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This study presents a comprehensive quantitative risk assessment and safety zone delineation for a pressure vessel located in the Gachsaran oil field using the Process Hazard Analysis Software Tool (PHAST) version 7.2. Regarding the importance of accurate consequence modeling in the oil and gas industry, our research integrates site-specific meteorological data—encompassing wind speed, ambient and surface temperatures, atmospheric stability, relative humidity, and solar radiation, to simulate realistic accident scenarios under varying environmental conditions. In this regard, two primary release scenarios were evaluated: a 20 mm horizontal leak and a 50 mm time-varying short pipe release. These scenarios were analyzed to determine the extents of hazardous zones based on thermal radiation intensities (15.9, 4.7, and 3.2 kW/m²) and explosion overpressure thresholds (0.2, 0.14, and 0.05 bar). The simulation results indicate that the dimensions of the fire, restricted, and impacted zones are highly sensitive to both the nature of the leak and the prevailing meteorological conditions. Notably, under stable conditions (class F), the most severe hazard extents were observed, underscoring the influence of environmental factors on incident propagation. These delineated safety zones are essential for establishing effective emergency response measures, optimizing facility layout, and minimizing risk to personnel, assets, and the environment. The findings of this study contribute novel insights into the integration of real-time environmental data with process safety management and also support the development of tailored mitigation strategies for high-risk industrial operations.
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