Introduction: using fossil fuels, some hazards such as explosion and fire are probable. This study was aimed to consequence modeling of fire on Methane storage tanks in a gas refinery using analyzing the risk, and modeling and evaluating the related consequences.

Method: Hazard analysis by PHA was used to choosing the worst-case scenario. Then, causes of the scenario were determined by FTA. After that, consequence modeling by the PHAST software was applied for the consequence analysis.

Results: Based on some criteria, the fire of methane gas tank (V-100) was selected as the worst-case scenario at the refinery. The qualitative fault tree showed three factors including mechanical, process, and human failures contribute in gas leakage. The leakage size and weather conditions were effective on the distance of radiation. Using consequence modeling, thermal radiation was considered as the major outcome of the incident. Finally, for outcome evaluating, probit equations were used to quantify losses and the percentage of fatalities due to the methane gas leakage and fire occurrence. The maximum number of fatalities caused by fire was obtained 23 persons.

Conclusions: In conclusion, the methane gas vessel in the refinery can be considered as the main center of hazard, therefore the implementation of the safety rules, eliminating mechanical failures, personal protection and education, and Effective measures to prevent and fighting of fire are proposed for decreasing the probable losses and fatalities.