Apex Petrochemical Complex
Safety limits & hazards
Centralized operating thresholds and the plant hazard catalog. Future risk presentation and AI explanations should cite these bands instead of inventing new cutoffs.
Applicable standards
Governance framework for Apex operations and SENTINEL demo narratives
Operating thresholds
Hydrogen Sulfide (H₂S)
Parameter gas_h2s · ppm
| Band | Range |
|---|---|
normal | 0–10 ppm |
warning | 10–25 ppm |
danger | 25–45 ppm |
critical | ≥ 45 ppm |
Aligned with industrial hygiene practice for fixed-point detectors. Escape / ESD logic may trigger earlier based on wind and occupancy.
Process Temperature
Parameter temperature · °C
| Band | Range |
|---|---|
normal | 0–120 °C |
warning | 120–180 °C |
danger | 180–250 °C |
critical | ≥ 250 °C |
Generic process band; reactor bed and boiler steam circuits apply equipment-specific setpoints via DCS while SENTINEL uses this shared severity ladder.
Process Pressure
Parameter pressure · bar(g)
| Band | Range |
|---|---|
normal | 0–15 bar(g) |
warning | 15–28 bar(g) |
danger | 28–40 bar(g) |
critical | ≥ 40 bar(g) |
Covers intermediate hydrocarbon headers. LPG bullets and steam drums have PSV setpoints documented on equipment tags.
Worker Density
Parameter worker_presence · persons / zone
| Band | Range |
|---|---|
normal | 0–8 persons / zone |
warning | 8–15 persons / zone |
danger | 15–25 persons / zone |
critical | ≥ 25 persons / zone |
Simultaneous operations and turnaround crewing elevate density. Pair with permit status for confined-space work.
Ambient Noise
Parameter noise · dB(A)
| Band | Range |
|---|---|
normal | 0–85 dB(A) |
warning | 85–95 dB(A) |
danger | 95–105 dB(A) |
critical | ≥ 105 dB(A) |
Hearing conservation and escape-audibility thresholds for outdoor process areas.
Relative Humidity
Parameter humidity · % RH
| Band | Range |
|---|---|
normal | 20–70 % RH |
warning | 70–85 % RH |
danger | 85–95 % RH |
critical | ≥ 95 % RH |
High humidity affects electrostatic control at loading and corrosion rates on piping.
Critical Valve Deviation
Parameter valve_state · % open vs setpoint
| Band | Range |
|---|---|
normal | 0–5 % open vs setpoint |
warning | 5–15 % open vs setpoint |
danger | 15–30 % open vs setpoint |
critical | ≥ 30 % open vs setpoint |
Absolute deviation from expected ESD / process position. Stuck-open isolation on H₂S or LPG service is treated as critical.
Hazard catalog
Hydrogen Sulfide Release
Sour-service H₂S exposure risk from flanges, knockout drums, and vapor recovery. Immediately dangerous above occupational exposure limits; ignition risk when mixed with air in confined spaces.
Zones: zone-a-12zone-c-03
LPG BLEVE / Vapor Cloud
Pressurized LPG inventory can produce boiling liquid expanding vapor explosion (BLEVE) or dense vapor clouds if tank integrity or loading arms fail.
Zones: zone-d-05zone-e-09
High-Pressure Steam Jet
Superheated steam leaks from boiler headers and steam tracing can cause severe burns and force zone evacuation.
Zones: zone-b-07
Catalytic Runaway / Overpressure
Exothermic reaction excursions in the catalytic reactor train can drive rapid pressure and temperature rise requiring ESD.
Zones: zone-c-03
High-Pressure Hydrocarbon Line Break
Transfer headers between process units carry pressurized hydrocarbons; rupture creates jet fire and toxic dispersion pathways.
Zones: zone-a-12zone-b-07zone-c-03zone-d-05zone-e-09
Loading Arm Spillage / Vehicle Impact
Road tanker and rail rack operations introduce vehicle impact, hose disconnect, and static ignition hazards during product dispatch.
Zones: zone-e-09