154364437.xls.

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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

Minor Moderate Major Segment No. 1

CPI 2 15 80

CPR 0 5 20

CEI 0 5 0

CCI 0 0 0

Minor Moderate Major Segment No. 1

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

$ legal liabil CLL $1 0 $1,000 2 $10,000 5

Minor Moderate Major Segment No. 1

CBI 3 16 53

CPI 2 20 50

CPR 1 10 20

CEI 0 0 0

CCI 0 0 0

$ legal liabil CLL $100 1 $1,000 2 $20,000 6

Minor Moderate Major

CBI 3 40 99

CPI 15 20 90

CPR 4 10 20

CEI 0 20 80

CCI 0 10 40

$ legal liabil CLL $1,000 2 $10,000 5 $100,000 11

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=

Risk 829 455 100 1,866 20 3,270

Rank 2 3 4 1 5

R.A. Hawrelak

1:12 AM

The chlorine is supplied from a railcar containing 30.000 10 Release of Toxic Gas or Vapor C L E Risk Minor 3 4 20 240 Moderate 1 2 91 182 Major 0.5 1 293. The facility is state-of-the-art in all respects.5 Overall Summary RS1 RS2 3.75 Major 0.000.000 $1.000 $1.75 75 168.5 579. PSV maintenance is done by the supplier. defined as Segment 2.000 $10.000 CBI 3 16 40 CPI 2 13 40 CPR 2 10 20 CEI 4 5 10 CCI 3 20 30 $ legal liabil $1 $100. 2 Summary $ Bus Interupt $1. Chlorine feedstock is highly toxic.7 0.270 872.000 $100.000.5 Segment No.5 1 315 157. The procedures.000 CBI 3 7 40 CPI 5 30 100 CPR 2 10 20 CEI 5 10 80 CCI 5 23 50 CLL 0 11 25 $ Bus Interupt $1.000 $250.25 293 Segment No. Segment No. The facility is located in a densely populated suburban location. The second step is a chlorination raction in an aqueous reaction media. operating parameters and personnel are excellent. 2 (See Table 2 above for "X" indicating this segment to be applied) (min = $1) $ legal liabil $1 $100.5 . 2 20 Hurricane C L E Risk Minor 5 1 14 70 Moderate 3 0.5 155 54.000 $1.0 2 RS2 = 872.Plant B The second step of the synthesis is carried out in Plant B.000 lbs that is properly designed and protected.The products produced are non-toxic and non-flammable.000 CLL 0 11 15 10 Release of Toxic Gas or Vapor 20 Hurricane Risk Rank 579.000.

Lo-Point. Once Through.) 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 . Specific. etc.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. # of Air Changes.

Bomb Threat Firebomb Disruption of Utilities (Water. Natural Gas. Electric. 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.Table 2 Product Manufacturing Risk Assessment Generic Hazardous Events Segment 2 Segment 1 Selected Events X X X X Hazard Source Fire No. Material Process Hdlg Fatality X . etc) Blocked Access to Site Physical harm to Key Personnel Materials That Are Extremely Toxic In Low quantities High Risk Matenance Operations Explosions Hazard Mtl Release With Signif Impact X X Natural Disasters X Terrorism Arson Theft Civil Disorder Personnel Safety Risk (Toxicity.

2 Fire In Processing Area Minor Spill while sampling or charging from drum. C HAZARDOUS MATERIAL RELEASE Minor Release from a PSV. gallons. gallons. Levels 2 to 5 by TNO method.S. Major Spill involving more than 50 U.000 lbs of flammable). No major damage. Major damage to equipment and buildings. Moderate Spill involving 10 to 50 U. 3 Warehouse Fire Minor Trash fire controlled by fire extinguisher. Level 2 by TNO method. Fire controlled by local extinguishers.0 psig overpressure on IRI Damage Table. drum storage) resulting from spill of material Minor (Involving less than 50 U. extensive water and smoke damage. Moderate Explosion in process area from release of flammable gas or vapor. gallons).S. (Can use New 94 Baker V3. punctured drum. Major Fire involving stored material.0 to 10. gallons. gallons. Major Involving more than 500 U. Major D Water ingress to a reactive mixture: continuous release from a PSV or rupture disc. Moderate Involving 50 to 5500 U. such as failed bottom outlet on storage tank or ruptured transfer line. (Max 100 lbs of flammable). Levels 5 to 10 by TNO method.0 psig overpressure on IRI Damage Table. From 1.Table 3 Product Manufacturing Risk Assessment Hazardous Event Consequences A FIRE 1 Flammable liquid fire in storage area (tank farm. some water and smoke damage. leaking hose or flange. Major Confined vapor cloud explosion (VCE) in congested process area.0 to 5.2 Model adapted for insurance company evaluation). gallons. etc. B EXPLOSIONS Minor Explosion in equipment resulting in damage to equipment only.0 psig overpressure on IRI Damage Table. From 5.S. Fire resulting in major damage to the building. (100 to 1. Moderate Release of a toxic gas from a 150 lb cylinder. such as overfilling of a vessel. Damage to equipment and relief panels activated. Controlled by fixed fire protection. Controlled by fire extinguishers. ruptured unloading hoses. To max of 1. such as a spill while sampling. NATURAL DISASTERS .S. Moderate Fire involving stored material.S. loss of batch. (less than 10 U. PSV reseats to a tight shut-off.S. Damage to instrumentation.

Moderate Siding / pannels blown off buildings Major Loss of utilities / communications. Loss of tilities. 2 Flood Minor Moderate Loss of utilities. arson. . above ground vessels moved off supports. Major Foundations weakened / compromised. Moderate Building damage from snow loading. Water ingress to storage vessels. civil disorders or riots? F PERSONNEL SAFETY RISK (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). Impact on availability of plant personnel and emergency response personnel. Is the site in a recognized flood plain? Water / mud / silt damage to equipment. Frozen sprinkler lines.1 Earthquake Minor Is the site in a recognized eathquake zone? Cracks in walls / floors. disruption of surface travel (impact on availability of plant personnel and emergency response personnel). Major E Impact on availability of plant personnel and emergency response personnel. Damage to control systems. TERRORISM / ARSON / CIVIL DISORDERS / RIOTS Does the location introduce any risk associated with terror. Major Loss of buildings. Impact on availability of plant personnel and emergency response personnel. 4 Snow / Extreme Cold / Ice Minor Frozen process lines. Moderate Dislodged / ruptured pipe racks. Vessels shifted off their supports. Does the site have a history of hurricane / tornado exposure? 3 Hurricane / Tornado Minor Damage from windblown objects.

6 0.1 L Description Might Well Be Expected Possibly Expected Quite Possible Possible Unusual but Possible Only Remotely Possible Unlikely Conceivable but Very Unlikely Practically Impossible Virtually Impossible .4 0.3 0.7 0.8 0.2 0.5 0.Table 4 Product Manufacturing Risk Assessment Likelihood Rating 10 9 8 7 6 5 4 3 2 1 0.

5 2 1.5 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 .5 1 0.75 0.Table 5 Product Manufacturing Risk Assessment Exposure E Rating 10 9 8 7 6 5 4 3 2.

50 16.000 16 16.000 $1.000.62 6.09 Event Class Minor Minor Moderate Moderate Major Major Business Interuption and Property Loss $ 100 CBI Factor LINEST = CBI $ $100 $1.000 $10.06 2.000 $10.000 10 1 $100 $1.97 99.000.97 $10.3943081 -1.000 $ Value Personal Injury CPI 0 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 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 Superficial Injury or Illness Minor Injury or Illness Public Relations CPR 0 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 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 Moderate Injury or Illness .000.12 $1.62 $10.000 100 99.09 Slope Constant b 0.000.000 $100.000.000.000 $1.000 $10.000 40 39.000 6 6.000 $100.12 39.000 3 2.50 $100.06 $1.Table 6 Product Manufacturing Risk Assessment Risk Consequences CBI Business Interuption and Property Losses CBI $ CBI Factor Calc'd CBI $100 1 1.7595079 Calc'd CBI 1.000 $10.

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 Community Impact CCI 0 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 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 Superficial Odor.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 Major Injury or Illness 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. ERPG 1 Moderate Irritation. ERPG-2 Sever and Life Threatening ERPG-3 .

000 $1.000 2 2.000. Major regional.000. Widespread and Outside Site Dissastrous Contamination.000 5 4.99 $3.48 Event Class Minor Minor Moderate Major Major 10 1 $1.000 $100.000.000 $1.47 59.000 60 59.000 40 40.48 Legal Liability 100 CLL Factor LINEST = CBI $ $1. $ .000 $10. Rural area.00 3.000.000 $10.8517646 Calc'd CBI 2. Local area persistant.000 Value.000 Slope Constant b 0.000 $10.62 10.500.41 $10. Catastrophic Contamination.000 $100.000 $5.50 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 Contamination.000.91 25.3683734 -1. water source Legal Liability 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 $1.00 $12.

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