MONDS TOXICITY INDEX

JITHIN.K.JOSE NIRMAL.A RAHUL SREEKUMAR VISHNU VENUGOPAL B090311CH B090540CH B090995CH B090369CH

NEED FOR AN INDEX

To get an approximate yet workable assessment of risk at much lesser costs, indices have been developed which link typical findings of elaborate risk analysis to scales of risk.

NEED FOR A TOXICITY INDEX

Many possible effects, both chronic and acute. There are several different routes of exposure length of exposure frequency important Individuals may differ markedly in response to a particular dose. There is often difficulty in getting an agreed doseresponse relationship for humans, Therefore, the task of constructing a meaningful toxicity index is formidable

BASIS FOR THE TOXICITY INDEX

The inhalation route was selected as the basis for assessing toxic hazard potential.

In a fully quantitative analysis, the area affected by the release would be estimated

Skin effects, either absorptive, corrosive, or scalding, can be very severe but are usually confined to a very short distance from a release point, whereas inhalation effects may be important over a considerably greater range and may extend off-site.
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How to Rank the Hazards?

Two indices are mainly used for the ranking of hazards. Dow Index and the Mond Index, used for Systematically identifying hazards Providing a method of ranking priorities

The Dow Index was originally developed by the Dow Chemical Company to assist in the selection of fire protection methods.

The Mond Index was developed by ICI for the chemical industry, after the Flixborough disaster. It expands on the Dow Index

MONDS TOXICITY INDEX

The monds toxicity index was developed from dow F and dow E index by personnel at the ICI Mond division.

This edition (1973) was extended to cover a wider range of

process and storage installations.

Also included was a procedure to allow for the effects of

good design, and of control and safety instrumentation.
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MONDS TOXICITY INDEX

It takes account of circumstances other than processing, such as storage, loading, unloading and toxicity hazards Assess the potential for immediate toxic effects to humans from the material within the unit.
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PROCEDURE

The process is first divided into a number of units which are assessed individually

The dominant material for each unit is then selected and its material factor determined

The material factor in the mond index is a function of the energy content per unit weight(the heat of combustion).
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The material factor is then modified to allow for the effect of general and special process and materials hazards, the physical quantity of the material in the process step, the plant layout and the toxicity of process materials

Separate fire and explosion indices are calculated. An aerial explosion index can also be estimated, to assess the potential hazards of aerial explosions

The individual fire and explosion indices are combined to give an overall index for the process unit, The overall index is the most important in assessing the potential hazard. The magnitude of the potential hazard is determined by the reference to rating tables.

After the initial calculation of the indices,the process is reviewed to see what measures can be taken to reduce the rating(the potential hazard)

The appropriate offsetting factors to allow for the preventive features included in the design are then applied, and final hazard indices calculated.

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PREVENTIVE MEASURES They fall into 2 categories:

1)those that reduce the number of incidents,such as sound mechanical design of the equipment and piping,operating and maintenance procedures,and operator training

2)Those that reduce the scale of a potential incident,such as measures for fire protection,and fixed fire fighting equipment.

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IMPLEMENTATION
The mond technique of hazard evaluation is fully explained in the ICI technical manual,ICI1993,to which reference should be made to implement the method

The calculations are made using a standard form,A computer program is available for use with IBM compatible personal computers
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STAGES OF DETERMINING THE TOXICITY INDEX

Divide the plant into units, each to be analyzed separately Identify the dominant toxic material within the unit

Estimate the maximum rate of vapor generation (Q) using the guidelines Select an appropriate value for the limiting vapor concentration (X).

Calculate the base toxicity factor from Q and X. Allocate penalty factors for material, process, and layout features
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Dividing the plant into units

The process of division into units should match changes of process conditions or operations within the overall plant It is important not to mask units of high potential by including them within a large section with materials of lower toxicity so that a low toxicity factor is used in the index

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Estimating the rate of vapor generation

For all conditions, there are standard formulas or procedures for quantitative estimation, and computer programs are available for the calculations. Examples of such programs are Whazan (Technica), Chems-Plus (Arthur D. Little). To make the estimate, the physical properties of the material are needed in addition to the conditions at the release point. These will include the size and shape of the release orifice

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 External conditions may affect the vapor generation rate, for example, when a cold liquid is spilled and the vapor generation rate depends on the area

covered and the rate of heat flow from the ground

into the spilt material

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Selecting the toxic concentration

The basis of the 5-min period is that in an incident, it can be expected that within that time a worker on a chemical plant or process would either have escaped from the affected area or have donned protective equipment the basis for various limits, when available as Toxicity Reviews should be consulted because the required information for a tolerable level for a single short exposure may be provided.
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Calculating the base factor T from Q and X

to relate T to the area within which the chosen limiting concentration would be exceeded. a measure of the area potentially at risk from a release from a particular unit is the ratio (Q/X) of the rate of vapor generation (Q) and the toxic concentration (X) T = 2 /(Q/X) - 3
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Allocating penalty factors for material, process, and layout features

Material properties: penalty factor M. General process features: penalty factor P. This is intended to allow for features of the plant and process that may affect the likelihood of a release or its magnitude
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 Special process factors: penalty factor S. This section is intended to make allowance for features such as extremes of temperature or pressure because these make loss of containment more likely or more difficult to control. Material strength, corrosion, and erosion effects, as well as vibration and load cycling, are included here. In addition, material properties relating to flammability and any special operating conditions, L (e.g., closeness to the flammable region) are covered
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Determine the final index value by combination of T and these penalty factors; use the given scales to rank the toxic hazard as one of seven ranges from low to extreme
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Determining the final index value

Toxicity index = T[l + (M/100)][1+ P/100)] [1 + (S/100)+(L/100)]

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Mond Indices
Fire & Explosion index Toxicity Index :(F & E1) = MF x (GPH) (SPH) : Th + Ts (1+GPH+SPH) 100 MF SPH GPH Th Ts = Material Factor = Special Process Hazard = General Process Hazard = Toxicity factor based on the NFPA hazard index (0 4) = Correction factor (additional penalty) for toxicity based on Maximum Allowable Concentration (MAC) value in ppm

Where,

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Process Hazard Management

General Process Hazard (GPH)
GPH includes processes e.g. exothermic reaction, endothermic reactions, hydrogenation, alkylation, isomerisation, sulphurization, neutralization, esterification, oxidation, polymerization, condensation, halogenation, nitration, loadingunloading operation, enclosed process units, inadequate drainage and proper access etc. different penalties are assigned for different processes.

Process Hazard Management

Special Process Hazard (SPH)
SPH includes special hazards posed due to process parameters like temp., pressure, flammability ranges (UEL, LEL) of material and issues like internal and external corrosion, leakage from joints etc. additional penalties are assigned for special process hazards. Selection of the process units which may contribute to a fire or explosion or toxic release

Toxicity Factors and Correction Factor for MAC values

NFPA Index Number 0 1 2 3 4 MAC (in ppm) 5 and blow Toxicity Factory (Th) 0 50 125 250 325 TS 125

Between 5 and 50
50 and more

75
50
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Risk Analysis
General Principles of Risk Analysis
1. All

relevant addressed
Consider

risks

are

systematically

Identify major, dont concentrate on minor

those

aspects

of

work

which

are

hazardous Take into account & critically assess existing safety controls & measures provided

2. Address what actually happens Actual practice, not instruction Consider non-routine operations Pay attention to changes/interruptions

Risk Analysis
General Principles of Risk Analysis
3.
4. 5.

Include all who could be affected, including visitors, contractors, and general public
Take into account, and objectively assess, control measures The level of protection measures should match the level of risk (i.e. risk within the ALARP region) In most cases, make a rough assessment first, find out the need for detailed assessment and carry out the same, if needed.

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Indices and the Extent of Hazard

Dow F & E index 1 60 61 96 97 127 MondsToxicit y Index 16 6 10 > 10 Degree of Hazard Light Moderate Intermediate

128 158
> 159

> 10
> 10

Heavy
Severe

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