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6/27/2013
Plant A
A major process is produced in a two-step synthesis. The first step, defined as Segment 1, involves hazardous chemistry with runaway reaction potential. The reaction is carried out in a low flashpoint solvent with high accute toxicity. The flammable liquid is stored in an above tank. The facility is old and not well maintained. Operating procedures and safe operating parameters are not well defined. (See Table 2 above for "X" indicating this segment to be applied) 1 Flammable Liquid Tank Farm Fire C L E Risk $ Bus Interupt CBI 10 6 3 180 $100 1 3 3 41 369 $100,000 16 1 2 140 280 $1,000,000 40 829 (min = $1) $ legal liabil CLL $1 0 $1 0 $1 0
Segment No. 1
CPI 2 15 80
CPR 0 5 20
CEI 0 5 0
CCI 0 0 0
3 Flammable Liquid / Combustible Material Fire in Processing Area C L E Risk $ Bus Interupt CBI CPI CPR 5 5 3 75 $1,000 3 0 0 2 2 70 280 $100,000 16 40 12 1 1 100 100 $300,000 25 50 20 455 5 Flammable Vapor / Gas Explosion C L E Risk $ Bus Interupt 1 1 7 7 $1,000 1 1 48 48 $100,000 0.7 0.5 129 45.15 $2,000,000 100.2 7 Run-Away Chemical Reaction C L E Risk $ Bus Interupt 3 3 24 216 $1,000 2 3 105 630 $1,000,000 1 3 340 1020 $10,000,000 1866 $ Bus Interupt $1 $1,000 $100,000
CEI 0 0 0
CCI 0 0 0
CBI 3 16 53
CPI 2 20 50
CPR 1 10 20
CEI 0 0 0
CCI 0 0 0
CBI 3 40 99
CPI 15 20 90
CPR 4 10 20
CEI 0 20 80
CCI 0 10 40
Segment No. 1 11 Release of Toxic Liquid C L E Risk Minor 0.5 0.5 15 3.75 Moderate 0.3 0.5 68 10.2 Major 0.2 0.1 287 5.74 19.69 Segment No. 1 Summary 1 3 5 7 11
29 Materials that are extremely Toxic In Low quantities CBI CPI CPR CEI CCI $ legal liabil CLL 0 2 1 5 5 $1,000 2 3 30 10 10 10 $10,000 5 16 100 20 80 60 $100,000 11
Flammable Liquid Tank Farm Fire Flammable Liquid / Combustible Material Fire in Processing Area Flammable Vapor / Gas Explosion Run-Away Chemical Reaction Release of Toxic Liquid RS1=
Rank 2 3 4 1 5
R.A. Hawrelak
1:12 AM
Plant B
The second step of the synthesis is carried out in Plant B, defined as Segment 2. The second step is a chlorination raction in an aqueous reaction media.The products produced are non-toxic and non-flammable. Chlorine feedstock is highly toxic. The facility is state-of-the-art in all respects. The procedures, operating parameters and personnel are excellent. The chlorine is supplied from a railcar containing 30,000 lbs that is properly designed and protected. PSV maintenance is done by the supplier. The facility is located in a densely populated suburban location.
Segment No. 2
(See Table 2 above for "X" indicating this segment to be applied) (min = $1) $ legal liabil $1 $100,000 $1,000,000
10 Release of Toxic Gas or Vapor C L E Risk Minor 3 4 20 240 Moderate 1 2 91 182 Major 0.5 1 315 157.5 579.5 Segment No. 2 20 Hurricane C L E Risk Minor 5 1 14 70 Moderate 3 0.75 75 168.75 Major 0.7 0.5 155 54.25 293 Segment No. 2 Summary
CBI 3 7 40
CPI 5 30 100
CPR 2 10 20
CEI 5 10 80
CCI 5 23 50
CLL 0 11 25
CBI 3 16 40
CPI 2 13 40
CPR 2 10 20
CEI 4 5 10
CCI 3 20 30
CLL 0 11 15
Table 1
Product Manufacturing Risk Assessment Qualities of Design / Procedures Automatic Sprinklers Smoke / Heat Detectors Explosions Suppression Systems Damage Limiting Construction Inertion Systems Ventilation Systems (Hi-Point, Lo-Point, Specific, # of Air Changes, Once Through, etc.) Explosion Proof Equipment Intrinsically Safe Equipment Purge Boxes Hot Work Procedures Confined Space Entry Procedures Process Safety Interlocks Emergency Relief Devices Operator Training Emergency Backup Systems Emergency Response Teams Disaster Plans Alarm Systems Proximity to Community (distance to nearest neighbor) Personnel Protective Equipment Administrative Controls Initial process Development to Remove Undesirable Compounds
Table 2
Product Manufacturing Risk Assessment Generic Hazardous Events Segment 2 Segment 1 Selected Events X X X X
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Events Flammable Liquid Tank Farm Fire Flammable Liquid Drum Storage Fire Flammable Liquid / Combustible Material Fire in Processing Area Combustible Material Warehouse Fire Flammable Vapor / Gas Explosion Dust explosion Run-Away Chemical Reaction Overpressure (Mechanical Energy-Failure of Pressurized Container) Detonatable Material Release of Toxic Gas or Vapor Release of Toxic Liquid Environmentally Toxic Toxic to Humans Unloading Incident Failure of Vessel / Container Release of Highly Reactive Material Unknown Release Failure of Controlling Procedures Flood Hurricane Tornado Earthquake Snow Bomb, Bomb Threat Firebomb Disruption of Utilities (Water, Electric, Natural Gas, etc) Blocked Access to Site Physical harm to Key Personnel Materials That Are Extremely Toxic In Low quantities High Risk Matenance Operations
Explosions
X X
Natural Disasters
Terrorism Arson Theft Civil Disorder Personnel Safety Risk (Toxicity, Material Process Hdlg Fatality
Table 3
FIRE 1 Flammable liquid fire in storage area (tank farm, drum storage) resulting from spill of material Minor (Involving less than 50 U.S. gallons, such as a spill while sampling, leaking hose or flange. Fire controlled by local extinguishers.
Moderate Involving 50 to 5500 U.S. gallons, such as overfilling of a vessel, ruptured unloading hoses, punctured drum. Major Involving more than 500 U.S. gallons, such as failed bottom outlet on storage tank or ruptured transfer line.
2 Fire In Processing Area Minor Spill while sampling or charging from drum, (less than 10 U.S. gallons). Controlled by fire extinguishers. No major damage.
Moderate Spill involving 10 to 50 U.S. gallons. Controlled by fixed fire protection. Damage to instrumentation, loss of batch, etc. Major Spill involving more than 50 U.S. gallons. Major damage to equipment and buildings.
Moderate Fire involving stored material; some water and smoke damage. Major Fire involving stored material; extensive water and smoke damage. Fire resulting in major damage to the building. (Can use New 94 Baker V3.2 Model adapted for insurance company evaluation).
EXPLOSIONS Minor
Explosion in equipment resulting in damage to equipment only. (Max 100 lbs of flammable). Level 2 by TNO method. To max of 1.0 psig overpressure on IRI Damage Table.
Moderate Explosion in process area from release of flammable gas or vapor. Damage to equipment and relief panels activated. (100 to 1,000 lbs of flammable). Levels 2 to 5 by TNO method. From 1.0 to 5.0 psig overpressure on IRI Damage Table. Major Confined vapor cloud explosion (VCE) in congested process area. Levels 5 to 10 by TNO method. From 5.0 to 10.0 psig overpressure on IRI Damage Table.
HAZARDOUS MATERIAL RELEASE Minor Release from a PSV, PSV reseats to a tight shut-off.
Moderate Release of a toxic gas from a 150 lb cylinder. Major D Water ingress to a reactive mixture: continuous release from a PSV or rupture disc.
NATURAL DISASTERS
1 Earthquake Minor
Moderate Dislodged / ruptured pipe racks. Loss of tilities. Major Loss of buildings, disruption of surface travel (impact on availability of plant personnel and emergency response personnel). Is the site in a recognized flood plain? Water / mud / silt damage to equipment; above ground vessels moved off supports.
2 Flood Minor
Moderate Loss of utilities. Damage to control systems. Water ingress to storage vessels. Major Foundations weakened / compromised. Impact on availability of plant personnel and emergency response personnel. Does the site have a history of hurricane / tornado exposure?
Moderate Siding / pannels blown off buildings Major Loss of utilities / communications. Impact on availability of plant personnel and emergency response personnel.
4 Snow / Extreme Cold / Ice Minor Frozen process lines. Frozen sprinkler lines.
Moderate Building damage from snow loading. Major E Impact on availability of plant personnel and emergency response personnel.
TERRORISM / ARSON / CIVIL DISORDERS / RIOTS Does the location introduce any risk associated with terror, arson, civil disorders or riots?
(Extreme toxicity)
Does the process handle any highly toxic material, or can the process accidentaly form a highly toxic material? (Highly toxic is defined as lethal in small doses).
Table 4
Product Manufacturing Risk Assessment Likelihood Rating 10 9 8 7 6 5 4 3 2 1 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 L Description Might Well Be Expected Possibly Expected Quite Possible Possible Unusual but Possible Only Remotely Possible Unlikely Conceivable but Very Unlikely
Table 5
Product Manufacturing Risk Assessment Exposure E Rating 10 9 8 7 6 5 4 3 2.5 2 1.5 1 0.75 0.5 Description Continuos Almost Continuous (10x/day) Semi-Continuous (5x/day) Very Frequent (2x/day) Frequently (daily) Practically Daily (5x/wk) Practically Daily (3x/wk) Occasional (weekly) Occasional (biweekly) Unusual (monthly) Very Unusual (quarterly) Rare ( a few per year) Very Rare
Table 6
CBI
CBI $ CBI Factor Calc'd CBI $100 1 1.06 $1,000 3 2.62 $10,000 6 6.50 $100,000 16 16.12 $1,000,000 40 39.97 $10,000,000 100 99.09 Slope Constant b 0.3943081 -1.7595079 Calc'd CBI 1.06 2.62 6.50 16.12 39.97 99.09 Event Class Minor Minor Moderate Moderate Major Major
10
1 $100
$1,000
Description
CPI Class Minor Minor Minor Minor Minor Minor Minor Minor Minor Minor Minor Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate
Description
CPR Class Minor Minor Minor Minor Minor Moderate Moderate Moderate Moderate Moderate Major Major Major Major Major Major
Minor Problem
Moderate Problem
Major Problem
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100
One Fatality
A Few Fatalities
Many Fatalities
Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major
Environmental Impact Description CEI 0 1 2 3 4 5 Minor Contamination easily cleaned 6 7 8 9 10 12 14 16 18 20 Sever contamination. Major effort 22 to clean 24 26 28 30 32 34 36 38 40 42 44 46 48
CEI Class Minor Minor Minor Minor Minor Minor Minor Minor Minor Minor Minor Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate
Description
CCI Class Minor Minor Minor Minor Minor Minor Minor Minor Minor Minor Minor Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Moderate Major Major Major Major Major
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 CLL
Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major
50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100
One Fatality
A Few Fatalities
Many Fatalities
Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major Major
CBI $ CBI Factor Calc'd CBI $1,000 2 2.00 $12,000 5 4.99 $3,500,000 40 40.41 $10,000,000 60 59.48
Legal Liability
100 CLL Factor
Slope Constant b 0.3683734 -1.8517646 Calc'd CBI 2.00 3.62 10.91 25.47 59.48 Event Class Minor Minor Moderate Major Major
10
1 $1,000
$10,000