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Chemical Reactivity Evaluation Tool Help Guide

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RMT Help Guide v1.0 January 2012 CChheemmiiccaall RReeaaccttiivviittyy EEvvaalluuaattiioonn TTooooll HHeellpp GGuuiiddee Edward M Davis Daniel E Sliva John F. Murphy Robert W. Johnson Steven W. Rudy Copyright © 2012 AIChE P a g e | 1 RMT Help Guide v1.0 January 2012 Table of Contents Follow links ending with an * to a more detailed sectional table of contents. READ ME FIRST ..............................................................................................................3 Acknowledgments .............................................................................................................................5 Legal Disclaimer and Limits of Liability ...............................................................................................7 Preface ...............................................................................................................................................8 Quick Start .......................................................................................................................10 1 Introduction ...................................................................................................................11 1.1 Background ............................................................................................................................... 12 1.2 Objectives ................................................................................................................................. 13 1.3 Limitations ................................................................................................................................ 13 1.4 Approach ................................................................................................................................... 14 1.5 Intended Audience .................................................................................................................... 14 2 Program Flow ................................................................................................................15 2.1 Primary Flow Chart..................................................................................................................... 15 2.2 Evaluate Pure Componant Reactivity Hazards ............................................................................ 16 2.3 Evaluate Chemical Interaction Hazards ...................................................................................... 17 2.4 Develop Chemical Reactivity Scenarios ...................................................................................... 18 2.5 Evaluate Heat Release and Pressure Generation Hazards........................................................... 19 2.6 Overview of Workflow and Chemical Data Entry ........................................................................ 20 3 Program Usage ..............................................................................................................26 3.1 Installing and Starting the Program * ......................................................................................... 26 3.2 Step by Step Program Instructions * .......................................................................................... 47 4 Strategy ..........................................................................................................................77 4.1 Selection of Process Chemicals ................................................................................................... 77 4.2 How to Determine DOT Information from an MSDS ................................................................... 79 4.3 Guidance on Selected Pure Componant Hazards * ..................................................................... 80 4.4 Developing Credible Scenarios ................................................................................................... 99 4.5 Determining Heat of Reaction .................................................................................................. 100 4.6 Calculation of Adiabatic Temperature Rise and MTSR .............................................................. 103 4.7 Determining Temperature of Concern ...................................................................................... 103 4.8 Determining Maximum Reaction Pressure ............................................................................... 104 4.9 Determining Pressure of Concern ............................................................................................. 105 4.10 Determining the Validity of Information from Matrix Reports ............................................... 106 5 Worked Examples .......................................................................................................107 5.0 Common Preliminary Steps * ................................................................................................... 107 5.1 Warehousing Example* ............................................................................................................ 116 5.2 Napp Technologies - Physical Processing * ............................................................................... 122 5.3 XYZ Pharmaceuticals – Intentional Chemistry * ........................................................................ 140 APPENDICES ................................................................................................................186 Appendix A: Program Code Keys * ................................................................................................. 186 Appendix B: FAQ * ......................................................................................................................... 191 Appendix C: Abbreviations and Acronyms ..................................................................................... 195 Appendix D: Developing a Reactivity Management System ........................................................... 196 Appendix E: Glossary ..................................................................................................................... 198 Appendix F: Bibligraphy: Suggested Referances for Further Reading *........................................... 209 Appendix G: Known Programming Bugs ......................................................................................... 215 Afterword: Future Direction........................................................................................................... 216 Index ................................................................................................................................217 Copyright © 2012 AIChE P a g e | 2 RMT Help Guide v1.0 January 2012 READ ME FIRST The authors do not expect the average user to read through the entire manual in order to become proficient in the use of the chemical reactivity evaluation Tool (RMT) however the novice would be well served to study the following sections prior to attempting to use the program or follow the step by stem instructions or worked examples: Entire Read Me First section Section 1 Introduction Section 2 Program Flow Section 4 Strategy Appendix D: Developing a Reactivity Management System. The Table of Contents on the previous page has been set up to aid the user in quickly locating information on a particular topic. Main topics with an * next to the name denote that this section contains a more detailed table of contents to further aid the user in locating specific help within that section. EVERYONE: It is strongly suggested you use the QUICK START section to properly install the program and its independent supporting programs. More detailed step by step installation instructions are located in Section 3.1 should the user require them. The program has some ―quarks‖ which are explained in the FAQ section. Reviewing theses two sections will save the user much time and frustration. It is critical that all users understand the objectives and limitations of the program and how these might relate to your specific site objectives and goals. This information is presented in the introduction section of this guide (pages 11 through 14). The user, both experienced and inexperienced, will also benefit from reviewing the programs block flow diagram located in section 2. Sections 2.1 gives a one page overview of the entire program flow with links to four one page sub-routine block flow charts. Section 2.6 presents the entire program block flow with one to 2 sentence explanations of each block After that, even the user knowledgeable in process safety evaluations, will benefit from reading the STRATEGY section. Each strategy sub-section is a detailed how-to guide for the key program inputs. Look for the following icons that call out helpful suggestions or common mistakes Copyright © 2012 AIChE P a g e | 3 RMT Help Guide v1.0 January 2012 PROCESS SAFETY NOVICES: For those new to process safety evaluation, the STEP BY STEP INSTRUCTIONS in section 3 are laid out such that the user is taken through the program screen by screen with detailed information on the data required for each screen and how to obtain it. Finally the WORKED EXAMPLES sections present detailed examples with screen by screen instructions from data entry through evaluation and report generation. The novice would be well advised to make full use of this section to practice process hazard evaluation. Copyright © 2012 AIChE P a g e | 4 RMT Help Guide v1.0 January 2012 Acknowledgments The Center for Chemical Process Safety (CCPS) thanks all of the members of the Reactivity Subcommittee of CCPS‘ Technical Steering
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