Hazard Studies & Risk Assessment

Fire & Explosion Risk Analysis (FERA)

3D CFD-class fire and explosion modelling — VCE, BLEVE, jet fire, flash fire, domino

What this study delivers

Fire & Explosion
Risk Analysis (FERA)

FERA underpins facility siting, occupied-building protection, F&G mapping, fireproofing scope, emergency response, and quantitative escalation logic. The discipline has shifted decisively over the last decade from empirical TNT-equivalent and Multi-Energy methods to 3D CFD-class modelling (FLACS, KFX, Ansys Fluent) that captures real congestion, confinement, and ventilation — the difference being orders of magnitude in overpressure prediction for typical petrochemical layouts. The Buncefield 2005 event, where overpressures exceeded all prior modelling expectations, drove a regulator-led move toward CFD for high-consequence cases. Modern FERA work integrates leak frequency from OGP 434 / FRED, ignition probability per Cox-Lees with congestion uplift, BLEVE consequence per Roberts / CCPS, jet-fire radiation per Chamberlain / Cook-Cullis, and Bow-Tie escalation pathways for domino assessment. The hardest decisions remain the boundary conditions: which scenarios merit CFD vs phenomenological modelling, and how to communicate uncertainty to non-technical decision-makers.

Fire & Explosion Risk Analysis (FERA) — Overview
Study execution

How the study is executed

A structured, facilitated process — from scope definition through close-out — producing defensible, actionable outputs.

Scenario Catalogue & Source-Term Modelling

Define FERA scenario set from leak frequency data (OGP 434 / HSE FRED); specify orifice sizes (3 / 10 / 25 mm equivalent for gas; 3 / 50 mm for liquid), fluid phases, and release orientations; calculate source terms including two-phase flash and cryogenic pool formation.

Fire Consequence Modelling

Model pool fires (Thomas / Mudan thermal flux model), jet fires (Chamberlain / Cook-Cullis with radiant fraction), and flash-fire LFL envelopes; calculate radiation iso-contours at 4 / 12.5 / 37.5 kW/m² for PFP scope, detector siting, and occupied-building impact.

Explosion Consequence Modelling

Apply TNT, Multi-Energy, and Baker-Strehlow-Tang methods for screening; deploy FLACS or KFX 3D CFD for high-consequence VCE cases requiring congestion parameterisation (volume blockage ratio, obstacle density); produce overpressure and positive-impulse iso-contours.

BLEVE, Domino & Fireball Assessment

Model BLEVE fireball (Roberts / Hasegawa correlation) for LPG / LNG / pressure-liquefied gas; calculate fragment trajectory and mechanical damage radius; apply Cozzani / IChemE domino thresholds (radiation 37.5 kW/m², overpressure 0.3 bar) for escalation identification.

Ignition Probability & Risk Integration

Apply Cox-Lees ignition model with delayed-ignition conditional split (VCE vs pool / jet fire); integrate frequency × consequence to produce risk metrics; identify dominant risk contributors; generate F&G mapping cloud-size inputs and facility-siting overpressure dataset.

Design Recommendations & Facility-Siting Input

Issue PFP scope optimisation from actual thermal radiation field; provide blast-load specification (peak overpressure, impulse) per API RP 752 for occupied-building assessment; recommend firewater demand and deluge coverage; produce COMAH / EPA RMP-compliant consequence documentation.

Fire & Explosion Risk Analysis (FERA) — Scope
Study scope

What the study covers in full

Source-term modelling — leak orifice, two-phase flashing, cryogenic, fragmentation
Pool fire / jet fire radiation per Chamberlain and Cook-Cullis with view-factor correction
Flash fire envelope per LFL contour with weather and stability binning
VCE modelling — TNT, Multi-Energy, Baker-Strehlow-Tang for screening; FLACS / KFX CFD for high-confidence
BLEVE assessment for LPG / LNG / pressurised liquefied gas — Roberts / Hasegawa fireball correlations
Congestion and confinement parameterisation (volume blockage ratio, obstacle density)
Ignition probability per Cox-Lees with VCE / pool-fire conditional split
Domino effect assessment per Cozzani / IChemE guidance with escalation thresholds
Passive fire protection (PFP) scope optimisation per actual thermal radiation field
F&G mapping input — detector coverage against credible cloud size at LFL fraction
Why it matters

Outcomes of Fire & Explosion Risk Analysis (FERA)

VCE / BLEVE Consequence Accuracy
  • Captures the congestion-driven VCE intensification that Buncefield made visible
  • Identifies BLEVE consequence and escalation pathways before they manifest in incidents
  • Drives PFP scope, F&G coverage, and blast-resistant design from physics, not rules of thumb
  • Anchors realistic muster-point and evacuation-distance siting
API 752 / COMAH Modelling Defence
  • Defensible under API RP 752 / 753 / 756 occupied-building siting examination
  • Supports COMAH / Seveso III consequence-modelling demonstration
  • Provides EPA RMP off-site consequence evidence with high modelling fidelity
  • Withstands underwriter and insurance broker challenge in renewal cycles
PFP & F&G Design Optimisation
  • Right-sizes firewater demand, deluge coverage, and PFP scope to actual thermal load
  • Drives F&G detector siting to credible cloud sizes — not regulatory minima
  • Informs realistic emergency-response drill scenarios
  • Identifies the small subset of equipment driving the dominant fire / explosion risk
PFP Scope & BI Exposure Reduction
  • Avoids the 20–50% PFP over-scoping common in legacy installations
  • Defers building reinforcement capex through quantified blast-load evidence
  • Reduces underwriter loadings via demonstrated high-fidelity modelling
  • Cuts loss-of-containment business-interruption exposure
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