zones. The grouping criteria are: 1. For solid products storage equipment (see decision flowchart 1.7): solid storage are

    separated according to simple geometric criteria (warehouses, storage areas, ... ) and according to the stored substances.

    2. For pressure storage equipment (see decision flowchart 1.7): Each equipment zone

    belonging to the category 'pressure storage equipment' includes storage vessels presenting the following common features: substances likely to produce the same types of accidents; a location in a same bund if there is a bund, or a same location on the plant in case of

    lack of bund. Furthermore, if the involved substances are likely to give rise to a BLEVE, the equipment zone can only be constituted of vessels presenting a similar geometry (sphere, horizontal cylinder, vertical cylinder). If vessels differ from one another in one criterion quoted above, they have to be grouped in distinct equipment zones.

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    Flowchart 1.6: determination of category for storage equipment

    The equipment item isa storage one

    Substancestored in a solid

    form ? Solid substances storage END

    yes

    Substancestored in a gaseousform (and volume

    higher than1 m) ?

    Pressure storage END

    yes

    Pressure storage END

    no

    no

    yes

    Pressure inthe tank higher than

    2 bar ?

    yes

    Atmospheric storage END

    no

    no

    Possible classification in thesmall conditionings category

    Substancestored in a liquid

    form (and volumehigher than

    1 m) ?

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    Flowchart 1.7: Grouping in equipment zones for:storage, loading/unloading equipment and pipes networks

    Are the consideredsubstances likely to produce the same

    type of accidents ? (closely relatedhazard classes)

    yes

    Presence of a bund ?

    The consideredequipment items are located at

    a same place on theplant ?

    The consideredequipment items are in

    the same bund ?

    yes

    yesyes

    no

    Are the consideredequipment items likely to give rise to

    a BLEVE ?

    Do theequipment itemspresent the same

    geometry ?

    yes

    The equipment items belongto different equipment zones

    The equipment items belong tothe same equipment zone

    no no

    no

    yes

    no

    no

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    3. For atmospheric storage equipment (see decision flowchart 1.7): the atmospheric tanks are

    grouped in a same equipment zone if they are located in a same bund and if the contained substances are likely to cause the same types of accidents. If there is no bund, the tanks are grouped according to simple geographical criteria. The equipment zones are defined according to the presence of traffic ways, buildings, ... The division by substances is always kept. In no case, a single equipment zone can include equipment items belonging to distinct bunds.

    4. For 'small conditionings' equipment (see decision flowchart 1.7): small conditionings will

    be grouped in equipment zones according to geographical criteria (storage areas, warehouses, ...) and according to the nature of the stored substances.

    5. For loading/unloading equipment (see decision flowchart 1.7): An equipment zone will be

    defined in every plant location where there is a loading or unloading area. If different substances are handled in a same place and if they present different hazards, several equipment zones will be defined.

    6. For process equipment: The process equipment are grouped in a single equipment zone if

    they are located at a same place in the plant and if they are likely to give only rise to the same types of accidents.

    III.1.6. Sixth point: "note pipes linking equipment zones or feeding the flare". Once the grouping in equipment zones (storage, loading / unloading and process) is achieved, the linking pipes can be selected and grouped. The selection is based on the decision flowchart 1.5. Equipment zones are created by separating pipes according to their location and the nature of the considered substances, as shown in the decision flowchart 1.7. III.1.7. Seventh point : "Meet the safety manager and visit the establishment". The meeting with the safety manager of the concerned establishment is essential. This meeting is notably useful in order to:

    review all the selected equipment zones and discuss their relevance; gain from the safety manager's experience and from his in-depth knowledge of his

    establishment; be bothered about accidents which previously occurred in the establishment or in other

    companies using similar process. At the end of this meeting, equipment items for which an equipment data sheet is needed should have been chosen. If necessary, a second visit of the establishment can be useful, especially for the choice of the congested zones.

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    III.1.8. Eighth point : "Fill in the equipment data sheets" Equipment data sheets will be filled in by the safety manager. III.1.9. Ninth point : "Final definition of the equipment zones" The received equipment data sheet allow to complete the definition of the equipment zones. III.2. PROCESSING OF THE RESULTS During the first step, the user must draw up a first list (DOMINO98-L1) presented hereunder. For each establishment, the user must write down the name of the concerned industrial area, the name of the establishment, the date, the person in charge of the study. He must also list and describe succinctly the sections present in the establishment:

    storage sections; loading / unloading sections; process sections; buildings.

    A second list, also presented hereunder (DOMINO98-L2), allows the person in charge of the

    study to draw up a list with all the equipment items constituting the above described sections, with the following information:

    the concerned section; the identification number or code of the equipment item; the equipment item description; the substance stored or handled in this equipment item; the hazard classes of the considered substance (see Technical Appendix [2] or

    [4]); possibly the temperature and pressure conditions (to be specified for process

    equipment); the stored or handled quantity (content or concerned flow); the selection or not of the equipment item for the continuation of the domino

    study. if the equipment item is selected, it is classified in one of the seven categories

    previously defined (solid storage SOL, pressure storage PS, atmospheric storage ATM, small conditionings SM, loading/unloading LU, process PRO, pipes networks PIP);

    the equipment zone number: several selected equipment may belong to a same equipment zone. This zone will be considered in the continuation of the domino study.

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    Industrial area:

    Establishment: Date :

    Person in charge of the study:

    DOMINO98 - L1: LIST OF SECTIONS

    Types of sections : Storage; loading and unloading; Process : "power","classic", "miscellaneous"; Buildings.

    Identification Type of

    section Description

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    Once these lists are filled in, the user of the methodology can begin to prepare a table (DOMINO98-L3) including the following columns:

    column 1: equipment zone number; column 2: code allowing to identify the equipment zone on the plan; column 3: description of the equipment zone, nature and quantity of handled substances

    considered as characteristic of the equipment zone; column 4: type of equipment zone (SOL, PS, ATM, SC, LU, PRO, PIP).

    This table, actual summary of the information gathered during the domino study, will be completed during the following steps. The reader can see the Technical Appendix [2] in order to examine a fictitious example of application of the methodology.

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    IV. STEP 2: SELECTION OF PRIMARY EQUIPMENT ITEMS OR EQUIPMENT ZONES - PRIMARY ACCIDENTS, ASSOCIATED EFFECTS AND EPICENTRES The purpose of this second step is to select equipment or equipment zones likely to develop a primary accident, among those previously selected. Moreover, potential effects and epicentres must be associated with these equipment. Only equipment or equipment zones likely to cause an accident with thermal and/or mechanical effects are selected as primary equipment or equipment zones. Equipment zones only presenting toxic hazards are to be considered among secondary equipment zones. According to a data analysis on past accidents [5], it can be noted that some types of equipment zones or some types of accidents cannot be the first event producing a domino effect. Those are listed as follows:

    Small conditionings equipment rarely cause a major primary accident. Actually, the simultaneous failure of several containers is unlikely. On the contrary, they can produce a secondary fire or lead to missile effects.;

    A BLEVE can only occur if the vessel is fire engulfed (or nearly). The BLEVE is then a secondary accident. The primary accident is often a pool fire or a jet fire;

    A boilover is a secondary accident, too. It is the consequence of a primary fire, namely a tank fire or a pool fire.

    However, these secondary equipment or accidents can become primary ones in domino effects in series (the secondary accident in the first domino effect becomes the primary accident in a second domino effect). Therefore, small conditionings are nevertheless retained among primary equipment, as well as BLEVE and boilover are studied with primary accidents. They are not the first event in a domino effect, but can be primary events during domino effects in series. IV.1. PRIMARY ACCIDENTS, ASSOCIATED EFFECTS AND EPICENTRE LOCATION The following tables summarize primary accidents, associated effects and epicentre location for each equipment type selected. In order to realize this association, one must accurately determine the scenarios, among possible ones, which must be associated with the considered equipment zone (see paragraph IV.IV.2.). IV.1.1. Solid products storage equipment Primary accident Primary effect Epicentre location

    Fire Radiation In the considered equipment zone Explosion and dust explosion

    Overpressure Missiles

    In the considered equipment zone

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    IV.1.2. Pressure storage equipment Primary accident Primary effect Epicentre location

    Pool fire Radiation In the considered equipment zone Jet fire Radiation In the considered equipment zone BLEVE Overpressure

    Missiles In the considered equipment zone

    VCE Overpressure In a congested zone located within a given range round the considered equipment zone

    NB.: Each time a VCE (Vapour Cloud Explosion) can occur, a flashfire can happen too. The flashfire is observed when the flammable cloud ignites outside a congested zone. In that case, the flame speed is not sufficient to lead to notable pressure effects. Moreover, the thermal effects of a flashfire are generally insufficient to induce a secondary accident. In most cases [5], the flashfire consequences are to cause a pool fire or a jet fire in the flammable release location. Therefore, the flashfire is not considered as a specific accident, but its eventual consequences are taken into account. IV.1.3. Atmospheric or cryogenic storage equipment Primary accident Primary effect Epicentre location

    Pool fire Radiation In the considered equipment zone Tank fire Radiation In the considered equipment zone Tank explosion Missiles In the considered equipment zone VCE following the vaporization of a flammable substance

    Overpressure In a congested zone located within a given range round the considered equipment zone

    Boilover (not for cryogenic storage)

    Radiation In the considered equipment zone

    IV.1.4. Small conditionings equipment Primary accident Primary effect Epicentre location

    Fire Radiation In the considered equipment zone Explosion Missiles In the considered equipment zone IV.1.5. Loading / unloading equipment Depending on whether the substance is solid or liquid at atmospheric pressure or under pressure (also gaseous substance) the effects and epicentres will be the same as considered respectively for solid products storage, atmospheric storage and pressure storage.

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    IV.1.6. Process equipment Primary accident Primary effect Epicentre location

    Fire Radiation In the considered equipment zone Jet fire Radiation In the considered equipment zone Explosion and dust explosion

    Missiles Overpressure

    In the considered equipment zone

    VCE Overpressure In a congested zone located within a given range round the considered equipment zone

    IV.1.7. Pipe networks Primary accident Primary effect Epicentre location

    Pool fire Radiation In the considered equipment zone Jet fire Radiation In the considered equipment zone VCE Overpressure In a congested zone located within a given range

    round the considered equipment zone IV.2. COUPLING EQUIPMENT AND ACCIDENT SCENARIO Each equipment or equipment zone retained during the first step of the methodology can, a priori, cause various primary accidents presented in the previous paragraph. However, according to the concerned type of equipment, the nature and the quantity of involved substances, some accident scenarios will be removed from the domino study. IV.2.1. Fire: The "fire" accident scenario must be associated with solid products storage equipment, small conditionings equipment, loading/unloading equipment and process equipment containing or handling a substance belonging to the flammability class 1, 2, 3 or 4 (for the substances belonging to the class 1, only if they are used at a temperature higher than their flash point), as far as the potential duration of the fire is longer than 10 to 15 minutes. Moreover, it is always necessary to verify that the fire smokes do not contain toxic substances (secondary accident). IV.2.2. Explosion and dust explosion: The "explosion" accident scenario must be associated with all the equipment in which a sudden pressure increase can occur, and cause the failure of the equipment item with a possible ejection of missiles. So, we consider: dust explosion in storage silos and in equipment handling pulverulent solids (crushing,

    drier, ...); tanks explosions; explosions of reactors (runaway), columns, intermediate storage tanks integrated in a

    process, equipment items working at a pressure higher than 30 bar; small conditionings explosion; ...

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    IV.2.3. Pool fire: The "pool fire" accident scenario can be associated with pressure storage equipment, atmospheric or cryogenic storage equipment, loading / unloading equipment and pipes networks. The decision flowchart 2.1 helps the user to realize the association between an equipment item and a pool fire scenario. The choice of the scenario depends on the fire duration. A method for calculating this duration is presented in the Technical Appendix [2]. IV.2.4. Jetfire: The "jetfire" accident scenario must be associated with all pressure equipment items containing a flammable substance. IV.2.5. BLEVE: The "BLEVE" accident scenario must be associated with all the pressure equipment items containing a substance quoted in the Table 1. This list is not exhaustive.

    Acetylene Hydrogen chloride Carbon dioxide Ethylene oxide Ammonia Methyl chloride Ethylene Oxygen Butadiene (and C4) Vinyl chloride monomer Liquefied natural gas Propane Butane, Butene and isomers Cyclohexane Hydrogen Propylene Butadiene chloride Dimethyl ether Methane

    Table 1: List of main substances likely to give rise to a BLEVE [6] IV.2.6. VCE: The "VCE" accident scenario can be associated with pressure storage, atmospheric or cryogenic storage, loading / unloading equipment, process equipment and pipes networks. The decision flowchart 2.2 helps the user to realize the association between an equipment item and a VCE scenario. The existence of a congested zone is needed in order to envisage a VCE scenario (see Technical Appendix [2]). This congested zone can be located in an establishment different from the establishment where the release occurs.

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    Flowchart 2.1: selection criteria for a pool fire scenario

    Flammablesubstance ?(class 1*, 2,

    3 ou 4)

    no

    DO NOT SELECT THE SCENARIO END

    yes

    Quantityhigher than

    5 tons ?

    no

    yes

    SELECT THE SCENARIO END

    Fire durationlonger than 10 to 15

    minutes ?

    no

    DO NOT SELECT THE SCENARIO

    END

    yes

    SELECT THE SCENARIO END

    *: a substance belonging to the first flammability class is only takeninto consideration if used at a temperature higher than its flash point

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    no

    Explosivesubstance ?

    (3,4)

    yes

    SELECTION

    yes

    yesno

    SELECTION

    END

    yes

    yesno

    SELECTION

    yes

    no

    no

    no

    END

    END

    no

    yes

    Flowchart 2.2: Selection criteria for a VCE** scenario

    NOSELECTION

    END

    ** it is tought that acongested zone is present

    The storedor handled substance

    is gaseous or liquid at a temperaturehigher than its boiling

    temperature at atmosphericpressure ?

    Is thesubstance reactivity

    high ?Quantity

    higher than 100kg ?

    Is thesubstance reactivity

    average ?

    Quantityhigher than 500

    kg ?

    The substancereactivity

    is low.Quantity

    higher than 1000kg ?

    page 1/2

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    The substanceis liquid

    Pool outsidea bund on a concrete

    soil ?

    yes

    Flowchart 2.2.

    page 2/2

    SELECTION IF the released quantity is higherthan the quantity shown in the table (tons)

    no

    Pool within a bund or on aground nature other than

    concrete SELECTION IF the pool surface is larger thanthe surface shown in the table (m)

    END

    END

    0.5 < Psat < 1 bar 2 5 100.1 < Psat < 0.5 bar 5 10 40Psat < 0.1 bar 40 no no

    Highreactivitysubstance

    Averagereactivitysubstance

    Lowreactivitysubstance

    0.5 < Psat < 1 bar 200 500 10000.1 < Psat < 0.5 bar 500 1000 4000Psat < 0.1 bar 4000 no no

    Highreactivitysubstance

    Averagereactivitysubstance

    Lowreactivitysubstance

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    IV.2.7. Tank fire: The "tank fire" accident scenario must be associated with all atmospheric or cryogenic storage equipment containing a substance belonging to the flammability class 2, 3 or 4. IV.2.8. Boilover: The boilover scenario can only be associated with atmospheric storage equipment meeting the conditions defined in the Technical Appendix [2]. IV.3. PROCESSING OF THE RESULTS In the table DOMINO98-L3 summarizing the results of the domino study, several columns can be filled in:

    column 5: primary or secondary nature of the equipment zone; column 6: primary accidents associated with the equipment zone (pool fire, VCE,

    BLEVE, ...); column 7: primary effects and thresholds associated with the accidents (overpressure

    160 mbar, radiation 8 kW/m, ...); column 8: epicentre of each accident (if the accident considered is a VCE, note down

    every congested zone located in a range of 200 m around the considered equipment zone).

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    V. STEP 3: SECONDARY EQUIPMENT DETERMINATION The purpose of this third step is to quickly select pairs of equipment zones belonging to different establishments and likely to be involved in a domino effect. In order to achieve this, for each effect associated with an accident related to a primary equipment or equipment zone, an effect distance is estimated, by means of simple criteria. An effect distance shall mean a distance at which a given effect threshold is reached. An equipment item or equipment zone exposed to this effect threshold runs the risk of being sufficiently damaged to produce a secondary accident (domino effect). V.1. DETERMINATION OF EFFECT DISTANCES A set of tools for estimating the effect distances are described in the Technical Appendix [2]. In order to identify equipment or equipment zone likely to give rise to a domino effect, the user must, on the plan of the concerned establishments, locate the geographical position of all the equipment items or equipment zones, as well as of all the congested zones. With the exception of the pipes, all the equipment items and the equipment zones, as well as the congested zones, are located by their centre. The pipes are located by the both ends of each segment constituting the pipe. With these data, the user can calculate the distances between any equipment items or equipment zones of the different establishments, including congested zones. Therefore, he can determine equipment or equipment zones likely to be reached by the effects of the different retained accident scenarios. All the results of the domino study must be summarized in the table DOMINO98-L3 (see "processing of the results" in paragraph 0.V.2.). V.2. PROCESSING OF THE RESULTS The last columns of the table DOMINO98-L3 can be filled in:

    column 9: effect distance associated with each primary effect related to the different types of accidents (see Technical Appendix [2]);

    columns 10, 11, ... : equipment or equipment zones likely to be reached by the considered effect according to the distance between the primary equipment zone and the secondary equipment or equipment zones considered (external domino effects, one column by external establishment);

    last column: equipment or equipment zones likely to be reached by the considered effect inside the establishment where the primary accident occured (internal domino effect).

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    VI. STEP 4: DETAILED ANALYSIS OF PAIRS RETAINED DURING THE THIRD STEP AS LIKELY TO BE INVOLVED IN A DOMINO EFFECT The purpose of the fourth step is to verify the relevance of pairs of equipment items or equipment zones selected in the third step as likely to be involved in a domino effect. Actually, during the third step, the determination of the effect distances is based on simple and rapid criteria. This rapidity and this simplicity are obtained with some approximations and simplifications in the used methods. During this fourth step, more precise approachs can be envisaged. The user of the methodology can especially tackle four topics:

    a more detailed approach of accidents; a study of aggravating factors; a study of safety systems and favourable circonstances; the historical knowledge.

    These points are presented in the document giving the principles of the methodology for studying domino effects [1]. These further analyses must always be relevant according to scientifically proved knowledge.

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    VII. BIBLIOGRAPHY [1] Delvosalle C., Benjelloun F., Fivez C.

    A methodology for studying domino effects. Ministre Fdral de l'Emploi et du Travail - Administration de la Scurit du Travail - Inspection technique - (Contrat de gr gr CRC/WPS/07/97) - Facult Polytechnique de Mons - July 1998.

    [2] Delvosalle C., Benjelloun F., Fivez C. Technical appendix for the application of the methodology for studying domino effects. Ministre Fdral de l'Emploi et du Travail - Administration de la Scurit du Travail - Inspection technique - (Contrat de gr gr CRC/WPS/07/97) - Facult Polytechnique de Mons - July 1998.

    [3] Council Directive 96/82/EC of 9 December 1996 on the control of major accident hazards involving dangerous substances. Official Journal of the European Communities - 14/01/1997 - N L 10/13 to 10/33.

    [4] Rpertoire des produits dangereux - Guide Orange des Sapeurs-Pompiers Genevois.

    Ville de Genve, Service d'Incendie et de Secours, 2me dition. [5] Levert J.M., Delvosalle C., Anstett P.A., Benjelloun F., Pons P., Verriest C. Mthodologie d'analyse des effets domino en milieu industriel - Rapport final -

    Ministre de l'Emploi et du Travail - Administration de la Scurit du Travail - Inspection technique - (Contrat de gr gr CRC/WPS/07/95) - Facult Polytechnique de Mons - Juillet 1996

    [6] Gonzales P. Une problmatique du feu. Institut National de lEnvironnement Industriel et des

    Risques, Verneuil-en-Halatte, France.