Professional Documents
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Table of Contents
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PROJECT DESCRIPTION ............................................................................................... 4 1.1 Introduction............................................................................................................ 4 1.2 Project Objective ................................................................................................... 4 1.3 TEBODIN Scope of Services ................................................................................ 4 1.4 Areas/Facilities covered under FRA study ........................................................... 5 1.5 Purpose of the Document ..................................................................................... 7 PROJECT INFORMATION .............................................................................................. 8 2.1 Project Title ........................................................................................................... 8 2.2 Definitions.............................................................................................................. 8 2.3 Abbreviations ........................................................................................................ 8 FRA METHODOLOGY ..................................................................................................... 9 3.1 Hazard Identification ........................................................................................... 10 3.2 Inventory Analysis ............................................................................................... 10 3.3 Consequence Analysis ....................................................................................... 11 3.4 Fire Risk Assessment ......................................................................................... 11 3.5 Escalation Analysis and Assessment Criteria .................................................... 11 3.6 Passive Fire Protection (PFP) ............................................................................ 12 3.7 Active Fire Protection (AFP) ............................................................................... 12 FRA ASSUMPTION REGISTER .................................................................................... 13
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1.
1.1
1.2
Project Objective
The objective of this Fire Risk Assessment (FRA) study is to assess the potential fire hazards in the facilities.
1.3
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3. 4. 5.
Perform the modelling for the identified potential hazards. Draft report will be provided to AKZO NOBEL. Final FRA report will be submitted to AKZO NOBEL.
1.4
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RAW MATERIALS PREPARATION Upon receiving a raw materials pick list, the raw materials handler prepares and weighs the required materials and places them on a wooden pallet. All pigments and powdery materials are prepared and weighed in a powder weighing booth provided with a dust collector. All solvents are weighed and prepared at the solvent dispensing area while the additives are prepared at the semi finish weighing area. All along, the hand pallet lorry and the explosion proof type of forklift truck are used to move the palletized raw materials and portable tanks containing the products in the production area. DISPERSION - PREMIXING All manufacturing recipes would be based on two routes: namely the HSD (High Speed Disperser) - Bead Mill route wherever secondary dispersion is required or the only HSD / Let down Mixing route otherwise. There are 4 units of HSD capable of dispersing products in portables tanks with capacities ranging from 500 up to 2,000 L. These units are installed in a closed ventilated room and the room is equipped with a dust collector. In this stage, solvent, dispersant additive, pigment and resin are slowly added into portables tanks and are stirred from low to high speed to achieve homogeneity of the products. The dust collector extracts the dust generated from the loading of pigment and other powdery raw materials. DISPERSION - BEADMILLING Once the intermediate from the above premixing stage is QC passed, it is then taken out from the Premix room to the bead milling area. In this stage the intermediate is run through a bead milling machine for several passes until the fineness of the product is achieved. In normal run, one pass goes for around 4 hours. The intermediates output from this stage is called mill base. There are 5 units of horizontal bead milling machines ranging from 5 up to 45 L grinding chambers. The grinding chamber is cooled with a chilled water of 3C to reduce the generated heat. The bead milling machines are dedicated to certain products based on mutual compatibility and to avoid cross contamination. LET DOWN Once the mill base is QC passed, it then must right away be processed in the next process stage called Let Down. The portable tank containing the mill base is transferred to the Letdown area. In here, the mill base is added with more resin and additives to stabilize the mill base to prevent the pigment from agglomerating again. It is then mixed well at a low speed to give a homogeneity product. Through color matching, adjustment and quality control test, the product is QC passed and is now ready to be filled into containers. A fume extraction unit is installed in all production area to tap off the released vapor. FILLING The portable tank containing the product is then transferred to the filling area for filling. From the filling batch ticket, the required packaging such as empty cans, labels, boxes and lids are prepared by the raw materials handler and issued to production. During the filling, the product is pumped through a pump filter set then goes into the hopper of the filling machine. There are 7 filling machines of type manual and semiautomatic available plus putty press filling machine. Three of them are manual and weight based type (gravity based). Four of them are of semi-automatic type and volumetric based. The filling machines are
DOC. NO.: 3415001
Z:\Dept - HSE\INDONESIA - AKZO NOBEL
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dedicated to certain products to avoid cross contamination. Upon finishing the filling, the packed product is then the next batch of paints. A portable tank cleaning unit is currently being ordered to eliminate the manual cleaning transferred to the Distribution Center for delivery to customers. The empty portable tank is then brought to the tank cleaning area for cleaning prior to be used for the tank. The cleaning solvent is recycled until several uses then collected in 200L drums as a dirty solvent which later on is sent to the legalized third party recycler. Fig 1: Process Flow
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2.
2.1
2.2
Definitions
COMPANY CONSULTANT AKZO NOBEL, INDONESIA M/s. Tebodin Consultants and Engineers India Ltd; (TCEI), appointed by the COMPANY (AKZO NOBEL, INDONESIA) to perform PROJECT. The contract between COMPANY (AKZO NOBEL) and CONSULTANT (TCEI) for PROJECT (FRA AND HAC ZONING FOR AKZO NOBEL). FRA AND HAC ZONING FOR AKZO NOBEL Services being provided by TEBODIN as per the CONTRACT for the PROJECT Tebodin Consultants and Engineers India Ltd;
CONTRACT
2.3
Abbreviations
AFP API FRA HA HAC HSD IP MTO MTS NFPA OGP PFD PFP PID QC TCEI VCE Active Fire Protection American Petroleum Institute Fire Risk Assessment Hectares Hazardous Area Classification High Speed Disperser Petroleum Institute Made to Order Made to Stock National Fire Protection Association Oil & Gas Producers Process Flow Diagram Passive Fire Protection Piping and Instrumentation Diagram Quality Control Tebodin Consultants and Engineers India Vapour Cloud Explosion
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3.
FRA METHODOLOGY
The methodology adopted for this FRA is presented graphically below:
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In summary, the FRA study will involve the following key steps: Identification of the hazardous material inventory applicable to the project includes flow rate, pressure, temperature, composition etc. Modelling of physical effects based upon the process conditions of the hazardous material inventories, and assumptions regarding release hole sizes Investigate the effect of flame impingement between equipment. Recommend additional requirements for Fire Protection Systems (AFP/PFP). The risk contribution that arises from this project will be calculated and this will be compared against OGP risk acceptance criteria.
3.1
Hazard Identification
Identify the potential hazards related to the fire scenarios. FRA study excludes the analysis of toxic impact as its purpose is to assess the impact of fire events onto assets.
3.2
Inventory Analysis
The first step in evaluating the FRA is the identification of fuel sources and their location. This includes information relating to the fuel itself, and the inventories stored or processed, together with the process conditions. Inventory analysis involves the following:
Identification of scenarios based on one Process/Storage Unit to another Process/Storage Unit within the process units. Calculation of volume hold-up for different scenarios with respect to gas or liquid within the equipment.
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3.3
Consequence Analysis
The Fire Hazard Information enables the likely fire scenario to be developed based on a consideration of the events that follow a release of material. For Example, a release of gas that undergoes immediate ignition will result in jet fire. This stage of the fire analysis involves determination of the impact of each of the identified hazardous outcomes from various release events (e.g. gas jet, flashing liquid jet, liquid pool). The consequence modelling is performed using the latest version of PHAST v 6.7 software. The outcome of the modelling will be reported in terms of the extent of thermal effects distances.
3.4
Assessment of the credible release from leak hole size. Investigate the effect of flame impingement between equipment. Recommend additional requirements for Fire Protection Systems (AFP / PFP).
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3.6
Vessels Pipework between vessels Manual valves* Vessel and pipework supports. Note*: All valves used are assumed to be Manual Valves.
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FRA FOR AKZO NOBEL AKZO NOBEL FRA Project Scope All Rev.: A Assumption No. Date: 1 08/10/2013
Tebodin scope of work is to perform Fire Risk Assessment for the Production Process which covers;
Diesel Storage Production Area which covers: Big Tank Mobile Tank Area Mixing Room Raw Material Filling Hardener Area SFG Storage Transfer Area
Drum Yard Warehouse Tank Area (Tanks 1 and 2 storing Xylene and Butyl Acetate) Color Warehouse
Site survey and Data collection. Review of collected data and present a list of assumptions in the form of FRA assumption register which shall be reviewed and approved. Perform the modelling for the identified potential hazards. Draft report will be provided to AKZO NOBEL. Final FRA report will be submitted to AKZO NOBEL.
Exclusions: [Ref 1]
The battery charger area is not likely to hold up hazardous material. Hence it has not been included in the hazard study. The QC lab will be holding up a minimal amount of hazardous material. Hence it has not been included in the hazard study.
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FRA FOR AKZO NOBEL AKZO NOBEL FRA Project Scope All Rev.: A Assumption No. Date: 1 08/10/2013
The Tank cleaning area is considered to have minimal amount of hazardous material capable of causing fire/explosion as its not used periodically. Hence it has not been included in the hazard study. The Labelling area is not considered to have very high amount of hazardous material capable of causing fire/explosion. Hence it has not been included in the hazard study. The Packaging Ware House area is considered to have minimal amount of hazardous material capable of causing fire/explosion. Hence it has not been included in the hazard study. Ruang Bonded Ware House is considered to have minimal amount of hazardous material capable of causing fire/explosion. Hence it has not been included in the hazard study.
Reference: 1. Site Visit Data TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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FRA FOR AKZO NOBEL AKZO NOBEL Atmospheric Condition All Rev.: A Assumption No. Date: 2 08/10/2013
Ambient Conditions [Ref. 1] 1. 2. 3. 4. Average Ambient Temperature Average Barometric Pressure Average Relative Humidity Solar Radiation : 28 C : 1 bar : 64 % : 0.882 kW/m2
The Pasquill Atmospheric Stability Classes Table 1: Pasquill Stability Class Stability Class A B C D E F Definition Very Unstable Unstable Slightly Unstable Neutral Slightly Stable Stable
Based on the Table 1, following stability / wind-speed categories shall be used in the study for two weather conditions representing day and night:
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FRA FOR AKZO NOBEL AKZO NOBEL Atmospheric Condition All Rev.: A Assumption No. Date: 2 08/10/2013
Table 2: Wind Direction Probability by Wind Speed [Ref 2] The meteorological data for the Jakarta, Indonesia airport for the years 2001 to 2010 as follows: (Wind direction coming from) N NNE NE ENE E ESE SE SSE S SSW SW WSW W WNW NW NNW Total Surface Roughness The ground characteristics are represented by surface roughness which will be assumed as 0.1m (10cm) Low crops, occasional large obstacles. Weather Class / Wind speed Probability F2 0.059 0.035 0.012 0.010 0.008 0.008 0.008 0.014 0.021 0.021 0.021 0.017 0.013 0.018 0.023 0.041 0.326 C5 0.078 0.049 0.020 0.019 0.019 0.014 0.009 0.019 0.028 0.028 0.029 0.018 0.007 0.013 0.020 0.049 0.416 C/D7 0.024 0.023 0.021 0.024 0.027 0.016 0.004 0.007 0.009 0.015 0.021 0.012 0.003 0.005 0.007 0.015 0.232 D9 0.001 0.003 0.005 0.004 0.003 0.001 0.000 0.000 0.001 0.002 0.003 0.001 0.000 0.000 0.000 0.001 0.025 TOTAL 0.162 0.110 0.058 0.057 0.056 0.038 0.021 0.040 0.059 0.066 0.073 0.047 0.022 0.035 0.049 0.105 1.000
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FRA FOR AKZO NOBEL AKZO NOBEL Atmospheric Condition All Rev.: A Assumption No. Date: 2 08/10/2013
Reference: 1. Atmospheric measurement Data provided by Client 2. Typical Weather Data for Jakarta from Internet (www.solarshine.com) TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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FRA FOR AKZO NOBEL AKZO NOBEL Scenarios All Rev.: A Assumption No. Date: 3 08/10/2013
Basis for Scenario: Each possible different section is considered to hold hazardous material capable of causing fire/explosion, at one possible time, within the plant facility. The following table represents the Scenarios that were considered for this study; Table 3: Scenarios : Scenario Number Description
Loss of containment from Diesel Storage Tank Loss of containment from Drums in Raw material storage area Loss of containment from Big Tank Loss of containment from Drums/Tanks Mobile Tank area Loss of containment from Drums in Mixing Room
Loss of containment from Drums in Cold Room Loss of containment from Drums in Transfer Area Loss of containment from Drums in Filling Hardener Area Loss of containment from Drums in Color WareHouse
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FRA FOR AKZO NOBEL AKZO NOBEL Scenarios All Rev.: A Assumption No. Date: 3 08/10/2013
Loss of containment from Drums in Drum Yard Loss of containment from Drums Outside Drum Yard Loss of containment from Tank in Tank Area Loss of containment WareHouse from Drums/cans in
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13
14 Reference:
TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
Table 4: Process and Operating Conditions: The following table represents the Process and Operating conditions for this study: Quantity (liters) 2000 Operating Pressure (barg) Amb Operating Temp. o ( C) Amb
Scenario
Description Loss of containment from Diesel Storage Tank Loss of containment from Drums in Raw material storage area1 Loss of containment from Big Tank 2
Phase
Material
Composition*
Liquid
Diesel
N-Undecane Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% Toluene: 60 % n-Butanol: 40 %
Liquid
SETALUX 1160 XS 51
2000
Amb
Amb
Liquid
Dianal DG 4040
3050
Amb
Amb
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
Liquid, Resin
n-hexane: (15-20)% Heptane & isomers: (3236)% Cyclohexane: (25-27)% Methylcyclohexane: (3-7)% n-hexane: (15-20)% Heptane & isomers: (3236)% Cyclohexane: (25-27)% Methylcyclohexane: (3-7)% n hexane: 25% xylene:25% toluene: 15% cyclohexane:15% pentane:15% heptane:5% n-hexane: (15-20)% Heptane & isomers: (3236)% Cyclohexane: (25-27)%
2000
Amb
Amb
Liquid
500
Amb
Amb
Liquid
Exxsol D30
10000
Amb
Amb
Liquid
700
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
Methylcyclohexane: (3-7)% 8 Loss of containment from 7 Drums in Transfer Area Loss of containment from Drums in Filling Hardener Area8 Loss of containment from 9 Drums in Color WareHouse Liquid SETALUX 1160 XS 51 SETALUX 1160 XS 51 SETALUX 1160 XS 51 Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% Xylene: 70% Ethyl Benzene: 16% n-butyl acetate: 14% n hexane: 25% xylene:25% toluene: 15% cyclohexane:15% pentane:15% heptane:5% n-butanol 2500 Amb Amb
Liquid
2500
Amb
Amb
10
Liquid
1700
Amb
Amb
11
Liquid
Exxsol D30
5200
Amb
Amb
12
Liquid
Butanol Normal
825
Amb
Amb
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
Liquid
n-Butyl Acetate
n - Butyl Acetate n hexane: 25% xylene:25% toluene: 15% cyclohexane:15% pentane:15% heptane:5%
1200
Amb
Amb
14
Liquid
Exxsol D30
800
Amb
Amb
Note: * - Composition taken up such that it is accepted by DNVs PHAST 6.7 software used for modelling.
1. Raw material storage is assumed to have Talc & Resin to a total quantity of 398.4 (498 <pallets>*4<drums>*200kg<weightage of each drum>) tonnes. Since it may have substances ranging in different flashpoints, we assume that it may have a total number of 55 different resins & 120 different Talc of equal Quantity i.e., 2.34 tonnes of each material roughly. 2. Big Tank Area consists of 12 Tanks. Each tanks processing capacity is given as 3000kg. Dianal DG 4040 is considered for this area. 3. Mobile Tank Area is assumed to have minimal processing capacity. Assuming it has processing capacity of 25 drums with each drum weightage of 200 kg, the quantity of hazardous material present is 5000 kg. Since it may have resins and solvents, we consider Exxsol DSP 80/100 to be at 2000 l for this study.
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
Assumption/ Rule Set: 4. Mixing Room has pigment, dispersant, additive & solvent. Assuming the maximum capacity of 2000 l, EXXSOL DSP 80/100 with a flashpoint of -15 C is assumed to have 500 l at one possible time. 5. SFG storage area is assumed to have solvents to a total quantity of 412.8 (516 <pallets>*4<drums>*200kg<weightage of each drum>) tonnes. Since it may have solvents ranging in different flashpoints, we assume it to have a total of 50 different solvents of equal Quantity i.e., 8 tonnes of each material roughly. 6. EXXSOL DSP 80/100 with a flash point of 15 C is considered for this area. Cold Room is assumed to store substances with flashpoints ranging from 15 to 10 C. Assuming it has 11 different substances, the volume of EXXSOL DSP 80/100 is taken as 700 l. 7. Assuming Big Tanks final outlet i.e., 3 tonnes of product is being sent to Transfer Area at one possible time. Hence, Transfer Areas capacity at one possible time is assumed to be 3 tonnes. Assuming the product to flash point above 10 C, SETALUX 1160 XS 51 or a material having a similar flash point is assumed for this study. 8. Filling Hardener Area is assumed to have 3 tonnes of capacity at one possible time. 9. Colour Ware House is assumed to have 5 different products. The total capacity is 50 drums with each drum having a capacity of 200 kg, at one possible time. 10. Drum Yard is assumed to have solvents with a total quantity of 202.4 (253 <pallets>*4<drums>*200kg<weightage of each drum>) tonnes. Since it may have solvents ranging in different flashpoints, we assume it to have a total of 50 different solvents of equal Quantity i.e., 4 tonnes of each material roughly. 11. Outside Drum Yard facility that extends upto area outside Packaging Warehouse, Ruang Bonded Warehouse & Loading area is assumed to have solvents to a total quantity of 33 ([112+32+32] <pallets>) tonnes. Since it may have solvents ranging in different flashpoints, we assume it to have a total of 50 different solvents
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
Assumption/ Rule Set: of equal Quantity i.e., 660 kg of each material roughly. Butanol Normal is assumed for this study. 12. Ware House is assumed to have a total of 25 different products of equal quantity stored in 20 litres can/drum. Ware House is assumed to have storage capacity of 1000 numbers at one possible time.
Reference: 1. Data provided by Client. TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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FRA FOR AKZO NOBEL AKZO NOBEL Process Condition & Material Composition All Rev.: A Assumption No. Date: 08/10/2013 4
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Project: Client: Assumption Calculation Run: Assumption/ Rule Set: Release Size
FRA FOR AKZO NOBEL AKZO NOBEL Release Size, Height, Duration & Direction All Rev.: A Assumption No. Date: 5 08/10/2013
The Following Leak Sizes are to be considered for this FRA study:[Ref 1] 10 mm 25 mm 50 mm
Since most of the storage is in Drums, leak sizes 25mm and above are the most suitable for this study. Release height The release height shall be assumed as 1 m. Release Duration The release duration shall be assumed as 30 minutes (1800 Seconds) or inventory depletion whichever is earlier. Release Direction The release direction is assumed as Horizontal.
Reference: 1. OGP Risk Assessment Data Directory, Report No. 434 1. TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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FRA FOR AKZO NOBEL AKZO NOBEL Impact Criteria All Rev.: A Assumption No. Date: 6 08/10/2013
The following impact criteria shall be used for this FRA study: Table 5: Impact Criteria [Ref 1] Accident Hazards Criteria 6 Unit kW/m2 Assessment Impairment of escape routes Extreme pain within 20s; movement to shelter is instinctive; fatality if escape is not possible. Outdoors/offshore: 70% lethality Indoors onshore: 30% lethality* 20 Incapacitation, leading to fatality unless rescue is done quickly. Immediate fatality (100% lethality)
kW/m2
kW/m
35
kW/m2
Reference: 1. OGP Risk Assessment Data Directory Report No: 434 14.1 TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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FRA FOR AKZO NOBEL AKZO NOBEL Vulnerability All Rev.: A Assumption No. Date: 7 08/10/2013
The following Table represents the Indoor / Outdoor vulnerabilities for this FRA Study: Table 6: Indoor / Outdoor Vulnerabilities Scenario Flash Fire (inside flame envelope) Jet Fire, Pool Fire ( 35 kW/m2) Indoor Vulnerability 0.2 0.2 Outdoor Vulnerability 0.7 0.7
Reference:
TEBODIN Assumption Initiated by (sign): TEBODIN Assumption Verified by (sign): AKZO NOBEL Assumption Agreed Upon (sign): Comments:
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