PROCESS & SAFETY
Proconics has a long-standing commitment to executing projects in hazardous hydrocarbon facilities. With over 25 years of experience and expertise, Proconics is uniquely positioned to help manage facility risks and ensure the highest safety standards are met.
Proconics provides services including but not limited to:
1. Hazard identification and analysis
2. Consequence modeling
3. Risk assessments
4. Facilitation of safety and risk management reviews
5. Process safety engineering and safety in design
6. Hazardous area classification
7. Functional safety design and evaluation
1. Needs assessment
2. Requirement analysis based on risk assessment
3. Data collection and information gathering
4. Site evaluations
5. Investigations, trade-offs and design criteria
6. Rational and prescriptive fire protection designs:
a. Active and passive fire protection systems
b. Fire and gas detection placement, layout, and design
7. Legal requirements compliance checks and inspections
8. Consultation with AHJ, public, and project stakeholders
9. Operations and maintenance manuals
10. As-built documentation.
1. Pre-feasibility and feasibility studies
2. Engineering studies and designs
3. Project and construction management
4. Advice on regulatory and statutory requirements, including environmental management and the need for surveys, analyses, tests, and site or other investigations, as well as approvals, where such are required for the completion of designs.
5. Financial modeling and project evaluation for pre-feasibility/feasibility studies.
OUR SAFETY MISSION
Identify and assess the risk associated with hazards and design them out of the process, either by eliminating the hazard or engineering reliable prevention and mitigation measures.
Proconics provide a wide range of Process Safety and Fire Protection services. The Proconics approach to Process Safety and Fire Protection is to identify and assess the risk associated with site-specific hazards and design them out of the process, either by eliminating the hazard or engineering reliable prevention and mitigation measures.
FIRE AND GAS DETECTION
Operators of hazardous installations in South Africa are obligated to ensure that the risk associated with their facilities is As Low As Reasonably Practicable (ALARP). Fire and Gas detection is a commonly utilised mitigation measure to ensure early detection of loss of containment. The efficacy of the solution is heavily reliant on the accurate layout and placement of detectors.
Detection started as canaries in cages but has been evolving with technology ever since. Prescriptive, geographic-based detector placement methodologies are often employed as they require less engineering effort upfront.
The drawback is that these methods result in a higher detector count of questionable contribution. These methodologies yield limited power to evaluate the performance of the design. In contrast to the blunt approaches that ignore the knowledge of physical and chemical conditions, Proconics provides Risk-Based Mapping (RBM) services utilising comprehensive modelling techniques and engineering tools within the In:flux platform, which enables the least cost, performance-based solution in a brown -or greenfield environment. RBM is now endorsed by local and international standards, including BS, ISA and SANS.
Where does Fire
The term “fire protection” includes the protection measures required for spillages of hazardous product, toxic flammable gas releases, fires and explosions. This layered model illustrates the different “phases” or “layers” in the hierarchy.
The third phase refers to the Mitigation of the effect of an incident (AKA Active and Passive Fire Protection) and the aim is the protection of people, physical assets and the environment from the effects of the remaining credible hazards with fire protection measures; Examples: Fire water system, Bunding, Spacing and Location, Remote isolation and Fireproofing.
FIRE AND GAS DETECTORS
Fire and Gas detectors are placed to reduce the risk of undetected gas and prevent the escalation of fires by accurately detecting incipient fires. Comprehensive simulation and modelling incorporate detailed 3D models. Within this 3D model multiple leak and composition combinations are contemplated. These leak scenarios are assigned leak frequencies and based on the comprehensive simulations, dispersion and fire models are developed. Each simulation considers the site-specific meteorological data to account for the impact of ventilation (both natural and forced) as well as ambient temperatures.
A major differentiator between RBM and other methodologies is that RBM considers both likelihood and
consequence. With dispersion models of gas clouds available, it is possible to determine the size of the resultant clouds. A consequence weighting is assigned to each leak, based on the severity of the vent/explosion, considering the size of the gas cloud. This approach ensures that gas detectors are placed to enable early detection, maximizing the opportunity for intervention.
Fire modelling accurately defines the design fire envelope for scenarios based on the radiant heat output (RHO) in kW. Several failure scenarios are considered simultaneously, for example: Overfill, pinhole or a high-pressure leak at a tank or accounting for the directionality of jet fires by modelling each scenario separately. A risk iso-surface, opposed to an assumed volume around equipment, considering both likelihood and consequence, are used as the basis to place line of sight fire detectors in 3D mapping software.
For both fire and gas detection, the ability to assess multiple leak scenarios simultaneously prevents blind spots and reduces superfluous detectors. This positions a single detector to detect leaks from several leak sources. Detectors are optimally placed by considering both the likelihood and consequence of each of the thousands of scenarios. Over the life of the facility, this approach achieves significant cost savings avoiding over capitalisation, reducing operational expenditure, and most importantly preventing life-threatening incidents.
Proconics uses experienced South African talent and applies cutting edge modelling techniques within a specialised modern simulation package. This new approach builds on international best practice. Our engineers work in close collaboration with the simulation platform developer, expanding and improving the capability to solve bespoke problems.
ISA-TR84.00.07-2018 – Guidance on the Evaluation of Fire, Combustible Gas, and Toxic Gas System Effectiveness – August 2018.
BS 60080 2020 – Explosive and toxic atmospheres - Hazard detection mapping - Guidance on the placement of permanently installed flame and gas detection devices using software tools and other techniques.
SANS/IEC 60079-29-2 – Explosive atmospheres Part 29-2: Gas detectors - Selection, installation, use and maintenance of detectors for flammable gases and oxygen.