Document G5Qqow0ew18jkx0v0JGvdwKjv

OPT: WOE_____ BROWSE WORK REQUESTS/ORDERS BY PLANT 09/18/95 WOE PLANT: POPG1 GLYCOL I W.O. STATUS: REQUEST, WORK ORDER REQUEST JOB REQUISITIONER NAME SERVICE GROUP --------------- --DATE-- DONE-------------------------------------------------------- 72412900 09/18/95 N PREJEAN GLYCOL #1 PROBLEM DESCRIPTION STEAM FLOW PRESSURES AND FLOWS 72411300 09/18/95 N PREJEAN GLYCOL #1 PROBLEM DESCRIPTION OIL SAMPLES , NEED CATCHING ON MRU-1,3,5 72411250 09/18/95 N PREJEAN GLYCOL #1 PROBLEM DESCRIPTION AR-593 R-102D MIXER PH PROBE ON BTM 72406600 09/18/95 N PREJEAN GLYCOL #1 ~ PROBLEM DESCRIPTION AR-287A R2D MIXER PROBE ON BOTTOM 72406550 09/18/95 N PREJEAN GLYCOL #1 PROBLEM DESCRIPTION ARC-593A R-102D BTMS PH PROBE ON BOTTOM 72406500 09/18/95 N PREJEAN GLYCOL #1 PROBLEM DESCRIPTION FFRC-972 T-400 WATER FLOW METER WENT TO ZERO 72406300 09/18/95 N ANDERSON GLYCOL #1 PROBLEM DESCRIPTION LRC-582> l.-XFR 2: BBWD 3:BFWD 4:DEL 5:HOLD 8:SS LIST 9:OPEN WO PF KEY: _ 10:HELP 11 M15 AlsLMNU ENTR:UPD/DETAIL 0AA oo * I AO COH'P1 0022 END OF DATA REACHED OPT: WOE_____ BROWSE WORK REQUESTS/ORDERS BY PLANT 09/18/95 PLANT: P0PG1 GLYCOL I WOE W.O. STATUS: REQUEST. WORK ORDER REQUEST JOB REQUISITIONER NAME ---------------- --DATE-- DONE----------------------------_ 72406300 09/18/95 N ANDERSON PROBLEM DESCRIPTION: LRC-582> _ 72406250 09/18/95 N ANDERSON PROBLEM DESCRIPTION: LRC 22562 y> _ 72385450 09/16/95 N THERIOT PROBLEM DESCRIPTION: P-1261A SEAL LEAK _ 66513401 06/03/95 N GLAVIANO JR PROBLEM DESCRIPTION: T/T OPEN PLAN SERVICE GROUP GLYCOL #1 GLYCOL #1 GLYCOL #1 P 1 " PROBLEM DESCRIPTION: " " PROBLEM DESCRIPTION: " " PROBLEM DESCRIPTION: " 1:XFR 2:BBWD 3:BFWD 4:DEL 5:HOLD 8:SS LIST 9:0PEN WO PF KEY: _ 10:HELP 11:M15 Al:LMNU ENTR:UPD/DETAIL DO A 044584 CONFTDFNTTAl MANUFACTURING UNIT RISK ANALYSIS SUMMARY ajka/counthy (MVKlOM ' "" LOCATION North America / USA am Louisiana Division recfaaco av Leigh Hilt Process Unit Malar Material 70 PO Storage Prepytana Oxide Louisiana Division alAMUFACTVneta MST Plequemlnc, La. TVS* os OStftATK* Glycol 1 TOTM mHL USfT SEPiACCMCNT VALUE Proovlene Oxide / Glvcol DATE 111.6 MM Dec. 12. 1996 Materiel Factor F&EI Value of Area of Expoaure MM Baee MPPD (1) *MM Actual Daye MPPD (1) Outage 4 MM MPDO (2) 24 68 2.00 1.30 0.71 16 BII3) Loee MM 0.86 PO Reactor Prspylana 21 61 12 6.21 2.91 36 6.1 PO Dietilletion 7M02B 24 106 15 11.46 6.16 67 7.96 Propylene Oxide PO DiatUlatkm /T-102C 24 97 16 11.11 6.96 56 7.8 Prepytana Oxide PO Distillation fT-300 24 117 22.40 17.84 Propylene Oxide 6.27 68 9.48 PO Filter Propylene Oxide 24 110 3.00 2.34 1.20 22 0.60 PDC Storage /DV-900 Propylene Dichloride 16 98 2.00 1.18 0.71 16 0.37 TPG Hydrogenator 21 66 12.60 6.86 4.20 46 6.96 Tri-Propylene Glycol PO Truck Loading Propylene Oxide 24 140 2.00 1.67 0.98 19 0.89 PDC Diatiilation/T-1000 Propylene Diohloride 16 48 1.00 0.39 0.23 8 0.19 U) Bate Maximum Prohibit Proparty Damaga (2) Actual Maximum Probable Property Damage (3) Busins** Interruption PiDCaaa Unit Mak>r Material PDC Dlatillatlon Propylene Dichloride Thermal Oxidizer Prepytana Dichloride Material Factor 18 F&E1 48 Value of Area of Exposure MM Bass MPPD (1) MM Actual Daye MPPD |1) Outage MM MPDO 12) 81(3) Loee MM 1.00 0.39 0.24 8 0.19 16 116 11.00 7.03 3.53 41 11.44 Save a* Excel 4.0 D0 A 044585 CONFIDENTIAL FIRE & EXPLOSION INDEX AREA/COUNTRY DIVISION LOCATION I- DATE USA SfTE LAD PREPARED BY: LEIGH HILL REVIEWED BY: LEIGH HILL MATERIALS IN PROCESS UNfT PROPYLENE OXIDE STATE OF OPERATION LAD MANUFACTURING UNIT PLAQUEMINE PROCESS UNIT 11/12/96 GLYCOL-1 70 PO STORAGE APPROVED BY; IStcwntoMfentf BUILDING CHARLES JACKSON REVIEWED BY; (Taafewfevy Caafer) 1S01 REVIEWED BY; (Safety a lam PiwaSanl STEVE JANDA BUCK BAILEY BASIC MATERIAU5) FOR MATERIAL FACTOR _DCUBM _tTART UP XHQftfeAl OfOUTWN _SMU1DOWW Propylene Oxide MATERIAL FACTOR ($ Tabt* 1 or Appandies* A or B) Not* requirement* when unit temperatures over 140 (00 *C) 24 1. General Proceee Hazarde Penalty Feetor Range Bate Factor................................................................................................................ 1.00 A. Exothermic Chemical Reactions 0.30 to 1.25 B. Endothermic Processes 0.20 to 0.40 C. Material Handling and Transfer D. Enclosed or Indoor Process Units 0.25 to 1.05 0.25 to 0.90 E. Access 0.20 to 0.35 F. Drainage and Spill Control 0 oallons 0.26 to 0.50 Penalty Feetor Ueed (1) 1.00 0.00 0.00 0.00 0.00 0.00 0.00 General Process Hazards Factor (FI)....................................................................................... 1.00 2. Special Process Hazards Base Factor................................................................................................................. 1.00 A. Toxic Matsriel(e) 0.20 to 0.80 B. Sub-Atmospheric Pressure (< 600 mm Ha) C. Operation In or Near Flammable Range INERTED X NOT INERTED 0.50 1. Tank Farms Storage Flammable Liquids 0.60 2. Process Upset or *urge Failure 0.30 3. Always in Flammable Range 0.80 D. Dust Explosion (See Table 3) 0.25 to 2.00 E. Pressure (Sea Figure 2) ODeratinc Pressure S osia Relief Settina 50 risia F. Low Temperature 0.20 to 0.30 G. Quantity of Fiammable/Unstable Material Quantity 260.000 lb He = 13.200 BTU/lb 1.00 0.60 0.00 0.60 0.00 0.00 0.00 0.12 0.00 1. Liquids or Gases in Process (Sea Figure 31 2. Liquids or Gases in Storags (Sss Figure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion L Leakage * Joints and Packing 0.10 to 0.76 0.10 to 1.50 0.00 0.61 0.00 0.00 0.00 J. Use of Fired Equipment (Sea Figure 6) 0.00 K. Hot Oil Heat Exchange System (See Table 5) 0.15 to 1.15 0.00 L. Rotating Equipment 0.50 0.00 Special Proceee Hazarde Factor (F2)....................................................................................... 2.83 Process Unit Hazards Factor (FI x F2) = F3....................................................................... 2.83 Fire and Explosion Index (F3 x MF F&EI1............................................................................ 68 (1) For no penalty use 0.00. D0 A 044586 CONFIDENTIAL Print Date: 1/14/97, Work File: A:\FEI7CALC\t70POSTORAGE.xlsJFEI7_TMP MF DatoFilc:C:\FEI7V2.5\AFEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Proeaaa Control Credit Factor IC1) Foatin a. Emergency Power b. Coolino e. Explosion Control d. Emergency Shutdown e. Computer Control Credt Factor Range 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Cradh Facto, Uoad (2) 0.98 1.00 1.00 0.98 1,00 Faatura f* Inert Gas 8- Operating Instructiona/Prooeduraa h. Reactive Chemical Reviaw i. Other Prooees Hazard Analysis Credt Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Uaod 12) 0.96 0.9$ 0.91 0.98 Cl Valuo (3) j 0.7B4 2. Material Isolation Credit Factor fC2> Faatm a. Remote Control Valves fa. Dump/Biowdown Credt Factor Ranoe 0.96 to 0.96 0.96 to 0.96 Crwit Factor Used (2) 0.90 1.00 Faatm 0. Drainage d. Interlock C2 Value (3) | 0.912 | Credit Factor ftenaa 0.91 to 0.97 0.98 Craift Footer Uoad 12) 0.85 1.00 3 Firo Protootlon Cradlt Factor (C3) Faatura a. Leak Detection b. Structural Steel c. Fira Watar Supply d. Specie! Systems e. Sprinkler Systems Credt Factor Rang. 0.94 to 0.98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 CrwSt Factor Utad 12) 0.98 0.98 0.97 1.00 0.87 Feature f. Water Curtaine o. Foam h. Hand Extinguishers/Monitors i. Cable Protection Credt Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.84 to 0.98 CrwSt Factor Uoad (2) 0.97 1.00 0.97 1.00 C3 Value (3) t 0.763 | Loaf Control Credit Factor - Cl X C2 x C3 13) - | 0.646 | PROCESS UNIT RISK ANALYSIS SUMMARY i 1. Firs snd Explosion Index (F&Et)...... 2. Radius of Exposure ........... (See Front) (ftp** 7) 68 67 ft 3. Area of Expoeure.............. 10,193 cq.ft. 4. Value of Area of Exposure 1993 Dolton... 5. Damage Factor.......... . near* S) 0.66 MM 2.00 6. Base Maximum Probable Property Damage - (Baia MPPDI14 x 6].................... MM 1.30 7. Loss Control Credit Factor 0.65 8. Actual Maximum Probable Property Damage (Actual MPPDI [6 x 7] .... ................. MM 0.71 9. Maximum Probable Days Outage - (MPDO) 16 day* 10, Business Inffraption*|Bl)....................... ........ ............................... .................... ....,,.,.,,..|fMM_______ 0,85 _____1 i (2) For no credit factor enter 1,00 (3) Product of all factors used Refer to "Fire tt Explosion Index Hazard Clessifioetion Guide" {Form #471-00001) for details BACK OF FOAM C-22380 *4 (471 -00030) . |H-7 Mm Vsr-2,.5 - 4M^0 D0 A 0445B7 CONFIDFNTXAL Print Date: 1/14/97, Work File: A:\FEI7CALC\I70P0ST0RAGE.xlsJFEI7_TMP MF DataFlle:C:\FEI7V2.5V\FEI7DEN\FEI7_0AT.XLS FIRE & EXPLOSION INDEX AREA/COUNT1IY DIVttiON LOCATION DATE ! USA bite LAD PREPARED BY: LEIGH HILL REVIEWED BY: (Mawginnifit) LEIGH HILL MATERIALS IN PROCESS UNIT PROPYLENE STATE OF OPERATION LA MANUFACTURING untt PLAQUEMINE FflOCEB* UNFT GLYCOL-1 PO REACTOR APPROVED BY: (SimkiMd-arl CHARLES JACKSON REVIEWED BY: (Taohwaingy Cmw| STEVE JANDA 11/12/96 BUUMNQ 1501 REVIEWED BY: (Safety 4 Ua* Pt-adan) BUCK BAILEY BASIC MATERIAL'S) FDR MATERIAL FACTOR ^jocstqm _staatup _k_nssmal operation __ sm/tdowm Propylana MATERIAL FACTOR (Sea Tabt* 1 or Appandieas A or &) Not* raquiramant* whan unit tampareturaa ovar 140 "F (00 *C) 1. General Process Hazards Penalty Fac tor Range Bass Factor................................................................................................................ A, Exothermic Chemical Reactions B. Endothermic Processes C. Material Handling and Transfer D. Enclosed or Indoor Process Units E. Access F. Drainage end Spill Control 0 Gallons 1.00 0.30 to 1.25 0.20 to 0.40 0.25 to 1.05 0.25 to 0.90 0.20 to 0.35 0.26 to 0.50 General Process Hazards Factor (FI)....................................................................................... 2, Special Process Hazards Bass Factor................................................................................................................ 1.00 A. Toxic Material(s) B. Sub-Atmospheric Pressure 1 < 500 mm Ho) 0.20 to 0.80 0.60 C. Operation In or Near Flammable Range INERTED X NOT INERTED 1. Tank Farms Storage Flammable Liquids 0.50 2. Process Upset or Purge Failure 3. Always in Flammable Range D. Dust Explosion (See Teble 3) 0.30 0.80 0.26 to 2.00 E. Pressure (See Fiaure 21 Operating Pressure 6 otto Relief Settlno 10 psip F. Low Temperature 0.20 to 0.30 G. Quantity of Flammeble/Unstable Material Quantity 100 lb He 19.700 BTU/tb 1. Liquids or Gasas In Process (See Figure 3) 2. Liquids or Gsses in Storage (See Figure 4) 3, Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion 1. Leakage - Joints and Packing 0.10 to 0.75 0.10 to 1.50 J. Use of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 5) 0.15 to 1.15 L. Rotating Equipment 0.50 Special Proceee Hazards Factor (F2)....................................................................................... Process Unit Hazards Factor (Fix F2) - F3....................................................................... Fire and Explosion Index (F3 x MF - F&EI)............................................................................. (1) For no penalty uaa 0.00. 21 Penalty Fac tor Used (1) 1.00 0.30 0.00 0.00 0.00 0.00 0.25 1.B5 1.00 0.20 0.00 0.00 0.00 0.00 0.00 0.16 0.00 0.00 0.00 0.00 0.10 0.10 0.00 0.00 0.00 1.56 2.42 51 FORM C-22390 Rar/01*84 (471-00030) - (RE-7 Byiton V*r-2.S - 4/4/90) Print Date: 1/14/97, Work File: A:\FEl7CALC\[POREACTOR.xle)FEI7_TMP MF DataFil:C:\FEl7V2.S\AFEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Process Control Credit Factor (Cl) Feature a. Emergency Rower b. Cooling c. Explosion Control d. Emergency Shutdown s Computer Control Credit Factor Range 0.98 0.97 to 0.99 0.84 to 0.88 0.98 to 0.99 0.93 to 0.99 Credit Factor Used (2) 0.98 1.00 1.00 0.98 0.93 Feature f. Inert Oat ? Operating Instruetions/Procedures h. Reactive Chemical Review i. Other Process Hazard Analysis Cl Volua 131 | 0.703 1 2. Material Isolation Credit Factor (C2) Featurs a. Remote Control Velvet b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Ueed 12) 0.96 1.00 Feature c. Drainage d. Interlock C2 Value (3) I 0.874 | 3 Fire Protection Credit Factor (C3) Featurs a. Leak Detection b. Structural Steel c. Fire Water Supply d. Special Sytteme e. Sprinkler Systems Credit Factor Range 0.94 to 0.98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Used 12) 0.98 0.98 0.94 1.00 0.87 Feature f. Water Curtains 9- Foam h. Hand Extinguishert/Monitore 1. Cable Protection C3 Value (3) | 0.762 1 Loea Control Credit Factor * Cl x C2 x C3 (3) = | 0.468 1 Credit Factor Range 0.94 to 0.99 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Ueed 12) 0.96 0.92 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 CndK Factor Used (2) 0.91 1.00 Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.08 0.94 to 0.98 Credit Factor Ueed (2) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire end Explosion index (F&EI)............ (See Front) SI 2. Radius of Exposure..... .................................. fi0ur* 7) 43 ft 3. Area of Exposure.......................................... 5,738 sq.ft. 4. Value of Area of Exposure 1993 Dollara.... SMM 12.00 6. Damage Factor ............................................... ............ 0.52 6. Base Maximum Probable Property Damage - (Bats MPPD) [4 x Si...................... SMM 6.21 7. Loss Control Credit Factor 0.47 8. Actual Maximum Probable Property Damage - (Actual MPPDI (6 x 7J .... *MM 2.91 9. Maximum Probable Days Outage * (MFDO)____________ P)_______________ 36_______ day__________________ 10. Business Interruption - (Bl|................................................................................................................ |tMM 5.10 1 1 | (2) For no credit factor enter 1.00 (3) Product of all factors used Refer to 'Fire & Explosion Index Hazard Classification Guide* (Form #471-000011 for details BACK OF FORM C 22380 IW01-B4 U71-0003l IFtE-7 System Vsr-2..S - 4/4/S* Print Date: 1/14/97, Work File: A:\FEI7CALC\(P0REACT0R.xls]FEI7 TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7 DAT.XLS DO ft Oft*58? confimwtt FIRE & EXPLOSION INDEX AREA/COUNTRY DIVISION LOCATION DATE E USA CfTE LAD PREPARED BY: LEIGH HILL reviewed by: (Mwivmmmi LEIGH HILL MATERIALS W PROCESS UNIT PROPYLENE OXIDE TATE OF OPERATION LA MANUFACTURING UNfT PLAQUEMINE PROCESS UNfT GLYCOL-1 T-102B APPROVED BY: (SijintoNmfeiiq CHARLES JACKSON REVIEWED BY: <T*ehfnkw Cwtw) STEVE JANDA 11/12/96 BUILDING 1501 REVIEWED BY: (Safety A U** Pievemtoiil BUCK BAILEY BASIC MATER1AU6) FOR MATERIAL FACTOR __pKMN ^STARTUP ^XjNOMMAL OPCftADON ^SM/IMWN Propylene Oxide MATERIAL FACTOR (Sss Table 1 or Appendices A or B) Not* requirement! when unit tmpratur*s over 140 F (60 'C) 1. Oanaral Procoaa Hazard* Pervefty Fee* tor Range Baaa Factor................................................................................................................. 1.00 A. Exothermic Chemical Raactlont 0.30 to 1.26 B. Endothermic Processes C. Material Handling and Transfer D. Encloaed or Indoor Proceaa Unit* 0,20 to 0.40 0.25 to 1.0S 0.25 to 0.90 E. Accea* 0.20 to 0.35 F. Drainage and Spill Control 0 aallon* 0.25 to 0.60 General Proceaa Hazard* Factor (Fit....................................................................................... 2. Special Proceaa Hazards Base Factor................................................................................................................. 1.00 A. Toxic Material(a) 0.20 to 0.80 B. Sub-Atmospheric Pressure (< 500 mm Hg) C. Operation In or Near Flammable Range 0.50 1. Tank Farms Storage Flammable Liquids 0.50 2. Process Upset or Purge Failure 0.30 3. Always in Flammable Range D, Dust Explosion (See Table 3) 0.60 0.25 to 2.00 E. Preiiure (See Future 21 ODeratino Pressure 0 osio Relief Setting 0 Oslo F. Low Temperature 0.20 to 0.30 G. Quantity of Flammable/Unitable Material Quantity E0.000 lb He - 13.200 BTU/lb 1* Liquids or Oases In Process (See Figure 3) 2. Liquids or Gases in Storage (See Flours 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion 1. Leakage - Joints end Packing 0.10 to 0.7S 0.10 to 1.50 J. Use of Firsd Equipment (See Figure 61 K. Hot Oil Heat Exchange System (See Table 5) 0.15 to 1.15 L. Rotating Equipment 0.50 Special Proceaa Hazards Factor (F2)....................................................................................... Proceaa Unit Hazards Factor (FI x F2) * F3........................................................................ Fire and Explosion Index (F3 x MF * F&EII............................................................................. (1) For no penalty uao 0.00. 24 Penalty Fac tor Used (1) 1.00 0.00 0.00 0.00 0.00 0.00 0.25 1.25 1.00 0.60 0.50 0.00 0.00 0.00 0.00 0.00 0.00 1.21 0.00 0.00 0.10 0.10 0.00 0.00 0.00 3.51 4.38 105 FOAM C-22380 Hav/01-M (471^)00361 IFIE-7 Sywro Var-2.6.4/4/MI Print Data: 1/14/97, Work File: A:\FEI7CALC\rn02B.xls]FEI7_TMP MF DetaFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS DO CONFIDFNTIft' LOSS CONTROL CREDIT FACTORS 1. Process Control Credit Factor (Cl I Feature a. Emergency Power b. Cooling c. Exploeion Control d. Emergency Shutdown a. Computer Control Credit Factor Range 0,98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Used (2) 0.98 1.00 1.00 1.00 0.99 Feature f. Inert Gat ? Operating Inttructiona/Procedurea h. Reactive Chemical Review 1. Other Process Hazard Analysis Cl Value (3) | 0.808 1 2. Material Isolation Credit Factor (C2) Feature a. Remote Control Valves b. Dump/Blowdown Credit Feetor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Uaed (2) 0.96 1.00 Feature c. Drainage d. Interlock C2 Value (31 | 0.874 H 3 Fire Protection Credit Factor (C3) Feature a. Leak Detection b. Structure! Steel c. Fire Water Supply d. Special Systems e. Sprinkler Systems Credit Factor Rang# 0.94 to 0.98 0.96 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Uaad (2) 0.98 0.98 0.94 1.00 0.87 Feature f. Water Curtains 9- Foam h. Hand Extinguishere/Monftors L Cable Protection C3 Value (31 I 0.762 1 Loea Control Credit Factor Cl x C2 x C3 (3) |___0;B37__| CredK Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 CradH Factor Used 12) 1.00 0.93 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 Credit Faator Used (2) 0.91 1.00 Credit Factor Rang# 0.97 to 0.96 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Ueed 12) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Exploeion Index (F&EI) ............ (See Front) 105 2. Radius of Exposure.................... ........... . 3. Area of Exposure........................ .................. r^i# 7i 88 24,498 4. Value of Area of Expoeure 1993 Dollars.... 6. Damage Factor ................ ........................... . 0.76 6. Base Maximum Probable Property Damage (Base MPPO) (4 X 6]...................... 7. Loee Control Credit Factor ................... .........(See Above) 0.54 8. Actual Maximum Probable Property Damage - (Actual MPPDI (6 x 7] .... 9. Maximum Probable Daye Outage - (MPDO) #=*** s 57 10. Business Interruption - (Bl)................. .................. ft sq.ft. IMM MM 9MM daye 15.00 11.45 6.16 1 | | (2) For no credit factor enter 1.00 (3) Product of all factors used Refer to `Fire & Explosion Index Hazard Claaaification Guide" (Form #471-00001) fordetaila BACH OF FORM C-22380 Rw/01-4 <471-000381 - IFIE-7 System Vv-2.,5 - 4/4/BB Print Data: 1/14/97, Work File: A;\FEI7CALC\[T102B.xls]FEI7_TMP MF DataHla:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS 00 t FIRE & EXPLOSION INDEX AREA/COUNTRY DIVISION LOCATION -<8>- date USA site LADD PREPARED BY: LEIGH HILL REVIEWED BYi IM**ng*nMl) LEIGH HILL MATERIAL* m PROCESS UNIT PROPYLENE OXIDE STATE OF OPERATION LA manufacturing UNTT PLAQUEMINE PROCESS UNIT GLYCOL-1 T-102C APPROVED BY: (BipwtnWftdMtJ CHARLES JACKGON REVIEWED BY: (Taohnatoer Cwiftarl STEVE JANDA 11/12/96 BLNLDMG 1501 REVIEWED BY: (Safety A teas Pt^-iBbi) BUCK BAILEY BASIC MATERIALISE FOR MATERIAL FACTOR _Dt**Q*l __ STARTUP _X_0MflAL OPERATION __ SHUTDOWN Propylene Oxide MATERIAL FACTOR (S*e Tabto 1 or Appendices A or 6) Not* requirement* whon unit temperatures ovor 140 *F (60 C) 1. General Process Hazards Penalty Fac tor Rang# Ba*a Factor................................................................................................................. A. Exothermic Chemical Reactions B. Endothermic Processes C. Materiel Handling and Transfer D. Enclosed or Indoor Process Units E. Access F, Drainage and Spill Control 0 Gallons 1.00 0.30 to 1.25 0.20 to 0.40 0.26 to 1.05 0.25 to 0.90 0.20 to 0.35 0.25 to 0.50 General Process Hazards Factor (FI)........................................................................................ 2. Special Process Hazards Base Factor................................................................................................................. 1.00 A. Toxic Material(e) B. Sub-Atmospheric Pressure (< 500 mm Hg| C. Operation In or Near Flammable Range 0.20 to 0.80 0.50 1, Tank Farms Storage Flammable Liquids 2. Process Upset or Puroe Failure 3. Always In Flammable Range D. Dust Explosion (See Table 3) 0.50 0.30 0.80 0.25 to 2.00 E. Pleasure ISee Future 21 Ooeratino Pressure 0 Oslo Relief Settino 0 osio F. Low Temperature G. Quantity of Flammable/Unstabla Material 0.20 to 0.30 Quantity 34.200 lb He 13.200 BTU/lb 1. Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids in Storage, Oust In Process (See Figure 51 H. Corrosion end Erosion 0.10 to 0.75 L Leakage - Joints end Packing 0.10 to 1.50 J. Use of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 6) L. Rotating Equipment 0.16 to 1.16 0.50 Special Process Hazards Factor (F2)........................................................................................ Proceee Unit Hazards Factor (FI x F2) -- F3....................................................................... Fire and Explosion Index (F3 x MF = F&EII............................................................................. (1) For no penalty use 0.00. 24 Penalty Fac tor Used (1) 1.00 0.00 0.00 0.00 0.00 0.00 0.25 1.25 1.00 0.60 0.50 0.00 0.00 0.00 0.00 0.00 0.00 0.94 0.00 0.00 0.10 0.10 0.00 0.00 0.00 3.24 4.04 97 00 A 044592 conftdentTAL FORM C-22390 R*v/0l-S4 (471-00030) - |HE-7 System Vr-2.5 - 4/4/M) Print Date; 1/14/97, Work File: A:\FEI7CALC\[T102C*xlsJFEI7_TMP MF DataFile:C:\FEI7V2e5V\FEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Proceee Control Credit Factor (Cl) Feature a. Emeroency Power b. Coolino c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Factor Range 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Ueed 12) 0.98 1.00 1.00 1.00 0.99 Feature f. Inert Gas 9' Operating Instmctions/Procadures h. Reactive Chemical Review 1. Other Proceaa Hazard Analyaia Cl Value (31 | 0.805 1 2. Material laolation Credit Fector (C2) Feature a. Remote Control Values b. Dump/Blowdown Credit Fector Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Used (2) 0.96 1.00 Feature c. Drainage d. Interlock C2 Value (3) [ 0.874 | 3 Fire Protection Credit Factor (C3) Feature a. Leak Detection b. Structural Steel c. Fire Water Supply d. Speclel Syatema e. Sprinkler Systems Credit Factor Range 0.94 to 0.98 0,96 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Fector Used (2) 0.98 0.98 0.94 1.00 0.87 Feature i. Water Curtalnc 9- Foam h. Hand Extingulahen/Monitor* 1. Cable Protection C3 Value (31 | 0.762 1 Loee Control Credit Fector = Cl x C2 x C3 (3) I 0.636 "1 Credit Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Ueed 12) 1.00 0.93 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 Credit Fector Ueed (2) 0.91 1.00 Credit Fector Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Fector Used (2) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Explotion Index IF&EII............ 2. Radius of Exposure ...................................... . (See Front) #90U* 7) 97 82 ft 3. Area of Expoturo.......................................... 20,877 tq.ft. 4. Value of Area of Exposure 1993 Doilara... MM 6. Damage Fector............................................... 0.74 6. Base Maximum Probable Property Damage - (Bate MPPDI (4 x 5]...................... MM 7. Loss Control Credit Factor ................ 0.54 8. Actual Maximum Probable Property Damage - (Actual MPPD) [6 x 7].... MM 9. Maximum Probable Daya Outage - (MPDOI 10. Busmen Interruption - (61)..................................... flow* St 56 daya .......................................... IfMM 15.00 11.11 5.95 7.80 | | | | (2) For no credit factor enter 1.00 (3) Product of all factora usad Refer to `Fire & Explosion Index Hazard Classification Guide' (Form #471-00001) for details BACK OP FORM C-22380 ftevrtl-M (471-00030). |RE~7 - 4/4/M Print Date: 1/14/97, Work File: A:\FEI7CALC\m 02C.xls]FEI7J'MP MF DataRle:C:\FEI7V2,5V\FEI7DEN\FEI7_DATeXLS ^0 A 044593 CONFrOFNTTAl FIRE & EXPLOSION INDEX AREA/COUNTRY ii. USA cm LAD PREPARED BY: LEIGH HILL REVIEWED BY: (MmommMI LEIGH HILL________ MATERIALS W PROCESS UNIT PROPYLENE OXIDE STATE OP OPERATION LA MANUFACTURING UNTT PLAQUEMINE process UNIT GLYCOL-1 T-300 APPROVED BY: (Siwwtownfent) CHARLES JACKSON REVIEWED BY; <Tmwto(ir Cwiferl STEVE JANDA 11/13/96 BUUXNO 1501 REVIEWED BY: (Safety A1 BUCK BAILEY BASIC MATERUVUSI FOR MATERIAL FACTOR START UP X NORMAL OPERATION Propylene Oxide MATERIAL FACTOR ($ Tsb4 1 or Apptndioaa A or B) Not* requirements whan unit temperatures over 140 *F (60 "C| 1. General Procees Hazarde Penalty Fac tor Range Base Factor............................................................... ................................................. A. Exothermic Chemical Reaction* B. Endothermic Procette* 1.00 0.30 to 1.26 0.20 to 0.40 C. Material Handling end Transfer D. Enclosed or Indoor Process Units 0.26 to 1.05 0.25 to 0.90 E. Access 0.20 to 0.35 F. Drainage and Spill Control 0 gallons 0.25 to 0.50 General Process Hazards Factor (FI)....................................................................................... 2. Special Process Hazarde Base Fedor................................................................................................................. 1.00 A. Toxic Material(t) B. Sub-Atmospheric Pressure (< 500 mm Hgl C. Operation in or Near Flammable Range 0.20 to 0.80 0.50 1. Tenk Farms Storage Flammable Liquids 2. Process Upset or Purge Failure 3. Alwaya in Flammable Range D. Dust Explosion (Saa Table 31 0.50 0.30 0.80 0.25 to 2.00 E. Preaeure (Sea Figure 2) Operating Pressure 0 paia F. Low Temperature Relief Setting 0 osia 0.20 to 0.30 G. Quantity of Flammable/Unatable Material Quantity 90.000 lb Ho = 13.200 BTU/lb 1. Liquids or Qsses in Process (See Figure 3) 2. liquids or Gases in Storage (See FIgure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion 1. Leakage Joints and Packing 0.10 to 0.75 0.10 to 1.50 J. Use of Fired Equipment (See Figure 6) K. Hot OH Heat Exchange System (See Table 5) O.ISto 1.16 L, Rotating Equipment 0.50 Special Process Hazards Factor (F2I....................................................................................... Process Unit Hazards Factor {FI x F2) = F3....................................................................... Fire and Exploaion Index (F3 x MF = F&EI)............................................................................. (1) For no penalty use 0.00. 24 Penalty Fee* tor Used (1) 1.00 0.00 0.00 0.00 0.00 0.00 0.25 1.25 1.00 0.60 0.50 0.00 0.00 0.00 0.00 0.00 0.00 1.59 0.00 0.00 0.10 0.10 0.00 0.00 0.00 3.B9 4.86 117 DO A 044594 CONFIDENTIAL FORM C-22380 fiav/01-94 1471-000381 IFIE-7 SyMam Vw-2.fi . 4/4/981 Print Dete: 1/14/97, Work File: A:\FEI7CALC\IT300.xlsJFEI7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. ProctM Control Cradit Factor (Cl) Feature a. Emergency Power b. Cooling c. Exploeion Control d. Emergency Shutdown a. Computer Control Credit Factor Range 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Ueed (21 0.98 1.00 1.00 1.00 0.93 Feature f. Inert Gas o. Operating Inetnictlone/Proceduree h. Reactive Chemical Review i. Other Process Hazard Analysis Cl Value (3) | 0.748 1 2. Material Isolation Cradit Factor (C2) Feature a. Remote Control Velvet b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Used (2) 0.98 1.00 Feature c. Drainage d. Interlock C2 Value (3) 1 0.892 1 3 Fire Protection Cradit Factor (C3I Feature a. Leek Detection b. Structural Steel e. Fire Weter Supply d. Special Systems e. Sprinkler Systems Credit Factor Range 0.94 to 0.98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Ueed (2) 0.98 0.98 0.94 1.00 0.81 Feature (. Water Curtain* 9- Foam h. Hand Extlnguiaheri/Monitof* i. Cable Protection C3 Value (3) I 0,695 1 Loaa Control Credit Factor Cl x C2 x C3 (3) - | 0.464 | GredR Factor Ra"9 0.94 to 0.96 0.91 to 0.99 0.91 to 0.96 0.81 to 0.98 CradK Factor lieed (2) 1.00 0.92 0.91 0.9B Credit Factor Range 0.91 to 0.97 0,98 Credit Factor Ueed 12) 0.91 1.00 Credit Footer Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 CradK Factor Ueed 12) 0.98 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire end Explodon Index (F&EI)............ (See Front) 117 2. Radius of Exposure....................................... lw 7 98 ft 3. Area of Expoeure........................................... 30,205 eq.ft. 4. Value of Area of Expoture 1993 Dollar*.... MM 5. Damage Factor............................................... 0.80 6. Base Maximum Probable Property Demage - (Baee MPPDI [4 x 5]...................... MM 7. Loss Control Credit Fector 0.46 8. Actual Maximum Probable Property Damage (Actual MPPDI (6 x 7] .... MM 9. Maximum Probable Payi Outage - (MPDO)68dayi 10, Business Interruption * (Bll.................................. ...................................... .................... ,,..,,e.,.**.T|tMM 22.40 17.84 8.27 9.48 I I 1 (2) For no credit factor enter 1.00 (3) Product of all factors used Refer to "Fire & Explosion Index Hazard Classification Guide* (Form #471-00001) for details DO A 044595 conftdfnttal BACK OF FORM C-22380 R#v/01-94 (471-00036) - IFtE-7 System V2..5 - 4/4/96 Print Data: 1/14/97, Work File: A:\FEI7CALC\lT300.xls]FEI7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS FIRE & EXPLOSION INDEX AREA/COUNTRY DIVISION LOCATION DATE F USA SITE LAD PREPARED BY: LEIGH HILL REVIEWED BY; LEIGH HILL MATERIALS M PROCESS UNIT PROPYLENE OXIDE state of operation LA manufacturing uNrr PLAQUEMINE PROCESS UNIT GLYCOL-1 AD-6201A APPROVED BY; ISwtfrirttondeni) CHARLES JACKSON REVIEWED BY: fTwMwfaey Cwttarl STEVE JANDA 11/13/96 building 1501 DEVKWto BYi f**tly a l*m fii e*e) BUCK BAILEY BASIC MATERIAUS) FOR MATERIAL FACTOR __ DEMON ^.STMTIJP JlJHOmtl OWMTCT __ SHUTDOWN Propylene Oxide MATERIAL FACTOR (S* T*bl 1 r Appendices A or B| Not* requirement* when unit t*mper*tur* over 140 (60'*C| 1. General Process Hazards Penalty Fac tor Range Base Factor................................................................................................................. 1.00 A. Exothermic Chemical Reactions 0.30 to 1.25 B. Endothermic Accesses 0.20 to 0.40 C. Material Handllno and Transfer D. Enclosed or Indoor Process Units 0.26 to 1.06 0.26 to 0.90 E. Acce** 0.20 to 0.35 F. Drainage and Spill Control 0 oallona 0.26 to 0.50 General Process Hazards Factoi (FI)....................................................................................... 2. Special Process Hazards Base Factor................................................................................................................. 1.00 A. Toxic Material!*) 0.20 to 0.80 B. Sub-Atmopheric Pre*ture (< 500 mm Ha) C. Operation In or Near Flammable Range X INERTED NOT INERTED 0.50 1. Tank Farm* Storage Flammable Liquid* 0.50 2. Proce** Upset or Purge Failure 3. Alway* in Flammable Range D. Duct Exploiion (See Table 3) 0.30 0.B0 0.25 to 2.00 E. Pressure (See Fioure 21 Ooeratino Pressure 80 otio F. Low Temperature G. Quantity of Flammable/Un*table Material Relief Settina 150 osia 0.20 to 0.30 Quantity BO.700 lb He = 13.200 BTU/lb 1. Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storege (See Figure 4) 3. Combuttiblo Solid* in Storage, Dust in Procest (See Figure 5) H. Corrotion and Erotion 0.10 to 0.76 1. Leakage - Joint* and Pecking 0.10 to 1.60 J. U*e of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 5) 0.16to 1.16 L. Rotating Equipment 0.50 Special Proceae Hazard* Factor (F2)....................................................................................... Procata Unit Hazards Factor (FI x F2I m F3........ .............................................................. Firs and Explosion Indax IF3 x MF - F&EI)............................................................................. (1) For no penalty un 0.00. 24 Penalty Fac tor Used (1) 1.00 0.00 0.00 0.00 0.00 0.00 0.25 1.25 1.00 0.60 0.00 0.00 0.30 0.00 0.00 0.26 0.00 1.53 0.00 0.00 0.00 0.00 0.00 0.00 0.00 3.68 4.60 110 DO A 044596 CONFIDENTIAL FORM C-223S0 R*v/01-M (471-00038) . IHE 7 SyttKil V-7.5 4/4/M] Print Date: 1/14/97. Work File: A:\FEI7CALC\lAD6201A.xlslFEI7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Proceee Control Credit Factor (Cl) Feature a. Emergency Power b. Cooling c. Exploeion Control d. Emergency Shutdown e. Computer Control Credit Feetor Rang* 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Feetor Ueed 12) 0.98 1.00 1.00 0.98 0.93 Feature f. Inert Gas 9- Operating Instructions/Procedures h. Reactive Chemical Review i. Other Procete Hazard Analyeit Cl Velue (3) | 0.743 ~\ 2. Material leolation Credit Factor (C2) Feature ft. Remote Control Valves b. Dump/Blowdown Credit Factor Renge 0.96 to 0.98 0.96 to 0.98 Credit Factor Used 12) 0.96 1.00 Feature 0. Drainage d. Interlock C2 Value (3) 1 0.874 | 3 Fire Protection Credit Factor (C3) Feature a. Leek Detection b. Structural Steel c. Fire Water Supply d. Special Systems e. Sprinkler Systems Credit Fedor Range 0.94 to 0.98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Ueed (2) 0.98 1.00 0.97 1.00 0.86 Feature f. Water Curtain* 0- Foam h. Hand Extinguishere/Monitor* i. Cable Protection C3 Value (3) | 0.792 ~1 Loee Control Credit Factor Cl x C2 * C3 (3) | 0.514 | Credit Fedor Renge 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Ueed (2) 1.00 0.93 0.91 0.98 Credit Fedor Range 0.91 to 0.97 0.96 Credit Feetor Ueed (2) 0.91 1.00 Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Fedor Ueed 12) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire end Explosion Index (F&EI)........... . (See Front) 110 2. Radlue of Expoiure......................................... f^.* 71 93 ft 3. Area of Exposure................................. ....................................... 27,049 tq.ft. 4. Value of Area of Exposure 1993 Dollars...................... ................................................................ *MM 6. Damage Factor................................................... ............. ftgir.nl 0.78 3.00 6. Base Maximum Probable Property Damage - (Bare MPPD) [4 x 51...................... 7. Loee Control Credit Factor ............................ ISee Above)) 0.51 (MM 2.34 8. Actual Maximum Probable Property Damage - (Actual MPPD) (6 x 7) .... ................ IMM 1.20 | 9. Maximum Probable Day* Outage - (MPOO) ftvn 22 day* 10. (2) For no credit factor enter 1.00 0.50 D0 ft OA4597 (3) Product of alt factors used CONFIDENTIAL Refer to "Fir* & Explosion Index Hazard Classification Guide' (Form #471-00001) for details BACK Of FORM C-22380 Rav/OVftt (471-00030) - IRE-7 System V*r.2..5 - 4/4/90 Print Date: 1/14/97, Work File: A:\FEI7CALC\IAD6201 A.xl*]FEl7 TMP MF DataRle:C:\FEI7V2-5V\FEl7DEN\FEI7 DAT.XLS FIRE & EXPLOSION INDEX AREA/COUNTRY (XVISION LOCATION DATE K USA srn LA PREPARED BY: LEIGH HILL REVIEWED BY: LEIGH HILL MATERIALS M PROCESS UNIT PDC STATE OF OPERADOR LA MANUFACTURING UNIT PLAQUEMINE PROCESS UNIT GLYCOL-1 DV-900 APPROVED BY: (Siyrinf*d*nt) CHARLES JACKSON REVIEWED BY: (TtehMfaoV CMf) STEVE JANDA 11/13/96 BUILDING 1501 REVIEWED SV: <Sa*My A |m Fn.--Siml BUCK BAILEY SASIC MATERIAUSI FOR MATEHIAL FACTOR _OCSIQN _STARTUP JtJtOmU. OFfRAIlOII __SMflDOWN Propylene Dichloride MATERIAL FACTOR (See Table 1 r Appendices A or B) Note requirements when unit tsmperaturee over 140 *F (60 *C) 1. General Proceaa Hazards Penalty Fac tor Range 16 Penalty Fac tor Used (1) Baee Factor................................................................................................................. A. Exothermic Chemicsl Reactions B. Endothermic Processes C. Material Handling and Transfer D. Enclosed or Indoor Process Units E. Access F. Drainage end Spill Control 0 gallons 1.00 0.30 to 1.26 0.20 to 0.40 0.26 to 1.06 0.26 to 0.90 0.20 to 0.36 0.26 to 0.60 1.00 0.00 0.00 0.00 0.00 0.35 0.50 General Proceaa Hazards Factor (F1I....................................................................................... 1.85 2. Special Process Hazards Bass Factor ................................................................................................................ 1.00 A. Toxic MateriaHs) B. Sub-Atmospheric Pressure (< 600 mm Hg) C. Operation In or Near Flammable Range 1. Tank Farms Storage Flammable Liquids 2. Process Upset or Purge Failure 3. Alweys in Flemmeble Range Da Dust Explosion (See Table 3) X INERTED NOT INERTED 0.20 to 0.80 0.60 0.50 0.30 0.80 0.25 to 2.00 E. Pressure (See Figure 21 Ooeratino Pressure 0 osia Relief Settlno 2 osia F. Low Temperature 0.20 to 0.30 G. Quantity of Flammable/Unstable Material Quantitv 1.200.000 lb He 6.300 BTU/lb 1, Liquids or Gases in Process See Figure 3) 2* Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids In Storage, Dust in Process (See Figure 6) H. Corrosion end Erotion 1, Leakage * Joints and Packing 0.10 to 0.75 0,10 to 1.50 J. Use of Fired Equipment (See Figure 6) 1.00 0.40 0.00 0.00 0.00 0.80 0.00 0.16 0.00 0.00 0.77 0.00 0.10 0.10 0.00 K. Hot Oil Heat Exchange System (See Table 5) o.ieto i.i5 0.00 L. Roteting Equipment 0.50 0.00 Special Process Hazards Factor (F2)....................................................................................... 3.32 Process Unit Hazards Factor (FI x F2) = F3....................................................................... 6.15 Firs and Explosion Index (F3 x MF = F&EII............................................................................ 98 (1) For no penalty u*o 0.00. DO A 044598 CONFIDENTIAL FOAM C-22380 Rev/01-94 (471-00038) - IFlE-7 System V-2.5 - 4/4/90] Print Date: 1/14/97, Work File: A:\FEI7CALC\lDV900eXlsJFEI7J*MP MF DntoRle:C:\FEI7V2.5\AFEI7DEN\FEl7JDAT.XLS LOSS CONTROL CREDIT FACTORS 1. Proceee Control Cradit Factor |C11 Feature a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Factor Range 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Feetor Ueed 12) 0.98 1.00 1.00 1.00 0.99 Feature f. Inert Gee 9 Operating Instructions/Procedures h. Reactive Chemical Review i. Other Procect Hazard Analyst* Credit Factor Ranga 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Ueed 12) 0.96 0.94 0.91 0,98 Cl Value (31 \ 0.778 | 2. Material Isolation Cradit Factor (C2) Feature a. Remote Control Valves b. Dump/Blowdown Credit Factor Ranga 0.96 to 0.98 0.96 to 0.98 Credit Factor Uaed 12) 1.00 1.00 Feature c. Drainage d. Interlock C2 Value (3) 1 0.970 1 3 Fir* Protection Cradit Factor IC3) Feature a. Leak Detection b. Structural Steal c. Fire Water Supply d. Special System* a. Sprinkler Syttem* Credit Factor Range 0.94 to 0,98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Cradit Factor Used (2) 0.98 1.00 0.97 1.00 0.86 Faetun f. Water Curtain* g. Foam h. Hand Extinguishen/Monitor* i. Cable Protection C3 Value (3) \ 0.792 ~\ Laa* Control Cradit Factor = Cl * C2 * C3 13) I 0.597 | Cradit Factor Range 0.91 to 0.97 0.98 Credit Factor Ueed (2) 0.97 1.00 Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Ueed 12) 1.00 1,00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Explocion Index (F&EI)............ (See Front) 98 2. Radiu* of Exposure ........... ................... 3. Area of Expoaura......................................... (Raw* 7) 83 21,422 ft sq.ft. 4. Value of Am* of Exposure 1993 Dollars... MM 2.00 5. Damage Factor................ ................... 0.59 6. Base Maximum Probable Property Damage - (Bate MPPDI (4 x S)...................... *MM 1.18 7. to** Control Credit Factor ................. .........(See Above) 0.60 8. Actual Maximum Probable Property Damage (Actual MPPDI [6 x 7] .... 9, Maximum Probable Pay Outage -(MPDO) 16 MM days 0.71 | 10. Business Interruption - (Bl) ....... .............................................................................................. D0 A 0A459C, (2) For no credit factor enter 1.00 (3) Product of all factors used conftdfnttai Refer to "Fire it Explosion Index Hazard Classification Guide* (Form #471-00001) for detail* BACK Of FORM &223B0 Rev/01-94 (471-00030) - (FlE-7 Syvtwn Vw-2.,5 - 4/4/96 Print Date: 1/14/97, Work File; A:\FEl7CALC\f0V900.xisIFEi7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT,XLS FIRE & EXPLOSION INDEX AREA/COUNTKY ! USA SITE LA MANUFACTURING UNIT PLAQUEMINE PROCESS UNIT 11/12/96 LAD PREPAREO RY; GLYCOL-1 TPG HYDROGENATOR APPROVED RY: <Si*wiMid.nt) RLHIUNO LEIGH HILL REVIEWED RY: IM--gt--Ml CHARLES JACKSON REVIEWED BY: (Tadnekw Canwl 1501 REVIEWED BY: Al LEIGH HILL MATERIAL* IN PROCESS UNIT STEVE JANDA BUCK BAILEY PROPYLENE GLYCOL / HYDROGEN STATE OP OPERATION BASIC MATERIAUSI POR MATERIAL FACTOR ^NORMAL OPStATON X SHUTDOWN Hydrogen MATERIAL FACTOR (See Tsble 1 or Appsndieaa A or B) Not* roquirmnti whan unit temperature* over 140 *F (BO *C) 1. General Prooeea Hazards Penalty Fac tor Rang# Bees Factor ................................................................................................................. 1.00 A. Exothermic Chemical Reaction* 0.30 to 1.25 B. Endothermic Processes 0.20 to 0.40 C. Material Handling and Transfer 0, Enclosed or Indoor Process Units 0.25 to 1.05 0.25 to 0.80 E. Access 0.20 to 0.35 F, Drainage and Spill Control 0 oallont 0.25 to 0.50 21 Penalty Feetor Used 11} 1.00 0.30 0.00 0.00 0.00 0.00 0.25 General Process Hazards Factor (FI).................................................................................... . 1.55 2. Special Process Hazards Base Factor................................................................................................................. 1.00 A. Toxic Material!*) 0.20 to 0.80 B. Sub-Atmospheric Pressure (< 600 mm Ho) 0.50 C. Operation In or Near Flammable Range INERTED X NOT INERTED 1. Tank Farm* Storao* Ftsmmsble Liquid* 0.50 2. Process Upsat or Purge Failure 0.30 3. Always in Flammable Range D. Duet Explosion (See Table 3) 0.80 0.25 to 2.00 E. Pressure (See Fiaure 2) Deretina Pressure 100 dsIo Relief Setting 175 Oslo F. Low Temperature 0.20 to 0.30 0. Quantity of Flammabla/Unstable Material Quantity 10 lb He = 51.600 BTU/lb 1. Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solid* In Storage, Dust In Process (See Figure 5) H. Corrosion and Erosion 0.10 to 0.75 1. Leakage - Joints and Packing 0.10 to 1.50 1,00 0.00 0.00 0.00 0.30 0.00 0.00 0.28 0.00 0.00 0.00 0.00 0.00 0.10 J Use of Fired Equipment (See Figure 6) 0.00 K. Hot Oil Heat Exchange System (See Teble 51 L. Rotating Equipment 0.15 to 1.16 0.50 0.00 0.00 Special Procese Hozerde Factor (F2)....................................................................................... 1.68 Procase Unit Hazerd* Factor (FI x F2) *= F3....................................................................... 2.61 Fire and Explosion Index (F3 x MF = F&EI)............................................................................. 55 ID For no penslty use O.OO. DO A 044600 CONFIDENTIAL FORM C-22380 ReWDl-M <471-0003) - |RE 7 Sytttnt Vw-2.5 . 4/4/801 Print Date; 1/14/97, Work File: A:\FEI7CALC\IHYDROGENATOR.xlslFEI7_TMP MF DstaFilo:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Proceea Control Credit Factor (Cl) Feature a. Emeroency Power b. Coolino c. Explotion Control d. Emergency Shutdown Or Computer Control Credit Factor Rang* 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Uaed 12) 0.98 1.00 1.00 0.98 0.97 Feature f. Inert Gat 9- Operating Initructiont/Procedure! h. Reactive Chemical Review i. Other Proceie Hazerd Anaiyaii Cl Valuo (3) | 0.784 ~| 2. Material leolation Credit Factor (C2) Feature a. Remote Control Valve* b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Ueed (2) 0.98 1.00 Feature e. Drainage d. Interlock C2 Value (3) i 0.892 f 3 Fire Protection Credit Factor (C3) Feature a. Leak Detection b. Structural Steal c. Fire Water Supply d. Special Syitemi a. Sprinkler Syitcmt Credit Factor Range 0.94 to 0.98 0.96 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Ueed (2) 0.98 0.98 0.97 1.00 0.97 Feature f. Water Curtain! 9- Foam h. Hand Extinguiehert/Monltore i. Cable Protection C3 Value (3) i 0.877 1 Lose Control Credit Factor = Cl X C2 X C3 (3) | 0.613 I Credit Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 CredK Factor Ueed 12) 1.00 0.94 0.91 0.98 CredK Factor Ranga 0.91 to 0.97 0.98 CredK Factor Ueed 12) 0.91 1.00 Credit Factor Ranga 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Ueed 12) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Exploiion Index (F&EI)............ (See Front) 55 2. Radiux of Expoture....................................... 3. Area of Exposure................. 7} 46 6,646 4. Value of Area of Expoture 1993 Dollar*... 5. Damage Factor............................................. 0.55 6. Base Maximum Probabie Property Damage * (Bate MPPD) (4 x 51...................... 7. Loss Control Credit Factor ............... 0.61 8. Actual Maximum Probable Property Damage * (Actual MPPD) [6 x 7) .... 9. Maximum Probabie Days Outage - (MPDO) W*s) 45 10. Buainess Interruption - (Bl).................. . ft *q.ft. IMM $MM MM day* 12.50 6.86 4.20 | | (2) For no credit factor enter 1.00 (3) Product of all factor* used Refer to 'Fire & Explotion Index Hazard Claitification Guide' (Form #471*00001) for detail! BACK OF FORM C-22380 AaWOl-M I471-0003a) - IFIE-7 Sftnm V2..5 - 4/4/BB Print Date: 1/14/97, Work File: A:\FEI7CALC\iHYDROGENATOR.xlslFEI7_TMP MF DotaFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS DO A 044601 CONFIDENTIAL FIRE & EXPLOSION INDEX AREA/COUNTHY DIVISION r DATE USA tm LAD PREPARED BY: LEIGH HILL REVIEWED BY: (RUmbnmm) LEIGH HILL MATERIAL* M PROCESS UNIT PROPYLENE OXIDE STATE OF OPERATION LA MANUFACTUfUNO UNIT PLAQUEMINE PHOCESS UNIT 11/14/96 GLYCOL-1 PO TANK TRUCK LOADING APPROVED BV; (SwwfciiHidMnl BUILDINO CHARLES JACKSON REVIEWED BY; (Tchnotor CmwI 1501 REVIEWED BY: (Batow A l STEVE JANDA BUCK BAILEY SASIC MATERIAUSI FOR MATERIAL FACTOR STARTUP It Nil OPERATION Propylene Oxida MATERIAL FACTOR (Ss Tabic 1 or Appendices A or B) Not* requirement* when unit temperature* over 140 *F <60 *C) 1. Ganaral Procass Hazarda Penalty Fac tor Range Basa Factor ................................................................................................................ 1.00 A. Exothermic Chemical Reaction* 0.30 to 1.26 B. Endothermic Processes 0.20 to 0.40 C. Material Handling and Transfer D. Enclosed or Indoor Process Units 0.25 to 1.06 0.26 to 0.90 E. Access 0.20 to 0.35 F. Drainage and Spill Control 0 Gallons 0.26 to 0.60 General Process Hazards Factor (FI)..........................*.......................... *............................... 2. Special Process Hazards Basa Factor................................................................................................................ 1.00 A. Toxic Material(s) B. Sub-Atmospheric Pressure (< 600 mm Hg) C. Operation In or Near Flammable Range X INERTED 0.20 to 0.B0 0.60 NOT INERTED 1. Tank Farms Storage Flammable Liquids 0.50 2. Process Upset or Purge Failure 3. Always in Flammable Range D. Duet Explosion (See Table 3) E. Pressure (See Fiaure 2) 0.30 0.B0 0.25 to 2.00 Operation Pressure 20 osic Relief Settlna 265 psio F. Low Temperature 0.20 to 0.30 G. Quantity of Flammable/Unstebte Material Quantity 40.000 lb He = 13,200 BTU/Ib 1. Liquids or Geese in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3* Combustible Solids in Storage, Dust In Process (See Figure 5) H, Corrosion and Erosion 1. Leakage Joints and Pecking 0.10 to 0.75 0.10 to 1.50 J. Usa of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 5) 0.15 to 1.16 L. Rotating Equipment 0.50 Special Proceed Hazards Factor (F2)....................................................................................... Process Unit Hazards Factor (FI x F2) * F3....................................................................... Fire and Explosion Index (F3 x MF * F&EI).................... ....................................................... (11 For no pnalty usa 0.00. 24 Penally Fac tor Used (1) 1.00 0.00 0.00 0.50 0.00 0.35 0.60 2.35 1.00 0.60 0.00 0.00 0.30 0.00 0.00 0.07 0.00 0.00 0.31 0.00 0.10 0.10 0.00 0.00 0.00 2.48 6.83 140 FORM C-223R0 Rpv/01-M <471-00030) (HE-7 SyalAoi V-2.S 4/4/801 Print Data: 1/14/97, Work File: A:\FEI7CALC\IPOTTLOADING.xls1FEI7_TMP MF DataF:le:C:\FEI7V2.5V\FEI70EN\FEI7_DAT.XLS D0 A 044602 CONFIDENTIAL LOSS CONTROL CREDIT FACTORS 1. Prooeaa Control Credit Factor (Cl) Feature a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown A. Computer Control Credit Factor Range 0.98 0,97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Used (2) 0.98 1.00 1.00 0.98 0.97 Feature f. Inert Oas 9- Operating Jnstroctions/Procedures h. Reactive Chemical Review i. Other Process Hazard Analysis Cl Valua (31 | 0.762 1 2. Matarial laolation Credit Factor (C2) Faatura a. Remote Control Valves b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Used (2) 0.96 1.00 Feature c. Drainage d. Interlock foo < c (3) 1 0.874 1 3 Fire Protection Credit Factor (C3) Feature a. teak Detection b. Structural Steel c. Fire Water Supply d. Special Systema a. Sprinkler Systems Credit Factor Range 0.94 to 0.98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Used 12) 0.98 1.00 0.97 1.00 0.97 Feature f. Water Curtains 0- Foam h. Hand Extinguishers/Monitors i. Cable Protection C3 Valua (3) I 0.894 *~l Lose Control Cradit Factor = Cl x C2 x C3 (3) = | 0.588 I Credit Factor Rang# 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0-9B Credit Factor Uied 12) 0.96 0.94 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 Credit Factor Ueed (2) 0.91 1.00 Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Used (2) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Explosion Index (F&EI) .......... . (See Front) 140 2. Radius of Exposure....................................... 3. Area of Exposure........................................... 4. Value of Area of Exposure 1993 Dollars.... 118 43,435 ft aq.ft. MM 5. Damage Factor.............................................. 0.83 6. Base Maximum Probable Property Damage * (Bate MPPD) (4 x 51...................... MM 7. Loaa Control Credit Factor ................... 0.59 8. Actual Maximum Probable Property Damage - (Actual MPPD) [6 x 7] .... MM 9. Maximum Probable Day* Outage (MPDO)____________ iVwti__________ 19___________ days 2.00 1.67 0.98 1 | | (2) For no credit factor enter 1,00 (3) Product of all factors used DO A 044603 CONF T DFNT T AL, Refer to 'Fire 6 Explosion Index Hazard Classification Guide* (Form #471-00001) for details BACK OF FORM C-22380 Rn/OI-M (471-00038) - IHE-7 Systam Vf-2..S - 4/4/88 Print Date: 1/14/97, Work File: A:\FEI7CALC\IPOTTLOADING.xlsJFEI7_TMP MF DaFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS FIRE & EXPLOSION INDEX AREA/COUNTRY DIVISION LOCATION DATE ! USA sm LAD PREPARED BY: LEIGH HILL REVIEWED BY: (Miw^iml LEIGH HILL MATERIAL? IN PROCESS UNIT PDC STATE Of OPERATION LA MANUFACTURING UNTT PLAQUEMINE PROCESS UNIT GLYCOL-1 T-1000 APPROVED BY: (St^arifiWAdoti CHARLES JACKSON REVIEWED BY: (TkAmIow CmNtI STEVE JANDA 11/13/96 BUILDING 1501 REVIEWED BY: ISalMy A Im FrwMHkM) BUCK BAILEY SASIC MATER1AUS) FOR MATERIAL FACTOR __ ntllSN ^STAfTTUP _X_MORMAL OPERATION __ SHUTDOWN Propylene Dichloride !MATERIAL FACTOR (So Tab)# 1 or Appmndic** A or 8} Not* rqu>r*m*nta whon unh temparaturo over 140 *F (60 *C) 16 1. General Process Hazards Penalty Fee- Penalty Fee- tor Rang# tor Used (1) Base Factor................................................................................................................ A. Exothermic Chemical Reactions B. Endothermic Processes C. Material Handling end Transfer D. Enclosed or Indoor Process Units Es Access F, Drainage end Spill Control 0 oallons 1.00 0.30 to 1.25 0.20 to 0.40 0.26 to 1.05 0.25 to 0.90 0.20 to 0.35 0.25 to 0.50 1.00 0.00 0.00 0.00 0.00 0.00 0,50 General Process Hazards Factor (FI)....................................................................................... 1.S0 2. Special Process Hezards Base Factor................................................................................................................ 1.00 A. Toxic Material!*) 0.20 to 0.80 B. Sub-Atmospheric Pressure (< 600 mm Hg) C. Operation In or Near Flammable Range 0.50 1. Tank Farms Storage Flammable Liquids 0,60 2. Process Upset or Purge Failure 0,30 3. Always In Flammable fiends D. Dust Explosion (See Tsble 3) 0.80 0.25 to 2.00 E. Pressure (See Figure 2) F. Low Temperature Ooeratina Pressure 9 P*`B Relief Settina 0 Pslo 0.20 to 0.30 G. Quantity of Flemmable/Unstable Material Quantity 11,700 lb He = 6.300 BTU/lb 1.00 0.40 0.60 0.00 0.00 0.00 0.00 0.00 0.00 1. Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 51 H. Corrosion end Erosion 1. Leakage - Joints and Packing 0.10 to 0.75 0.10 to 1.50 0.08 0.00 0.00 0.00 0.00 J. Use of Fired Equipment (See Figure 6} 0.00 K. Hot Oil Heat Exchange System (See Table 5) 0.15 to 1.16 0.00 L. Rotating Equipment 0.50 0.00 Special Process Hazards Factor (F2)....................................................................................... 1.98 Process Unit Hazards Factor (FI x F2I F3....................................................................... 2.97 Fire and Explosion Index (F3 x MF = F&EI)............................................................................ 48 (1) For no penalty use O.OO. 0 A 044604 Con^IDBNTTAL FOAM 0-22380 Rer/01-94 <471-00030) - [RE-7 Syttam Vw-2.5 - 4/4/861 Print Date: 1/14/97, Work File: A:\FEI7CALC\IT1000.xls]FEI7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XL$ LOSS CONTROL CREDIT FACTORS 1. Prooeee Control Credit Factor (Cl I Featuia a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Factor Range 0,98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Utad (2) 0.98 1.00 1.00 1.00 0.97 Feature i. Inert Qae 9- Operating Instructlons/Procedurea h. Reactive Chemical Review i. Other Proceet Hazard Analyele Cl Value (3) | 0.791 1 2. Material Isolation Credit Factor (C2) Feature a. Remote Control Valves b. Dump/Slowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Cndh Factor Ueed (2) 0.98 1.00 Feature c. Drainage d. Interlock C2 Value 13) 1 0.980 1 3 Fire Protection Credit Factor (C3) Feature a. Leak Detection b. Structural Steel c. Fire Water Supply d. Special Systems e. Sprinkler Systems Credit Factor Range 0.94 to 0.98 0.95 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Factor Ueed (2) 0.98 1.00 0.94 1,00 0.86 Feature f. Water Curtains 9- Foam h. Hand ExtinguishersfMonitort L Cable Protection C3 Value <31 I 0.767 1 Loss Control Credit Factor Cl xC2xC3 (3| = | 0.595 I CiedK Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Feetor Ueed (2) 1.00 0.93 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 Credit Feetor Ueod 12) 1.00 1.00 Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Ueed (2) 1,00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire end Explotion Index (F&EI)............ 2. Radius of Exposure ....................................... (See Front) 7) 48 40 ft 3. Area of Exposure ............................... 4. Value of Area of Exposure 1993 Dollars.... 5,001 eq.ft. $MM 1.00 1 6. Damage Factor.............................................. 0.39 6. Base Maximum Probable Property Damage - (Base MPPDI [4 x E)........ 0.39 | 7. Loss Control Credit Factor 8. Actual Maximum Probable Property Damage - (Actual MPPDI [8 X 7] .. 0.59 0.23 | 9. Maximum Probable Days Outage - (MPDOI 10. Business Interruption - fBli........... . fW* > 8 days ........... *MM 0.19 | (2) For no credit factor enter 1.00 (3) Product of ail factors usee Refer to "Fire A Explosion Index Hazard Classification Guide* (Form #471*00001) for details DO A 044605 CONFIDENTIAL BACK OF FORM C-22380 R*y/01-M 1*71-000381 - IHF-7 Sysuni V<r-2..S 4/4/98 Print Data: 1/14/97, Work File: A:\FEI7CALC\IT1000.xl8lFEI7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XL$ FIRE & EXPLOSION INDEX AREA/COONTRY DIVISION LOCATION DATE ! USA sm LAD PREPARED BY: LEIGH HILL REVIEWED BY: (Mwo-M*) LEIGH HILL MATERMIf Mt PROCESS UNIT PDC STATE OP OPERATION LA MANUFACTURING UNIT PLAQUEMINE PROCESS UNIT GLYCOL-1 T-1200 APPROVED BY: tSiqwintaftdefltf CHARLES JACKSON REVIEWED BY: (TeohnWogy Center} STEVE JANDA 11/16/96 BUfUXNG 1501 REVIEWED BY: (Safety A tea# Ftavamfenl BUCK BAILEY BASIC MATERIAUS) FOR MATERIAL FACTOR __ PCUQM ^STARTUP _X_MOMIAi. OPOIAtKM ^SHUtDOWN Propylene Dichloride MATERIAL FACTOR (See T*bl* 1 or Appendices A or B) Not* requirement* when unit temperature* over 140 *F (60 *C) 1. General Proceee Hazard, Penalty Fac tor Range Base Factor................................................................................................................ A. Exothermic Chemical Reactions B. Endothermic Processes C. Material Handling and Tranafer D. Enclosed or Indoor Process Units E. Access F. Drainage and Spill Control 0 gallons 1.00 0.30 to 1.26 0.20 to 0.40 0.26 to 1.06 0.25 to 0.90 0.20 to 0.35 0.25 to 0.50 16 Penalty Fac tor Used U) 1.00 0.00 0.00 0.00 0.00 0.00 0.50 General Proceee Hazards Factor (FI)....................................................................................... 1.50 2. Special Proceaa Hazards Baaa Factor................................................................................................................ 1.00 A. Toxic Materialist B. Sub-Atmotpheric Pressure (< 600 mm Ho) C. Operation In or Near Flammable Range 0.20 to 0.80 0.60 1. Tank Farms Storage Flammable Liquids 2. Process Upset or Purge Failure 3. Always in Flammable Range 0. Dust Explosion (See Table 3) 0.60 0.30 0.80 0.25 to 2.00 E. Pressure (See Roure 2) Ooeratino Pressure 0 osia Relief Settina 0 paid F. Low Temperature 0.20 to 0.30 G. Quantity of Flammable/Unstable Material Quantity 6.700 lb He - 6.300 BTU/lb 1, Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) Ha Corrosion end Erosion 1. Leakage * Joints end Packing 0.10 to 0.75 0.10 to 1.50 1.00 0.40 0.50 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.00 0,00 0.00 0.00 J, Use of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 6} L. Rotating Equipment 0.16 to 1.15 0.50 0.00 0.00 0.00 Special Proceee Hazard, Factor (F2I....................................................................................... 1.92 Proceee Unit Hazard* Factor (FI x F2I - F3....................................................................... 2.88 Fire and Explosion Index (F3 x MF *= F&EI)............................................................................. 46 (1) For no penalty uee 0.00. ft q4A&0& DO CONF"1 FORM 0*22380 Rev/01*B4 (471-00036) |Ft-7 System V*r-2.5 * 4/4/MI Print Date: 1/14/97, Work File: A:\FEI7CALC\IT1200,x!s]FEI7J"MP MF Datanie:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Process Control Credit Factor (Cl) Feature a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Factor Renge 0.8B 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Fector Ueed (2) 0.98 1.00 1.00 1.00 0.97 Feature f. Inert Gee 9- Operating Inttructtone/Procedure* h. Reactive Chemical Review i. Other Process Hazard Analysis Cl Value (3) I 0.791 | 2. Material Isolation Credit Factor (C2) Feature a. Remote Control Velvet b. Dump/Blowdown Credit Fector Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Ueed (2) 0.98 1.00 Feature c. Drelneoe d. Interlock C2 Value (3) 1 0.980 I 3 Fire Protection Credit Factor (C3) Feature ft. Leek Detection b. Structural Steel c. Fire Water Supply d. Special Systems e. Sprinkler Syttems Credit Fector Renge 0.94 to 0.98 0.96 to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Fector Used (2) 0.98 1.00 0.94 1.00 0.87 Feature f. Water Curtain* 9' Foam Hr Hand Extinguishers/Monitors 1. Cable Protection C3 Valua (3) I 0,801 H Loaa Control Credit Factor Cl x C2 x C3 (3) = I 0.621 I Credit Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Fector Ueed 12) 1.00 0.93 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 Credit Factor Ueed (2) 1.00 1.00 Credit Fector Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Ueed 12) 1.00 1.00 1.00 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Explosion Index (F&EI)............ 2. Radius of Exposure....................................... (See Front) 46 39 3. Area of Exposure........................................... 4,707 4* Value of Area of Exposure 1993 Dollar*. 5. Damage Factor.............................................. 0.39 6. Bae Maximum Probable Property Damage * (Base MPPD) [4 x 6]...................... 7. Lott Control Credit Factor ................... 0.62 8. Actual Maximum Probable Property Damage - (Actual MPPD) (6 x 7] .... 9. Maximum Probable Day* Outage - (MPDO) 8 10. Buainaas Interruption - |Bl).......... ........ ........ ft eq.ft. MM MM MM days ............ MM 1.00 0.39 0.24 0.19 1 1 I 1 (2) For no credit factor enter 1.00 (3) Product of all factor* used Refer to "Fire & Explosion Index Hazard Classification Guide" (Form #471-00001) for details BACK OF FORM 0-223*0 ReW01-M (471-000301 - IFrE-7 SyMem V,,.2,,S - 4/4/90 Print Data: 1/14/97, Work Hie: A:\FEi7CALCUT1200.xla]FEI7_TMP MF DataFile:C:\FEl7V2.5V\FEI7DEN\FEI7_DAT.XLS DO A 044607 CONFIDENTIAL FIRE & EXPLOSION INDEX AREA/COUNTRY ENVISION LOCATION DATE USA ftrTE LAD PREPARED BY: LEIGH HILL REVIEWED BY: (MaMgMMlI LEIGH HILL MATERIALS M PROCESS UNO- PDC STATE OF OPERATION LA MANUFACTURING UNfT PLAOUEMINE PROCESS UNIT GLYCOL-1 THROX APPROVED BY; (SuptrinwidMti CHARLES JACKSON REVIEWED BY: (Taehnobgy Cwitarl STEVE JANDA 11/13/96 BUILDING 1501 REVIEWED BY: <*<* A Uw PiwMoM BUCK BAILEY BASIC MATERIAL!*} FOR MATERIAL FACTOR _DCSMM _TAIITUP _XJ\BWMAL OTOIATIOW __SHUTDOWN Propylene Dichlodde MATERIAL FACTOR (See Table 1 or Appendioea A or B) Note requirement! when unit temperatures over 140 *F (00 *C) 1. General Process Hazards Penalty Fac tor Range Base Factor................................................................................................................. A. Exothermic Chemical Reactions 6. Endothermic Processes 1.00 0.30 to 1.25 0.20 te 0.40 C. Materiel Handling and Transfer D. Enclosed or Indoor Process Units 0.25 to 1.05 0.25 to 0.90 E. Access F. Drainage end Spill Control 0.20 to 0.35 0 oallons 0.25 to 0.50 General Process Hazards Factor (F1I....................................................................................... 2, Special Process Hazards Bass Factor................................................................................................................. 1.00 A. Toxic MeteriaKs) B. Sub*Atmospheric Pressure (< S00 mm Hg) C. Operation In or Near Flammable Range 0.20 to 0.80 0.50 1. Tank Farms Storage Flammable liquid* 2. Process Upset or Purge Failure 3. Always in Flammable Range D. Dust Explosion (See Table 31 E. Pressure (See Figure 2) 0.60 0.30 0.80 0.25 to 2.00 Ooeratino Pressure 0 osio F. Low Temperature G. Quantity of Flammable/Unstable Materiel Relief Settina 0 osla 0.20 to 0.30 Quantity 100 lb He = 6.300 BTU/lb 1. Liquids or Gases in Process (See Figure 3) 2. Liquids or Geses in Storage (See Figure 4) 3. Combustible Solids in Storage, Dust In Process (See Figure S) H. Corrosion and Erosion 1. Leakage * Joints end Pecking 0.10 to 0.76 0.10 to 1.50 J. U*e of Fired Equipment (See Figure 6) K. Hot Oil Meet Exchange System (See Table 5) 0.16 to 1.15 L- Rotating Equipment 0.50 Special Process Hazards Factor (F2)....................................................................................... Process Unit Hazards Factor (FI x F2) - F3....................................................................... Firs and Explosion Index (F3 xMF F&EI1............................................................................. (II For no penalty use 0,00. 16 Penalty Fector Used (1) 1.00 0.50 0.00 0.00 0.00 0.00 0.50 2.00 1.00 0.40 0.50 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.10 0.10 1.00 0,00 0.50 3.60 7.20 115 DO A 044608 CONFIDENTIAL FORM C-22380 fto,/0VB4 (471-000381 - IFIE7 Snun Vr-2.S - 4/4(801 Print Date: 1/14/97, Work File: A:\FEI7CALC\ITHROX.xlslFEI7_TMP MF DataFile:C:\FEI7V2.5V\FEI7DEN\FEI7_DAT.XLS LOSS CONTROL CREDIT FACTORS 1. Process Control Credit Factor (Cl) Feature a. Emeroanoy Power b. Cooling c. Explosion Control d. Emergency Shutdown 0. Computer Control Cndft Factor Rang* 0.98 0.97 to 0.99 0.84 to 0.88 0.96 to 0.99 0.93 to 0.99 Credit Factor Used (2) 0.98 1.00 1.00 0.96 0.93 Faatura f. Inert Gas 9- Operating Instructions/Proeedures H. Reactive Chemical Review i. Other Process Hazard Analysis Cl Value (3) | 0,672 1 2. Material Isolation Credit Factor (C2) Faatura a. Remote Control Valves b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor Used (2) 0.96 1,00 Feature c. Drainage d. Interlock C2 Value (3) I 0.960 ~| 3 Fire Protection Credit Factor (C3) Feature a. Leak Detection b. Structural Steel c. Fire Water Supply d. Speciel Systems a. Sprinkler Systems Credit Fector Rengs 0.94 to 0.98 0.9S to 0.98 0.94 to 0.97 0.91 0.74 to 0.97 Credit Fector Used 12) 0.98 1.00 0.94 1.00 0.87 Feeture f. Water Curtains 9- Foam h. Hand Extinguishers/Monitors 1. Ceble Protection C3 Value (3) I 0.777 1 Loce Control Credit Factor - Cl x C2 x C3 (31 = | 0.502 I CradK Factor ftanga 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Usad (2) 0.94 0.92 0.91 0.98 Credit Factor Range 0.91 to 0.97 0.98 Credit Factor Uaad (2) 1.00 1.00 Credit Fector Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Fector Ueed (2) 1.00 1.00 0.97 1.00 PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire and Explosion Index (F&EI) (See Front) 115 2. Redius of Exposure....................................... 7) 97 ft 3. Area of Exposure ............................ ............. 29,403 tq.ft. 4. Value of Area of Exposure 1993 Dollars.... MM 11.00 5. Demege Fector............................................... 0,64 6. Base Maximum Probable Property Damage * {Bote MPPDI [4 x 5)...................... *MM 7.03 7. Loss Control Credit Fector ................... 0.50 8. Actuel Maximum Probable Property Demege - (Actuel MPPD) (6 x 7] .... *MM 3.53 9. Maximum Probable Days Outage - (MPDOj____________ 0)_______________ 41____________daya__________________ IQ. Buainaaa Interruption - (Bll................................................................................................................ ItMM 11.44 1 I | (2) For no credit factor enter 1.00 (3) Product of all factors used Refer to "Fire & Explosion Index Hazard Classification Guide' (Form *471-00001) lor details SysumBACX OF FCSM C-JJ3S0 Rw/Of-M <471-000301 IF4E-7 V2..5 4/4<90 Print Data: 1/14/97, Work Hie: A:\FEI7CALC\[THR0X.xls]FEI7 TMP MF DataHle:C:\FEI7V2.5V\FEI7DEN\FEI7 DAT.XLS D0 A 04A609 confidential TABLE OF CONTENTS Preface.............................................................................................................................................................. 1 Introduction: The Fire & Explosion Index System........................................................................................ 2 Procedure for Risk Analysis Calculations...................................................................................................... 3 Selection of Pertinent Process Units................................................................................................................ 8 Determination of Material Factor................................................................................................................... 10 Process Unit Hazards Factors ......................................................................................................................... 15 General Process Hazards................................................................................................................................. 16 Special Process Hazards ................................................................................................................................. 20 Determination of Process Unit Hazards Factor............................................................................................. 37 Determination of Fire and Explosion Index................................................................................................... 38 Loss Control Credit Factors............................................................................................................................ 39 Process Unit Risk Analysis Summary............................................................................................................ 47 Discussion of MPPD, BI and Plant Layout....................................................................................................57 Manufacturing Unit Risk Analysis Summary................................................................................................ 58 Risk Analysis Package....................................................................................................................................... 59 TABLES 1 - Material Factor Determination Guide............................................................................................... 13 2 - Material Factor Temperature Adjustment......................................................................................... 14 3 - Dust Explosion Penalty ..................................................................................................................... 21 4 - High Pressure Penalty for Flammable and Combustible Liquids................................................... 22 5 - Hot Oil Heat Exchange System Penalty ........................................................................................... 36 6 - Degree of Hazard for F&EI............................................................................................................... 38 FIGURES 1 - Procedure for Calculating F&EI and Other Risk Analysis Information ........................................ 4 2 - Pressure Penalty for Flammable and Combustible Liquids............................................................... 23 3 - Liquids or Gases in Process............................................................................................................... 27 4 - Liquids or Gases in Storage............................................................................................................... 29 5 - Combustible Solids in Storage/Dust in Process ............................................................................... 31 6 - Fired Equipment Penalty.................................................................................................................... 34 7 - Radius of Exposure............................................................................................................................ 48 8 - Damage Factor.................................................................................................................................... 53 9 - Maximum Probable Days Outage..................................................................................................... 55 FORMS Fire and Explosion Index Form................................................................................................................ Loss Control Credit Factors Form........................................................................................................... Process Unit Risk Analysis Summary Form............................................................................................ Manufacturing Unit Risk Analysis Summary Form ............................................................................... 5 6 6 7 APPENDICES A- Material Factors.................................................................................................................................. 60 B - Special Material Factor Considerations for Mixtures....................................................................... 72 C~ Basic Preventive and Protective Features......................................................................................... 74 D- Loss Prevention Checklist.................................................................................................................. 75 E - Equations for Damage Factor Data................................................................................................... 81 F - Acronyms and Abbreviations.............................................................................................................. 83 DO A 04461 CONFIDENT TAl PREFACE Since the first edition of this guide was issued in 1964, the Fire & Explosion Index (F&EI) has evolved through the past 29 years into a comprehensive index that gives a relative value to the risk of individual process unit losses due to potential fires and explosions. The primary purpose of the F&EI is to serve as a guide to the selection of fire protection methods. Its broader purpose was to have a method for the relative ranking of individual process units focused on key items of equipment This index has been widely used in Dow and outside of Dow. It is the leading hazard index recognized by the chemical industry. The present F&EI provides key information to help evaluate the overall risk from fire and explosion. The F&EI can be used in conjunction with the Chemical Exposure Index Guide, 2nd ed. and other process information to form a Risk Analysis Package to better understand the potential risks to a manufacturing unit. This package is an important part of the Consolidated Audit process. The F&EI is one of the tools used for evaluation of realistic fire, explosion and reactivity potential of proc ess equipment and its contents as described in the Corporate Process Risk Management Guidelines for Facilities and Distribution. A facility with an F&EI greater than 128 will require further risk review. The F&EI is also tied into the Distribution Ranking Index (DRI); see Guidelinesfor Determining the Distribu tion Ranking Index. The seventh edition is primarily an update of the sixth edition, and there are no major conceptual changes. Improvements have been made in wording and updating has been done to remain consistent with Codes and Loss Prevention Principles. A major update has been made in Appendix A, Material Factors, which gives the latest NFPA ratings, flash points, boiling points and, most importantly, Material Factors. Improvements in the seventh edition include: Correction of the errata which had been noted in the sixth edition. Incorporation of a table of F&EI versus Degree of Hazard. Major updating of Appendix A to give most recent NFPA ratings and Material Factors which agree with Table 1. Revision of F&EI forms that have been streamlined and put into computerized spreadsheet formats. Updating of the Determination of Material Factor and Toxic Materials NFPA ratings in accordance with the latest NFPA 704 definitions. Addition of equations for the curves in the figures to aid in the calculation of factors and allow for computer determination of values. Inclusion of SI (International System of Units) units in addition to US/British units. Improvement and addition of examples. Some revamping in the Loss Control Credit Factors area with elimination of buried tank credit and reference to halons and new credit for process hazard reviews. Reorganization of Process Unit Risk Analysis Summary section. Updating discussion regarding Maximum Probable Property Damage and plant layout considerations. Minor revisions to the Loss Prevention Checklist It is a requirement of the Dow Corporate Minimum Requirements for Safety, Loss Prevention and Security that the Fire & Explosion Index Hazard Classification Guide shall be used to assess the hazard potential of all installations. The Fire & Explosion Index Hazard Classification Guide has been made available as an edited version to all interested parties through the American Institute of Chemical Engineers (AIChE), 345 East 47th Street, New York, NY 10017 [Phone (212) 705-7657]. Various countries have referenced the F&EI guide in their respective governmental regulations. 1 DO A 044613 CONFIDENTIAL INTRODUCTION: THE FIRE AND EXPLOSION INDEX The Fire and Explosion Risk Analysis System is a step-by-step objective evaluation of the realistic fire, explosion and reactivity potential of process equipment and its contents. The quantitative measurements used in the analysis are based on historic loss data, the energy potential of the material under study, and the extent to which loss prevention practices are currently applied. The purpose of the F&EI system is to: 1. QUANTIFY the expected damage of potential fire, explosion and reactivity incidents in realistic terms. 2. IDENTIFY equipment that would be likely to contribute to the creation or escalation of an incident. 3. COMMUNICATE the F&EI risk potential to management. Beneath all the numbers, graphs and figures, however, lies the most important goal of the F&EI System -- to make the engineer aware of the loss potential of each process area and to help the engineer identify ways to lessen the severity and resultant dollar loss of potential incidents in an efficient and cost effective manner. The F&EI is used in the Dow Risk Review Process as described in the Process Risk Management Guide lines for Facilities and Distribution. Determination of the F&EI must be done in conducting a Process Hazard Analysis or Level I Risk Review. Further risk review is to be done for facilities with an F&EI greater than 128. Insurance company assessments of potential exposures are typically based on the worst imaginable incident. They might anticipate, for example, that the complete contents of a reactor dump could vaporize instantaneously and ignite; and their insurance loss estimates, which are determined in part from this kind of analysis, can be extremely large. From a realistic point of view, this kind of situation is rare. The Dow F&EI system attempts to determine the realistic maximum loss that can occur to a process plant (or process unit) or related facility -- a loss that could actually be experienced under the most adverse op erating conditions. The calculation is based on quantifiable data. Finite spill rates, process temperature in relation to material flash points and boiling points and reactivity are just a few of the many contributors to a probable incident. Although the F&EI system is primarily designed for any operation in which a flammable, combustible or reactive material is stored, handled or processed, it may also be used in analyzing the loss potential of sew age treating facilities, distribution systems, pipelines, rectifiers, transformers, boilers, thermal oxidizers and certain elements of power plants. The system can also be used for risk evaluations of small processes with modest inventories of potentially hazardous materials; its application to pilot plants is strongly recom mended. The system can be applied if handling a minimum of approximately 1,000 lb (454 kg) of a flammable or reactive material. A word of caution is in order for those planning to use the F&EI system for the risk evaluation of facili ties. Common sense and good judgment must be used during the actual calculation and in the interpretation of its results. Process hazards that contribute to the magnitude and probability of losses have been quantified as "penalties" to provide factors for computation. Not every penalty may be applicable to a specific situation and perhaps some may have to be adjusted. The Loss Prevention Contact Person can serve as a valuable resource to assist in the calculations. DO A 044614 2 CONFIDENTIAL. PROCEDURE FOR RISK ANALYSIS CALCULATIONS To develop an F&EI and Risk Analysis Summary, the following are needed: a. An accurate plot plan of the plant (manufacturing unit) b. A process flow sheet c. A Fire & Explosion Index Hazard Classification Guide, Seventh Edition d. An Fire & Explosion Index Form (page 5 - F&EI, Seventh Edition) e. A Loss Control Credit Factors Form (page 6 - F&EI, Seventh Edition) f. A Process Unit Analysis Summary Form (page 6 - F&EI, Seventh Edition) g. A Manufacturing Unit Risk Analysis Summary Form (page 7 - F&EI, Seventh Edition) h. Replacement cost data for the installed process equipment under study. The procedure to be followed is listed below. Figure 1, page 4, presents a flowchart outlining the procedure for risk analysis calculations. 1. Selection should be made on the plot plan of the Pertinent Process Units that are considered of key importance to the process and that would have the greatest impact on the magnitude of a potential fire or explosioa 2. Determination is to be made of the Material Factor (MF) for each Process Unit The MF for a particular material in the Process Unit is to be obtained from Table 1, page 13 or Appendices A or B, pages 60 to 73. 3. Calculation is to be completed for the General Process Hazards Factor with application of the appropriate penalties according to the F&EI Form, page 5. 4. Calculation is to be completed for the Special Process Hazards Factor with application of the appropriate penalties according to the F&EI Form, page 5. 5. Determination of the Process Unit Hazards Factor is to be done by calculating the product of the General and Special Process Hazards Factors. 6. Determination of the F&EI is to be done by calculating the product of the Process Unit Hazards Factor and the Material Factor. 7. Determination of the Area of Exposure surrounding the Process Unit being evaluated is to be performed based on Radius of Exposure from Figure 7, page 48, and pages 47 to 50. 8. Determination of the replacement value of all equipment within the Area of Exposure and the inventory is to be done. 9. Determination of the Damage Factor, which represents the degree of loss exposure, is to be done using Figure 8, page 53, based on the MF and the Process Unit Hazards Factor (F3). 10. Determination of the Base Maximum Probable Property Damage (Base MPPD) is to be made by multiplying the Value of the Area of Exposure by the Damage Factor. 11. Application of the Loss Control Credit Factor to the Base MPPD allows for the determination of the Actual MPPD. 12. Determination of the Maximum Probable Days Outage (MPDO) is performed by using Figure 9, page 55, knowing the Actual MPPD. 13. Determination of the Business Interruption (BI) is done by using the equation given on page 56 where the MPDO is multiplied by the Value of Production for the Month (VPM) and by 0.70/30. Each of the steps given above is outlined and explained in the following pages of this guide. Appendix C, Basic Preventive and Protective Features, and Appendix D, Loss Prevention Checklist, are also provided for use in assessing the important loss control areas in a plant or manufacturing unit. When developing the F&EI, it is recommended that people with a working knowledge of the plant's his tory/experiences be contacted to discuss probable incident scenarios to assure the most viable F&EIs are developed. 3 DO A 044615 confidential ___________________________ FIGURE 1__________________ PROCEDURE FOR CALCULATING FIRE & EXPLOSION INDEX AND OTHER RISK ANALYSIS INFORMATION 4 D0 A 04A616 conftdfmtTAL FIRE & EXPLOSION INDEX AREA / COUNTRY DIVISION LOCATION DATE SITE PREPARED BY: REVIEWED BY: (Management) MANUFACTURING UNIT PROCESS UNIT APPROVED BY: (SupartntandMti) REVIEWED BY: (Technology Cental) BUILDING REVIEWED BY: (Salety A Lose Prevention) MATERIALS IN PROCESS UNfT STATE OF OPERATION __ DESIGN ___ STARTUP NORMAL OPERATION SHUTDOWN BASIC MATERIAL(S) FOR MATERIAL FACTOR MATERIAL FACTOR (See Table 1 or Appendices A or B) Note requirements when unit temperature over 140 F (60 C) 1. General Process Hazards Penalty Fac tor Range Base Factor........................................................................................................... A. Exothermic Chemical Reactions B, Endothermic Processes C. Material Handling and Transfer D. Enclosed or Indoor Process Units E. Access F. Drainage and Spill Control aalorcu.m. 1.00 0.30 to 1.25 0.20 to 0.40 0.25 to 1.05 0.25 to 0.90 0.20 to 0.35 0.25 to 0.50 General Process Hazards Factor (Fi).......................................................................................... 2. Special Process Hazards Base Factor........................................................................................................... A. Toxic Material(s) B. Sub-Atmospheric Pressure (< 500 mm Hg) C. Operation In or Near Flammable Range ___ Inerted ___ Not Inerted 1. Tank Farms Storage Flammable Liquids 2. Process Upset or Purge Failure 3. Always in Flammable Range D. Dust Explosion (See Table 3) E. Pressure (See Fiaure 21 Ooeratina Pressure Dsia or kPa aauae Relief Settina psig or kPa gauge F. Low Temperature G. Quantity of Flammable/Unstable Material: Quantity lb or ka Hc = BTU/lb or keal/kg 1. Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion 1. Leakage - Joints and Packing J. Use of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 5) L. Rotating Equipment 1.00 0.20 to 0.80 0.50 0.50 0.30 0.80 0.25 to 2.00 0.20 to 0.30 0.10 to 0.75 0.10 to 1.50 0.15 to 1.15 0.50 Special Process Hazards Factor (F2).......................................................................................... Process Unit Hazards Factor (F-| x F2) * F3............................................................................ Penalty Fac tor Used(i) 1.00 1.00 Fire and Explosion Index (F3 x MF = F&EI)............................................................................. FORM 022380 Rev/01-M (471-00036) (i) For no penalty use 0.00. 5 D0 A 04AM7 CONFIDENTIAL LOSS CONTROL CREDIT FACTORS 1. Process Control Credit Factor (Ci) F ature a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Factor Range 0.98 0.97 to 0.99 0.84 to 0.98 0.96 to 0.99 0.93 to 0.99 Credit Fact r Used<2) Feature f. Inert Gas g. Operating Instructions/Procedures h. Reactive Chemical Review i. Other Process Hazard Analysis Credit Factor Range 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 2. Material Isolation Credit Factor (C2) Feature a. Remote Control Valves b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Ci Value(3) Credit Factor Used(2) Feature c. Drainage d. Interlock Credit Factor Range 0.91 to 0.97 0.98 Credit Factor Used(2) Credit Factor Used(2) 3. Fire Protection Credit Factor (C3) Feature a. Leak Detection b. Structural Steel c. Fire Water Supply d. Special Systems Credit Factor Range 0.94 to 0.98 0.95 to 0.98 0,94 to 0.97 0.91 e. Sprinkler Systems 0.74 to 0.97 C2 Value<3) Credit Factor Used(2> Feature f. Water Curtains g. Foam h. Hand Extinguishers/Monitors i. Cable Protection Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Used(2) C3 Value<3) Loss Control Credit Factor = C1 X C2 X C3(3) = (Enter on line 7 below) PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire & Explosion Index (F&EI)........................ (See Front) 2, Radius of Exposure...........................................(Figure 7) ftorm 3. Area of Exposure.............................................................. ft2 or m2 4. Value of Area of Exposure.................................................................................................... $MM 5. Damage Factor.................................................(Figure 8) 6. Base Maximum Probable Property Damage - (Base MPPD) (4 x 5]................................... $MM 7. Loss Control Credit Factor............................ (See Above) J 8. Actual Maximum Probable Property Damage - (Actual MPPD) [6x7]............................... $MM 9. Maximum Probable Days Outage - (MPDO)..... (Figure 9) days 10. Business Interruption - (Bl).................................................................................................. $MM (2) For no credit factor enter 1.00. (3) Product of all factors used. Refer to Fire & Explosion Index Hazard Classification Guide (Form #471 -00001) for details. 6 BACK OF FORM C-22360 FW01-94 (471-00036) D0 A 044618 CONFTDFNTTAL | ] ~| MANUFACTURING UNIT RISK ANALYSIS SUMMARY I? AREA/COUNTRY SITE PREPARED BY DIVISION LOCATION MANUFACTURING UNIT TYPE OF OPERATION TOTAL MFG. UNIT REPLACEMENT VALUE DATE Process Unit Major Material Material Factor F&EI Value of Area of Exposure $MM Base MPPD1 $MM Actual MPPD1 $MM Days Outage MPDO2 Bl3 Loss $MM 1 Maximum Probable Property Damage 2 Maximum Probable Days Outage 3 Business Interruption FORM C-50010 REV/01-94 (471-00037) 7 DO A 044619 CONFIDENTIAL SELECTION OF PERTINENT PROCESS UNITS The F&EI calculation is a tool to help determine the areas of greatest loss potential in a particular process. It also enables one to predict the physical damage and business interruption that would occur in the event of an incident. The first step in making the F&EI calculation requires using an efficient and logical procedure to determine which process units should be studied. A process unit is defined as any major item of process equipment. The following process units could be identified in a fumace/quench section of a vinyl chloride monomer/ ethylene dichloride plant: ethylene dichloride preheater, ethylene dichloride evaporator, furnace, quench column, ethylene dichloride absorber and tarpot. A designation of the Process Unit must be entered in the appropriate space on the F&EI form, page 5. The Manufacturing Unit designation must also be entered on the F&EI form. A Manufacturing Unit is the entire production facility including chemical processes, mechanical processes, warehouse, packaging lines, etc. For example, manufacturing units may be a latex plant, DOWANOL plant or DowElanco Formulations plant. The process area of a latex plant could have the following process units: raw material storage tank/s, process stream storage tank/s, aqueous tank, reactor feed pumps, reactor, stripper, recovery tank/s, latex storage tank/s. A warehouse may also be treated as a process unit. The materials stored within a fire-walled area, or within the total storage area where fire walls are not provided, would constitute a Process Unit It is quite clear that most manufacturing units have many process units. To calculate the Fire and Explo sion Index, however, only process units that could have an impact from a loss prevention standpoint should be evaluated. These are known as Pertinent Process Units. Important factors for selecting Pertinent Process Units include: a. Chemical energy potential (Material Factor) b. Quantity of hazardous material in the Process Unit c. Capital density (dollars per square foot) d. Process pressure and process temperature e. Past history of problems that resulted in a fire and explosion incident f. Units critical to plant operation, i.e., thermal oxidizer Generally, the greater the magnitude of any of these factors, the greater the likelihood that the process unit needs to be evaluated. The destruction of scarce, critical or one-of-a-kind equipment in or near a process area could produce many days of downtime. Even with minimal fire and explosion damage, this could create large losses due to business interruption. The loss of such critical equipment is a valid reason for selecting a Pertinent Process Unit. There are no hard and fast rules governing the choice of Process Units for evaluation. For help in deter mining which pieces of equipment have the greatest potential for fire and explosion, consult with Technol ogy Centers, experienced plant engineers, process safety and loss prevention specialists or others with process experience. 8 DO A 044620 CONFIDENTIAL Important Considerations A. The Fire and Explosion Index system assumes that a process unit handles a minimum of 5,000 lb (2,268 kg), or about 600 gal (2.27 m3) of a flammable, combustible or reactive material. If less material is involved, generally the risk will be overstated. However, F&EI calculations can provide meaningful results for pilot plants if they handle at least 1,000 lb (454 kg) or about 120 gal (0.454 m3) of combustible or reactive material. B. Careful consideration is needed when equipment is arranged in series and the items are not effectively isolated from each other. An example would be a reaction train without an intermediate pump. In such situations, the type of process determines whether several vessels or just a single vessel should be considered as the Process Unit In a polystyrene train, for example, where the main hazard is from unreacted material in the first stage reactor, it is inappropriate to apply any penalties for vacuum operation in the flash tank or devolatilizer (which is effectively the third or fourth stage) because it is inconceivable to have both hazards occurring at the same point in the process. In this case, it would be reasonable to carry out two separate F&EI calculations, treating the first stage and fourth stage reactors as separate Process Units. It should rarely be necessary to calculate the F&EI for more than three or four Process Units in a single process area of a Manufacturing Unit. The number of Process Units will vary according to the type of process and the configuration of the Manufacturing Unit. A separate F&EI form (pages 5 and 6) must be completed for each process unit evaluated. The results of each calculation must also be listed on the Manufacturing Unit Risk Analysis Summary (page 7). C. It is also important to give careful consideration to the state or point in time of the operation. By their nature, such normal stages as start-up, steady-state operation, shutdown, filling, emptying, adding catalyst, etc., often create unique conditions having an impact on the F&EI. Generally, good judg ment will enable selection of the point in time of operation to perform the F&EI calculation. Occa sionally more than one point in time will have to be studied to determine the significant risk. 9 DO A 044621 CONFIDENTIAL DETERMINATION OF MATERIAL FACTOR The Material Factor (MF) is the basic starting value in the computation of the F&EI and other risk analysis values. The MF is a measure of the intrinsic rate of potential energy release from fire or explosion produced by combustion or chemical reaction. The MF is obtained from NF and Nr. The NF and Nr are NFPA ratings or "signals" expressing flamma bility and reactivity (or instability) respectively, as discussed below under "Unlisted Substances." Generally, NF and Nr are for ambient temperatures. It is recognized that the fire and reaction hazards of a material increase markedly with temperature. The fire hazard from a combustible liquid at a temperature above its flash point is equivalent to that from a flammable liquid at ambient temperature. Reaction rates also increase very markedly with temperature. If the temperature of the material on which the MF is based is over 140 F (60 C), a certain adjustment may be required, as discussed below under C. "Temperature Adjustment of Material Factor." Appendix A provides a listing of MFs for a number of chemical compounds and materials, and these values will be used in most cases. If Appendix A does not list the material, Np and Nr may possibly be found in NFPA 325M or NFPA 49 adjusted for temperature, if appropriate, and used with Table 1 to determine the MF. If the material is a combustible dust, use the Dust Hazard Class Number (St number) rather than the Np. A. Unlisted Substances If neither Appendix A, NFPA 49, nor NFPA 325M contains values for the substance, mixture or compound in question, these values will have to be determined from the flammability value (NF) or dust class (St) (see Table 1, page 13.). First, the parameters shown in the left column of the table on page 13 will have to be determined. The NF of liquids and gases is obtained from flash point data, and the St of dusts or mists is determined by dust explosion testing. The NF of combustible solids depends on the nature of the material as categorized in the left column. The reactivity value (Nr) can be obtained from a qualitative description of the instability (or reactivity with water) of the substance, mixture or compound at ambient temperature, as follows based on NFPA 704: Nr -- 0 Nr = 1 Materials that in themselves are normally stable, even under fire conditions. This degree usually includes: Materials that do not react with water, Materials that exhibit an exotherm at temperatures >300 C (572 F) but <500 C (932 F) when tested by Differential Scanning Calorimeter (DSC); Materials that do not exhibit in exotherm at temperatures 500 C (932 F) when tested by DSC. Materials that in themselves are normally stable but that can become unstable at elevated temperatures and pressures. This degree usually includes: Materials that change or decompose on exposure to air, light or moisture; Materials that exhibit an exotherm at temperatures >150 C (302 F), but <300 C (572 F). 10 DO A 044622 CONFIDENTIAL Nr = 2 Nr = 3 Nr = 4 Materials that readily undergo violent chemical change at elevated temperatures and pressures. This degree usually includes: Materials that exhibit an exotherm at temperatures 150 C (302 F) when tested by DSC; Materials that may react violently with water or form potentially explosive mixtures with water. Materials that in themselves are capable of detonation of explosive decomposition or explosive reaction but that require a strong initiating source or that must be heated under confinement before initiation. This degree usually includes: Materials that are sensitive to thermal or mechanical shock at elevated temperatures and pressures; Materials that react explosively with water without requiring heat or confinement Materials that in themselves are readily capable of detonation of explosive decomposition or explosive reaction at normal temperatures and pressures. This degree usually includes materials that are sensitive to localized thermal or mechanical shock at normal temperatures and pressures. Note that reactivity includes self-reactivity (instability) and reactivity with water. A guideline for the reactivity value (Nr) is looking at the peak temperature of the lowest Differential Thermal Analysis (DTA) or Differential Scanning Calorimeter (DSC) exotherm value as follows: Exotherm, C >300 to 500 >150 to 300 150 Exotherm, F >572 to 932 >302 to 572 302 Nr 0 1 2, 3, & 4 A couple of additional qualifiers are: 1. If the substance or compound is an oxidizer, increase Nr by one (but not over Nr = 4). 2. Any shock-sensitive material should be Nr = 3 or 4. 3. If the Nr obtained seems inconsistent with known properties of the substance, mixture or com pound, additional reactive chemicals testing should be done. 4. Assistance in interpreting the significance of DSC or DTA data can be obtained from the site Reactive Chemicals contact person. Once the Np or St has been obtained and determined, the Nr, the resulting Np (or St) and Nr are used with Table 1 to determine the MF. Make the necessary adjustments as discussed below under "Temperature Adjustment of Material Factor." B. Mixtures Mixtures of various kinds can be troublesome under certain conditions. Normally, materials that react violently - for example, fuel and air or hydrogen and chlorine - are mixed under controlled conditions. The reactions generally take place continuously and rapidly, producing nonflammable, stable products that are safely contained within a process unit such as a reactor. The combustion of fuel and air in a ll furnace is a good example of this sort of controlled reaction. However, since ``flame-outs'' and other breakdowns can still occur, the MF should be based on the initial reactive mixture, which fits the description of "most hazardous material present during a realistic operating scenario." For additional information see Appendix B, page 72. Mixtures of solvents or of a solvent with a reactive material can also create troublesome situations. The best MF for mixtures should be obtained from reactive chemical testing data, as recommended in Appendix B. If reactive chemical testing data is not available, an approximation can be obtained by using the MF of the component with the highest MF value. This component should be one of significant concentration such as 5% or more. One particularly troublesome mixture is the "hybrid." This is a mixture of combustible dust and flammable gas, which can form an explosive mixture in air. The Material Factor must adequately reflect the material hazard present in this unique situation, and reactive chemical testing data must be employed to determine the proper MF. It is recommended that a reactive chemicals specialist be consulted. C. Mists One special condition can lead to explosions similar to having a flammable or combustible vapor above its flash point. A suspension of finely divided drops of flammable or combustible liquid in air can give a flammable mixture that has many of the characteristics of a flammable gas/air mixture. Mists of flammable or combustible liquids at temperatures well below their flash points can be as explosive as flammable vapor/air mixtures. For example, for suspensions in which the droplet diame ter is less than 0.01 mm (0.0004 in), the lower flammability limit of the suspension is nearly the same at ambient temperature as that of the substance at its flash point. It is important that mists not be processed inside enclosed process structures because flammable concentrations are more easily attained and overpressures from explosions can result in structural damage. The best defense against mist explosions is to avoid the conditions where a mist will form. If a mist is possible, the material factor can be raised one step (ref. Table 1, page 13) to account for the increased risk, and it is also recommended that a loss prevention specialist be consulted. 12 A 0446?4 Conf^oenttal ____________________ TABLE 1____________________ MATERIAL FACTOR DETERMINATION GUIDE Reactivity or Instability Liquids & Gases Flammability or NFPA 325M ro II o it Nr= 1 Nr = 2 Nr = 4 Combustibility1 Non-combustible2 or 49 Nf = 0 1 14 24 29 40 F.P. > 200 F(> 93.3 C) Nf= 1 4 14 24 29 40 F.P. > 100 F (> 37.8 C) Nf = 2 10 14 24 29 40 < 200 F( 93.3 Q F.P. > 73 F (> 22.8 C) Nf = 3 16 16 24 29 40 < 100 *F (< 37.8 Q or F.P. < 73 F (< 22.8 C) & BP. > 100 F (> 37.8 0O F.P. < 73 F (< 22.8 C) & Np = 4 21 21 24 29 40 B.P. < 100 F (< 37.8 C) Combustible Dust or Mist3 St-1 (KSt 200 bar m/sec) 16 16 24 29 40 St-2 (KSl = 201-300 bar m/sec) 21 21 24 29 40 St-3 (KSl > 300 bar m/sec) 24 24 24 29 40 Combustible Solids Dense > 40 mm thick4 Np = 1 4 14 24 29 40 Open < 40 mm thick5 Np = 2 10 14 24 29 40 Foam, fiber, powder, etc.6 Nf = 3 16 16 24 29 40 F.P. = Flash Point, closed cup B.P. = Boiling Point at Standard Temperatures and Pressure (STP) Notes: 'Includes volatile solids. 2 Will not bum in air when exposed to a temperature of 1500 F (816 C) for a period of five minutes. 3Kst values are for a 16 liter or larger closed test vessel with strong ignition source. See NFPA 68, Guide for Venting ofDeflagrations. 4Includes wood - 2 inches nominal thickness, magnesium ingots, tight stacks of solids and tight rolls of paper or plastic film. Example: SARAN WRAP. sIncludes coarse granular material such as plastic pellets, rack storage, wood pallets and non-dusting ground material such as polystyrene. `Includes rubber goods such as tires and boots, STYROFOAM brand plastic foam and fine material such as METHOCEL cellulose ethers in dust/leak-free packages. 13 DO A 044625 CONFIDENTIAL D. Temperature Adjustment of Material Factor It is important to recognize that the MF represents the hazard of the selected material at ambient tem perature and pressure. If the material has a flash point less than 140 F (60 C) or exhibits reactiv ity at temperatures less than 140 F (60 C), no adjustment is required. This is because the flamma bility and reactivity hazard have already been incorporated in the Material Factor. The effect of pressure is discussed in detail later under "Special Process Hazards." If the Process Unit temperature is above 140 F (60 C), the MF itself will require adjustment. If the material is above its flash point at ambient temperature, the material factor is not adjusted. The temperature adjustment of the material factor is determined using Table 2: TABLE 2 MATERIAL FACTOR TEMP. ADJUSTMENT Nf St Nr a. Enter Nf (St for dusts) and Nr. b. If temperature less than 140 F (60 C), go to "e." c. If temperature above flash point or if temperature greater than 140 F (60 C), enter "1" under NF. Mg . ..'ill, 2P$ d. If temperature above exotherm start (see paragraph below) or autoignition, enter "1" under NR. .. e. Add each column, but enter 4 where total is 5. f. Using "e." and Table 1, determine Material Factor (MF) and enter on F&EI Form (page 5) and Manufacturing Unit Risk Analysis Summary (page 7). Note: 140 F (60 Q can be reached in storage due to layering and solar heat. Flash point and autoignition data are generally available and understood, but "Exotherm Start" requires explanation. Exotherm Start is the temperature at which a heat-generating chemical reaction is first detected in Accelerating Rate Calorimetry (ARC) or similar calorimeter. Exotherm Start can be estimated from data secured by Differential Thermal Analysis (DTA) or Differential Scanning Calorimetry (DSC) either by: a. subtracting 70 C (126 F) from the first exotherm start temperature or b. subtracting 100 C (180 F) from the first exotherm peak temperature. The use of "a." is preferred. Of course, if the "real" exotherm start temperature is known from operating experience (with a reactor in a plant, for example), the "real" temperature should be used. Consultation with a reactive chemicals testing person can be of great help in interpreting test data. If the Process Unit is a reactor, the exotherm from the intended reaction is disregarded for purposes of temperature adjustment due to reactivity. This is because the various reaction penalties take this into account. Example:__________________________________________________________________________________________ DOWTHERM, a heat transfer fluid, has a flash point of 255 F (124 C) and an autoignition temperature of 1150 F (621 C). It has no DSC exotherm below 752 F (400 C) (the usual limit of testing). When in drums in storage, it has an MF of 4 (Np = 1 and Nr = 0). When used as a solvent above 140 F (60 C), the MF is still 4 up to 255 F (124 C). When it is used at temperatures above its flash point of 255 F (124 C), its NF is increased to 2, making MF= 10. _____ 14 00 A 0446P6 CONFIDENTIAL PROCESS UNIT HAZARDS FACTORS After the appropriate Material Factor has been determined, the next step is to calculate the Process Unit Hazards Factor (F3), which is the term that is multiplied by the Material Factor to obtain the F&EI. The numerical value of the Process Unit Hazards Factor is determined by first determining the General Process Hazards Factor and Special Process Hazards Factor listed on the F&EI form. Each item which contributes to the Process Hazards Factors contributes to the development or escalation of an incident that could cause a fire or an explosion. When calculating the penalties comprising the Process Unit Hazards Factor, F3, pick a single specific in stant in time during which the material under consideration is in the most hazardous normal operation state associated with the Process Unit Startup, continuous operation and shutdown are among the opera tional states that may be considered. This rather strict definition is intended to prevent double or triple counting of hazards occurring during the process. Since the MF is taken to be that of the most hazardous substance present in the Process Unit, it can be certain that the Fire and Explosion analysis will really be based upon a "worst case" when focus is placed on the most hazardous operational point involving the MF, and this will be a realistic worst case -- one that could actually occur. In the F&EI system, only one hazard may be evaluated at a time. If the MF is based on a flammable liquid present in the Process Unit, do not take penalties relating to combustible dusts, even though dust may be present at a different time. A reasonable approach might be to evaluate the Process Unit once using the MF of the flammable liquid and a second time using the MF of the dust. Only the calculation resulting in the highest F&EI and Actual Maximum Probable Property Damage need to be reported. One important exception is the hybrid, described previously under "Mixtures." If a hybrid mixture is selected as the most hazardous material present, it is penalized both as a dust and as a flammable vapor in the Process Unit Hazards Factor sections of this manual. Some items on the F&EI form have fixed penalty values. For those that do not, determine the appropriate penalty by consulting the text that follows. Remember - analyze only one hazard at a time, relating the analysis to a specific, most hazardous time (e.g., startup, normal operation or shutdown). Keep the focus on the Process Unit and Material Factor selected for analysis and keep in mind that the results of the final calculation are only as valid as the appropriateness of the penalty assessments. GENERAL PROCESS HAZARDS General Process Hazards are factors that play a primary role in determining the magnitude of a loss incident The six items listed in this section as contributing hazards are applicable to most process situations. Although it may not be necessary to take penalties for each part of this section, these items have historically played large roles in fire and explosion incidents, and careful evaluation of the particular Process Unit in question is of paramount importance. Remember, to evaluate the exposure risk of any Process Unit realistically, each General Process Hazard Penalty must be applied under the most hazardous normal operating conditions that might occur during the association of a specific Material Factor with the Process Unit being analyzed. A. Exothermic Chemical Reactions Take this penalty only if the Process Unit in question is a reactor in which a chemical reaction takes place. The reactivity hazard of the material being evaluated is inherent in the Material Factor. 1. MILD EXOTHERMS require a penalty of 0JO. Examples include: a. Hydrogenation - Addition of hydrogen atoms to both sides of a double or triple bond. b. Hydrolysis - Reaction of a compound with water, as in the manufacture of sulfuric or phosphoric acids from oxides. c. isomerization - Rearrangement of the atoms of an organic molecule such as a change from a straight chain to a branched molecule. d. Sulfonation - Introduction of an SO3H radical into an organic molecule through reaction with H2SO4. e. Neutralization - Reaction between an acid and a base to produce a salt and water or of a base and an alcohol to produce the corresponding alcoholate and water. 2. MODERATE EXOTHERMS require a penalty of 0JO. Examples include: a. Alkylation - Addition of an alkyl group to a compound to form various organic compounds. b. Esterification - Reaction between an organic acid and an alcohol. c. Addition reactions - Reactions occurring between inorganic acids and unsaturated hydrocarbons. When the acid is a strongly reactive material, increase the penalty to 0.75. d. Oxidation - Combination of substances with oxygen by combustion, releasing CO2 and H2O or a controlled reaction of some substances with oxygen that does not result in CO2 and H20. For combustion processes and where vigorous oxidizing agents such as chlorates, nitric acid, hypochlorous acids and salts are used, increase the penalty to 1.00. e. Polymerization - Joining together of molecules to form chains or other linkages. f. Condensation - Joining together of two or more organic molecules with the splitting off of H20, HC1 or other compounds. 3. CRITICAL-TO-CONTROL EXOTHERMS require a penalty of 1.00. These are a class of reactions in which a significant fire and explosion potential would exist if control was lost. Example: a. Halogenation - Introduction of a halogen or halogens into an organic molecule. 4. PARTICULARLY SENSITIVE EXOTHERMS, which are quite hazardous exothermic reactions, require a penalty of 1.25. Example: a. Nitration - The replacement of a hydrogen atom in a compound with a nitro group. 16 DO A 044628 CONFIDENTIAL B. Endothermic Processes A penalty of 0.20 is taken for any endothermic process taking place in a reactor. Note: This penalty applies only to reactors. When the energy input for the endothermic process is provided by the combustion of a solid, liquid or gaseous fuel, the penalty is increased to 0.40. Examples include: 1. Calcination - Heating a material to remove chemically bonded water or other volatile material. This generally requires a penalty of 0.40. 2. Electrolysis - Separation of ions by means of an electric current. This generally requires a penalty of 0.20. 3. Pyrolysis or Cracking - Thermal decomposition of molecules to smaller ones by use of high temperatures, high pressures and/or a catalyst. The penalty is 0.20 for electric or remote hot gas heat or 0.40 for direct fired heat. C. Material Handling and Transfer This item is evaluated with regard to the potential for fire involving the pertinent Process Unit during the handling, transfer and warehousing of materials. 1. Any loading or unloading operation involving Class I flammables or LPG-type materials where transfer lines are connected and disconnected receives a penalty of 0.50. 2. Where the introduction of air during manual addition of some ingredients into centrifuges, batch reactors or batch mixers may create a flammability or reactivity hazard, a penalty of 0.50 is applied. Note: These penalties apply whether or not the equipment vapor space is inerted. 3. Ranges of penalties based on material fire hazards are applied to warehouse storage or yard storage of various items. a. A penalty of 0.85 is applied for Nf = 3 or 4 flammable liquids or gases. This category includes drums, cylinders, portable flexible containers and aerosol cans. b. A penalty of 0.65 is applied for Nf = 3 combustible solids as identified in Table 1, page 13. c. A penalty of 0.40 is applied for Np = 2 combustible solids as identified in Table 1. d. A penalty of 0.25 is taken for combustible liquids (closed cup flash point above 100 F (37.8 C) and below 140 F (60 C)). If any of the above are stored on racks without in-rack sprinklers, add 0.20 to the penalty. This area of consideration is not for normal storage tanks. D. Enclosed or Indoor Process Units The maintenance of open and freely ventilated construction for areas in which flammable liquids and gases are processed will permit rapid dissipation of any vapors released, thereby reducing the explosion potential of the unit. Dust collectors and filters should also be located in an open area away from other equipment An enclosed area is identified as any roofed area with three or more sides or an area enclosed by a roofless structure with walls on all sides. Even properly designed mechanical ventilation is not as effective as open construction; but if a mechanically ventilated system is designed in such a way that all flammables are collected and dispersed, the penalty can be reduced. 17 DO A 044629 CONFIDENTIAL The penalty categories are as follows: 1. When dust filters or collectors are located inside an enclosed area, a penalty of 0.50 is applied. 2. Any process in which flammable liquids are handled at temperatures above their flash point in an enclosed area receives a penalty of 0.30. For quantities of liquid in excess of 10M lb. (= 1,000 gallons), a penalty of 0.45 is used. 3. Any process in which liquefied petroleum gas (LPG) or any flammable liquids are handled at temperatures above their boiling point within an enclosed area requires a penalty of 0.60. For quantities of liquid in excess of 10,000 lb (4,535 kg) (= 1,000 gal)[3.785 m3], a penalty of 0.90 is used. 4. Where properly designed mechanical ventilation has been installed, the penalties listed in 1. and 3. above may be reduced by 50%. E. Access Emergency equipment must have ready access to the area housing the pertinent Process Unit Access from at least two sides is considered the "Minimum Requirement." Strong consideration should be given to this penalty for major Process Units located in enclosed areas. At least one of the access approaches must be from a roadway. A monitor nozzle that would remain easily accessible and operational during a fire could be considered a second access. All process areas over 10,000 fit? (925 m2) not having adequate access receive a penalty of 0.35. All warehouses over 25,000 ft2 (2,312 m2) not having adequate access receive a penalty of 0.35. For areas smaller than those listed above, judgment must be used in assessing the access requirement Such areas may be penalized 0.20 if sound engineering judgment indicates the potential for fire control problems due to inadequate access. F. Drainage and Spill Control This section lists penalties for design conditions that could cause large spills of flammable or com bustible liquids to be retained around or near process equipment. Inadequate design of drainage has been a contributing factor in a large number of losses involving liquid spills. These penalties are to be applied only if the material in the Process Unit has a flash point below 140F (60 C) or if the material is being processed above its flash point. To evaluate the adequacy of drainage and spill control, it is necessary to estimate the combined volume of flammable/combustible material as well as fire fighting water that would have to be safely drained away or handled in an actual incident 1. The F&EI calculation of drainage capacity will be based on the following guidelines: a. For process and storage facilities, use 100% of the unit's largest tank capacity plus 10% of the next largest tank. b. Assume 30 minute flow rate of fire fighting water, (i.e., 30 min x gpm = gal fire water) [Assume 60 min flow rate for agricultural chemicals or environmentally harmful chemicals see LPP 4.5.6. Discuss with the site environmental contact person.] Enter the sum of a. and b. above into the appropriate space under General Process Hazards -- Item l.FonpageS. Do a n. 18 CON^0^o 2. Penalty Selection: a. Diking, which is designed to prevent a spill from going to other areas but exposes all the equipment within the dike, receives a penalty of 0.50. b. Generally, a flat area around the process unit will allow spills to spread out, exposing large areas to fire if ignited. A penalty of 0.50 is required for this situation. c. A diking design that surrounds three sides of an area and directs spills to an impounding basin or non-exposing drainage trench receives no penalty if the following criteria are met: i. Slope to basin or trench is a minimum of 2% for earthen surfaces or 1% for hard surfaces. ii. Distance to equipment from nearest edge of trench or basin is at least 50 ft (15 m). This distance can be reduced if a fire wall is installed. iii. The impounding basin must have the capacity at least equal to the sum of l.a. and l.b. above. d. If a basin or trench exposes utility lines or does not meet the distance requirements, a penalty of 0.50 is applied. In short, excellent drainage is required if penalties are to be avoided. Once all of the general process hazards have been evaluated, a calculation is to be made of the sum of the base factor and all penalty factors applied in this section on General Process Hazards. The total is to be entered in the box labeled "General Process Hazards Factor (FO" on the F&EI Form, page 5. 19 D0 A 0A4631 __..--rnFNTl AL SPECIAL PROCESS HAZARDS Special process hazards are factors that contribute primarily to the probability of a loss incident. They con sist of specific process conditions that have shown themselves to be major causes of fire and explosion incidents. There are twelve items listed in this section as follows; A. Toxic Material(s) Toxic materials can complicate the response of emergency personnel, thereby reducing their ability to investigate or mitigate damage during an incident. Use 0.20 x Nh as the penalty. For mixtures, use the component with the highest Nh- Nh is the health factor of a material as defined in NFPA 704 or given in NFPA 325M or NFPA 49. The Nh for many materials may be found in Appendix A. An Industrial Hygiene Specialist can be of assistance in determining a Nh for new materials. Listed below is a summary of Nh value definitions from NFPA 704; Nh = 0 Materials that on short exposure under fire conditions would offer no hazard beyond that of ordinary combustible materials. Nh = 1 Materials that on short exposure could cause irritation but only minor residual injury, including those requiring the use of an approved air-purifying respirator. Nh = 2 Materials that on intense or short exposure could cause temporary incapacitation or pos sible residual injury, including those requiring the use of respiratory protective equipment that has an independent air supply. Nh = 3 Materials that on short exposure could cause serious temporary or residual injury, including those requiring protection form all bodily contact. Nh = 4 Materials that on very short exposure could cause death or major residual injury, Note: These factors are intended to represent emergency response limitations which can cause addi tional loss. They are not intended to be applied as industrial hygiene or environmental considerations. B. Sub-Atmospheric Pressure This section applies to a process condition where air leakage in a system could create a hazard. A hazard may result from air contact with moisture-sensitive or oxygen-sensitive materials or from the formation of flammable mixtures upon the introduction of air. This penalty is applied only if the absolute pressure is less than 500 mm Hg (equivalent to 10 in Hg vacuum). The penalty is 0.50. If the penalty is applied, do not duplicate or repeat the penalty specified in Section C below, "Operation In or Near Flammable Range," or in Section E, "Relief Pressure." Most stripping operations, some compressor operations and a few distillation operations are the major Process Units penalized in this category. 20 DO A 04463,? CONFIDENTIAL C. Operation In or Near Flammable Range There are certain operating conditions which can cause air to enter and be entrained into the system. The introduction or entry of air could lead to the formation of a flammable mixture and create a haz ard. This section is intended to cover the following conditions for flammable and combustible liquids: 1. Tank storage of Np = 3 or 4 flammable liquids, where air can be breathed into the tank during pump-out or sudden cooling of the tank. The penalty is 0.50. Open vent or non-inert gas padded operating pressure-vacuum relief system would require a penalty of 0.50. Storage of combustible liquids at temperatures above their closed cup flash points without inerting would also require a penalty of 0.50. If an inerted, closed vapor recovery system is used and its air-tightness can be assured, no penalty is applied. See next paragraph. 2. Process equipment or process storage tanks that could be in or near the flammable range only in the event of instrument or equipment failure would require a penalty of 0JO. Any process unit that relies on inert purge to keep it out of the flammable range requires a penalty of 0.30. This penalty also applies to padded barges or tank cars. No penalty is applied here if the penalty specified in B., "Sub-Atmospheric Pressure" has already been taken. 3. Processes or operations that are by nature always in or near the flammable range, either because purging is not practical or because it was elected not to purge, receive a penalty of 0JO. D. Dust Explosion The maximum rate of pressure rise and maximum pressure generated by a dust are largely influenced by the particle size. In general, the finer the dust, the greater the hazard because of the rapid rate of pressure rise and maximum pressures attained. The penalties listed in this section are intended to apply to any Process Unit involving dust handling operations: transferring, blending, grinding, bagging, etc. All dusts have a particle size range. For determination of the penalty, use the 10% size; that is, the particle size at which 90% of the dust is coarser and 10% is finer. See Table 3 for appropriate penalties. Unless dust explosion testing has shown that no dust explosion hazard exists, dust penalties should be applied. TABLE 3 DUST EXPLOSION PENALTY Particle Size Microns Tyler Mesh Size Penalty (Use 1/2 if in an inert gas) 175+ 150 to 175 100 to 150 75 to 100 <75 60 to 80 80 to 100 100 to 150 150 to 200 >200 0.25 0.50 0.75 1.25 2.00 21 DO A 044633 CONFIDENTIAL E. Relief Pressure Where operating pressures are above atmospheric, a penalty is applied for the higher release rates caused by higher pressure in the event of a leak. The concern is the possibility of failure of some component in the Process Unit causing the release of flammable materials. Example:_____________________________________________________ ________________________________ The release of hexane liquid through a one-square-inch (6.5 cm2) orifice at 75 psig (517 kPa gauge) would be almost 600 lb/min (272 kg/min). At 300 psig (2,069 kPa gauge), the release would be 2-1/2 times as great or 1,500 lb/min (680 kg/min). The relief pressure penalty evaluates the specific spill hazard potential at different pressure levels. Relief pressure also affects dispersion characteristics. Since the spill potential greatly increases at higher pressures, equipment design and maintenance become more critical as the operating pressure increases. Systems operating at pressures above 3,000 psig (20,685 kPa gauge) are outside the range of standard codes (ASME Code for Unfired Pressure Vessels, Section VIII, Division 1). For such systems, lens ring joints, cone seals or equivalent closures must be used in flange design. To determine the appropriate penalty, consult Figure 2, page 23, and use the operating pressure to determine an initial penalty value. The equation below applies from 0 to 1,000 psig (0 to 6,895 kPa gauge). Y 0.16109+ 1.61503X 1.42879 X I +0.5172 1000 1000 or Y = 0.16109 + 1.61503*(X/1000) - 1.42879*(X/1000)A2 + 0.5172*(X/1000)A3 For pressures from 0 to 1,000 psig (0 to 6,895 kPa gauge) determine the penalty from Table 4 below (also included in Figure 2, page 23): TABLE 4 HIGH PRESSURE PENALTY FOR FLAMMABLE & COMBUSTIBLE LIQUIDS Pressure psig Pressure kPa gauge Penalty 1,000 6,895 0.86 1,500 10,343 0.92 2,000 2,500 3,000 to 10,000 13,790 17,238 20,685 to 68,950 0.96 0.98 1.00 > 10,000 > 68,950 1.50 The curve in Figure 2 can be used directly to determine penalties for flammable and combustible liquids with a flash point below 140 F (60 C). For other materials, the penalty provided by the curve must be adjusted as follows: OO A 044634 CONFIDENTIAL FIGURE 2 - PRESSURE PENALTY FOR FLAMMABLE & COMBUSTIBLE LIQUIDS 0.9 -- -------- 1------------------ Y = 0.1610 9 + 1.61503*>C/1000 - 1.42879*(X/1000)A 2 + 0.5172 *(J</1000)A3 0.8 0.7 0.6 ttuo> 0.5 < Z 0.4 0.3 / 0.2 7*-- FOR PRESSURES ABOVE 1,000 psig PRESSURE PENALTY psig kPa FACTOR 1,500 2,000 10,343 13,790 0.92 0.96 2,500 17,238 0.98 3,000 to 10,000 20,685 to 68,950 1.00 >10,000 >68,950 1.50 -- 0.1 0 0 100 200 300 400 500 600 700 800 900 1000 PRESSURE, PSIG For kPa multiply by 6.895. DO A 0 4 4 6 3 5 C O N F ID E N T IA L . 1. For highly viscous materials such as tars, bitumen, heavy lubricating oils and asphalts, multiply the penalty by 0.70, 2. For compressed gases used alone or flammable liquids pressurized with any gas above 15 psig (103 kPa gauge), multiply the penalty by 1.2. 3. For liquefied flammable gases (including all other flammable materials stored above their boiling point), multiply the penalty by 1.3. There is no penalty for extrusion and molding operations. To determine the final penalty, first find the penalty associated with the operating pressure from Figure 2. Then find the penalty associated with the set pressure of the relief device. Divide the operating pressure penalty by the set pressure penalty to get a final pressure penalty adjustment factor. Multiply the operating pressure penalty by this adjustment factor to get the final pressure penalty. Thus, credit is given for having a relatively high set pressure and vessel design pressure. Note that it is often advantageous to set the relief pressure close to the vessel design pressure. For example, reactions in a volatile solvent, especially if a gassy, unwanted higher temperature reaction can be avoided by setting the relief pressure so that the solvent can boil and remove heat before the higher temperature is reached. Computer simulation is generally used, based on reactive chemicals or other kinetic data, to decide whether a low relief pressure is desirable. However, this is not always desirable in some reactive systems. For some special situations, it is advantageous to increase the design pressure of a pressure vessel to minimize the likelihood of release and in some special cases perhaps containment of the maximum ex pected pressure can be obtained. See the following example of a vessel holding a viscous material. Example:______________________________________________________________________________________ Vessel design pressure is 150 psig (1,034 kPa gauge) Normal operation is at 100 psig (690 kPa gauge) Rupture disk is set at 125 psig (862 kPa gauge) From Figure 2, the 100 psig (690 kPa gauge) operating pressure has a penalty of 0.31 and 125 psig (862 kPa gauge) set pressure has a penalty of 0.34. Viscous materials receive an adjustment of 0.7, so the penalty becomes: 0.31 X 0.7 = 0.22 adjusted penalty The final penalty is determined by multiplying this penalty by the pressure adjustment factor: 0.22 X (0,31/0.34) = 0.20 = final penalty _______________________________________ _ See the second example of an emulsion polymerization reactor showing the difference between a low and a high design pressure. DO A 044636 24 CONFIDENTIAL Examples: A. __________________________________________________________ Reactor design pressure is 150 psig (1,034 kPa gauge) Normal operating is at 120 psig (827 kPa gauge) Relief device set pressure at 150 psig (1,034 kPa gauge) _____________ _ From Figure 2, the operating pressure penalty is 0.34. The set pressure penalty of 0.37. The pressure adjustment factor is 0.34/0.37. The final penalty is: ___________________ 0.34 X (0.34/0.37) = 0.312 = final penalty____________________________ B. Reactor design pressure is 300 psig (2,068 kPa gauge) Normal operating is at 120 psig (827 kPa gauge) Relief device set pressure at 300 psig (2,068 kPa gauge) From Figure 2, the operating pressure penalty is 0.34. The set pressure penalty of 0.53. The pressure adjustment factor is 0.34/0.53. The final penalty is: ____________________________0.34 X (0.34/0.53) = 0.218 = final penalty____________________________ F. Low Temperature This section makes allowances for the possible brittleness of carbon steel or other metals that may be exposed to temperatures at or below their ductile/brittle transition temperatures. If a careful evalu ation has been made and no possibility of temperatures below the transition temperature exists due to normal and abnormal operating conditions, no penalty is applied. It would be very rare to have a vessel designed with this potential. New vessel design would avoid the low temperature hazard. The usual method of determining the transition temperature is to test samples of the metal used in the fabrication of the Process Unit, using a standard Charpy Impact test to determine that the design and, therefore, operating temperature is above the transition temperature. Proper design should avoid these low temperature process conditions. The following penalties are applied: 1. For processes utilizing carbon steel construction and operated at or below the ductile/brittle transition temperature, a penalty of 0.30 is applied. If no data are available, a 50 F (10 Q transition temperature should be assumed. 2. For materials other than carbon steel where the operating temperature is at or below the transi tion temperature, use a penalty of 0.20. Remember that no penalty is applied if the material is appropriate for the lowest possible operating temperature. G. Quantity of Flammable/Unstable Material This section considers the additional exposure to an area as quantities of flammable and unstable material in the process unit are increased. There are three categories in this section, each evaluated by a separate penalty curve. Apply only one penalty for the entire section, based on the material that was selected as the Material Factor. 25 DO A 044637 CONFIDENTIAL 1. Liquids or Gases in Process (Figure 3, page 27). This section applies a penalty to a quantity of material that might be spilled and create a fire hazard, or that might, on exposure to fire, create a reactive chemical event. The penalty applies to any process operation, including pumping into holding tanks, and is valid for the following materials when they are selected as the MF: a. Flammable liquids and those combustible liquids with a flash point below 140 F (60 6C). b. Flammable gases. c. Liquefied flammable gases. d. Combustible liquids with closed cup flash points above 140 F (60 C) when the process temperature is above the flash point of the material. e. Reactive materials regardless of their flammability (Nr = 2,3 or 4). In using this penalty section, the first task is to determine the pounds of materials in process. The penalty is based upon the amount of fuel for a fire that can be released from the Process Unit or a connected line within 10 minutes. Common sense must be used in judging how much material might be released. Experience has shown that this amount can be reasonably estimated by taking the larger of the following: i. The quantity of material in the Process Unit or ii. The quantity of material in the largest connected unit Any connected unit that can be isolated by closure valves operable from a remote location in times of emergency is removed from consideration. Before accepting this approximation of the quantity of material in process, the question to be asked is "What is the maximum probable quantity that could be spilled?" If, using good engi neering judgment and familiarity with the process, it is determined that a number which is sig nificantly different from the above, use the latter number, being sure to document its validity. Remember, good judgment and process familiarity will always lead to a more realistic ap proximation. Note, however, that if instability (reactivity) is involved, the quantity of concern is the quantity of material normally inside the Process Unit Example:____________________________________________________________________ __________ Charge drums, surge drums and reflux vessels are types of connected equipment that might possibly contain more material than the Process Unit being evaluated. However, if such vessels are equipped with remote-controlled shut off valves, they should not be considered as "vessels connected to a Process Unit." Enter the appropriate quantity of flammable/unstable material on the space provided, Item "G" of Special Process Hazards, page 5. To establish the value to be applied in using Figure 3, multiply the appropriate quantity of flammable/unstable material by a factor He (in BTU/lb) and obtain total BTU x 109. The factor Hc is the heat of combustion of the material. This can be taken from Appendix A or obtained from reactive chemical test data. D A 044638 26 confidential FIGURE 3 - LIQUIDS OR GASES IN PROCESS K) DO A 0 4 4 6 3 9 C O N F T D F N T IA L The He for unstable materials (Nr of 2 or more) is taken as (1) six times the heat of decomposition or (2) the heat of combustion, whichever is larger. Heats of decomposition can also be obtained from reactive chemical test data. Enter the factor He (BTU/lb) cat the appropriate space. Item "G" of Special Process Hazards, page 5. The penalty is determined by entering Figure 3 with the Process Unit energy content (BTU x 109). The point of intersection with the curve indicates the penalty. The equation for this plot to Total BTU x 10 in Process (X) versus Penalty (Y) is: logY = 0.17179 + 0.42988(logX) - 0.37244(logX)2 + 0.17712(log X)3 - 0.029984(logX)4 or logY = 0.17179 + 0.42988*logX - 0.37244*logXA2 + 0.17712*log XA3 - 0.029984*logXM Liquids of Gases in Storage (Outside the Process Area) (Figure 4, page 29) Flammable and combustible liquids, gases or liquefied gases in storage outside the process area receive a lower penalty than those in the "in process" or 2. G.l category (page 5), since there is no process involvement. Process involvement contributes to the probability of an incident. MF materials in the 2.G.2 (page 5) category include raw material feedstock in drums or tanks, material in tank farms and material in portable containers and containers. This penalty is determined by entering Figure 4 with the total BTU (quantity of material in storage times a factor He) in any single storage vessel. In the case of portable containers, use the total quantity of material in all stored containers. When two or more vessels are located in a common dike which would not drain into an ade quately sized impounding basin, use the total BTU content of all the tanks within the dike to obtain the penalty from the curve in Figure 4. Unstable materials should be evaluated in the same fashion as in 2.G.1 (page 5) taking as the He factor either (1) six times the heat of decomposition or (2) the heat of combustion (whichever is larger) and using Curve A of Figure 4 to determine the appropriate penalty. Example: Three vessels containing process chemicals (750,000 lb [340,100 kg] of styrene monomer, 750,000 lb [340,100 kg] of diethyl benzene and 600,000 lb [272,100 kg] of acrylonitrile) are located in a common dike that does not drain to an impounding basin. Ambient storage temperature of 100 F (38 Q is assumed, and all He factors are taken as heats of combustion. 750,000 lb styrene X 17.4 X 1(P BTU/lb 750M lb diethyl benzene X 18.0 X 103 BTUAb 600M lb acrylonitrile X 13.7 X 103 BTUAb TOTAL BTU = = 13.0X109 BTU = 13.5 X 109 BTU = 8.2X109 BTU 34.7 X 109 BTU Do A 044640 CONFIDENTIAL 28 PENALTY FIGURE 4 - LIQUIDS OR GASES IN STORAGE TOTAL 10A9 BTU IN STORAGE For kcal multiply by 0.2520. For Joules (J) multiply by 1.05506 x 10*3. Curves Indicated by the Materials Styrene Acrylonitrile Diethyl Benzene Class I Flammable Liquid (Curve B, Figure 4) Gass I Flammable Liquid (Curve B, Figure 4) Gass II Combustible Liquid (Curve C, Figure 4) If more than one substance is being dealt with, use the TOTAL BTU and find the penalty shown at the point of intersection with the highest curve indicated for any individual material using Figure 4. In this example, the highest curve referenced by a single material is Curve B and the appropriate penalty is 1.00. Note: NFPA 30 calls for subdivision by diking of these types of materials. The equations for Curves A, B and C in Figure 4 for BTU X 109 in Process (X) versus Penalty (Y) are: Curve A: logY = - 0.289069 + 0.472171(log X) - 0.074585(log X)2 - 0.018641(logX)3 or logY = -0.289069 + 0.472171 log X -0.074585*log XA2 - 0.018641 *logX*3 Curve B: logY * - 0.403115 + 0.378703(log X) - 0.046402(log X)2 - 0.015379(log X)3 or logY = - 0.403115 + 0.378703*log X - 0.046402*log XA2 - 0.015379*log X*3 Curve C: log Y = - 0.558394 + 0.363321(log X) - 0.057296(log X)2 - 0.010759(log X)3 or log Y = - 0.558394 + 0.363321 *log X - 0.057296*log X*2 - 0.010759*log X*3 Combustible Solids in Storage/Dust in Process (Figure 5, page 31) This category covers the penalty requirements for various quantities of stored solids and for dusts encountered in a Process Unit when the solid or dust involved is the basis material for the MF. The measurements used in this penalty assessment are the density of the material and ease of ignition and its ability to sustain fiame. The total weight in pounds of stored solid or of dust contained within the process unit is used with Figure 5 to determine the penalty. If the material's bulk density is less than 10 lb/ft3 (160.2 kg/m3), use Curve A; if it is greater than 10 lb/ft3 (160.2 kg/m3), use Curve B. For unstable materials (Nr = 2 or higher), take six times the actual weight of material in the Process Unit and use Curve A to determine the appropriate penalty (see the following example). 30 FIGURE 5 - COMBUSTIBLE SOLIDS IN STORAGE/DUST IN PROCESS PENALTY For kg x 10*6 multiply by 0.45359. TOTAL POUNDS X 10A6 Example: Ignoring aisle space, an area of 20,000 ft2 (1,860 m2) with a 15 ft (4.6 m) storage height would con tain 300,000 ft3 (8,500 m3) of stored material. If the material being stored in the area (open-cell foam and cardboard boxes with polystyrene tubs) have an average density of 2.2 lb/ft3 (35.2 kg/m3): 2.2 lb./ft3 x 300,000 ft3 = 660,000 lb Using Figure 5, Curve A for density < 10 lb/ft3, we determine that the penalty should be 1.54. Now compare this with storage of polyethylene pellets or cellulose powder in bags (average density of 28 lb/ft3 (449 kg/m2)): 28 lb/ft3 x 300,000 ft3 = 8,400,000 lb Using Curve B for density > 10 lb/ft3, we determine that the penalty should be 0.92. While it is true that the fire load (in terms of both BTUs and pounds per cubic foot) is much lower for foam or boxes than for bagged polyethylene pellets or methylcellulose powder, foam and cardboard boxes are much easier to ignite and would sustain flame more readily than the denser materials. In short, because these light materials pose a greater fire hazard than the heavier ones, they are assessed a higher penalty, even though fewer pounds are stored. The equations for Figure 5, page 31, for the plots of Curves A and B of Combustible Solids versus Penalty for Curves A and B are: Curve A: log Y = 0.280423 + 0.464559(log X) - 0.28291(log X)2 + 0.0662l8(log X)3 or log Y = 0.280423 + 0.464559*Iog X-0.2829 l*log XA2 + 0.066218*log XA3 Curve B: log Y = - 0.358311 + 0.459926(Iog X) - 0.141022(log X)2 + 0.02276(log X)3 or log Y = -0.358311 + 0.459926*log X -0.141022*log XA2 + 0.02276*log XA3 H. Corrosion and Erosion Although good design makes allowances for corrosion and erosion, scane corrosion/erosion problems may still occur in certain processes. The corrosion rate is considered to be the sum of the external and internal corrosion rates. Be sure not to overlook the possible effects of minor impurities in the process stream that might cause greater than normal internal corrosion and the possibility of external corrosion due to the chemical breakdown of paint Porosity of bricks and imperfections in plastic linings are likely sites for accelerated corrosion. >o coNp 32 Hie following penalties apply: 1. For corrosion rates less than 0.5 mri/vr (0.005 in/yr) [0.127 mm/yr] with risk of pitting or local erosion, the penalty is 0.10. 2. For a corrosion rate over 0.5 mil/yr (0.127 mm/yr) and less than 1.00 mil/yr (0.254 mm/yr), the penalty is 0.20. 3. For corrosion rates higher than 1 mil/yr (0.254 mm/yr), the penalty is 0.50. 4. If there is a risk that stress-corrosion cracking might develop, apply a penalty of 0.75. This is common in process areas exposed to contamination by chlorine vapor over prolonged periods. 5. Where a lining is required to prevent corrosion, a penalty of 0.20 is applied. However, if the lining is simply to protect a product from developing color, no penalty is taken. I. Leakage - Joints and Packing Gaskets, seals of joints or shafts and packing can be sources of leaks of flammable or combustible materials, particularly where thermal and pressure cycling occurs. A penalty factor should be selected according to the design of the Process Unit under study and the material being used in the process. The following penalties should be applied: 1. Where the pump and gland seals are likely to give some leakage of a minor nature, the penalty is 0.10. 2. For processes known to give regular leakage problems at pumps, compressors and flange joints, the penalty is 0JO. 3. For processes in which thermal and pressure cycling occurs, the penalty is 0JO. 4 If the material in the Process Unit is penetrating in nature or is an abrasive slurry which can cause intermittent problems with sealing and if the Process Unit uses a rotating shaft seal or packing, .the penalty is 0.40. 5. For any Process Unit that has sight glasses, bellows assemblies or expansion joints, the penalty is 1J0. J. Use of Fired Equipment The presence of fired equipment in a process adds an additional probability of ignition when flamma ble liquids, vapors or combustible dusts are released. The penalty is applied in one of two ways: first, to the fired equipment itself when it is the Process Unit for the F&EI calculation, and, second, to the various Process Units in the vicinity of the fired equipment. The distance in feet from a probable leak point in the Process Unit being evaluated to the air intake of the fired equipment is the distance referenced in Figure 6, page 34. 1. Curve A-l (Figure 6) is used: a) For any Process Unit in which the material of the Material Factor could be released above its flashpoint. b) For any Process Unit in which the material of the Material Factor is a combustible dust 2. Curve A-2 (Figure 6) is used: a) For any Process Unit in which the material of the Material Factor could be released above its boiling point The penalty is determined by entering Figure 6 with the distance from a potential leak source to the air intake of the fired equipment and reading the penalty from the intersection with the appropriate curve (A-l or A-2) of Figure 6. 33 DO A 044645 CONFIDENTIAL FIGURE 6 - FIRED EQUIPMENT PENALTY DISTANCE IN FEET FROM POSSIBLE LEAK SOURCE For distance in meters multiply by 0.3048. DO A 0 4 4 6 4 6 CO NFIDENTIAL The equations for Curves A-l and A-2 for Distance from Possible Leak Source (X) and Penalty (Y) are: Curve A-I: or log Y = - 3.3243*(X/210) + 3.75127*(X/210)A2 - 1.42523*(X/210)A3 Curve A-2: or log Y a - 0.3745(X/210) - 2.70212*(X/210)A2 + 2.09171*(X/210)A3 If the fired equipment (process side) itself is the Process Unit being evaluated, the distance from the possible leak source becomes zero. If the equipment is heating a flammable or combustible material, the penalty is 1.00, even ifthe material is not being heated above itsflash point. The "J" penalty is not applied to the fire side. However, any other situation covered by this section involving a material processed below its flash point receives no penalty. If a piece of fired equipment is located within the process area and there is a possibility that the material in the Process Unit selected as MF could be released above its flash point, a minimum penalty of 0.10 is required, regardless ofthe distance involved. Fired equipment with "pressure burner" design will require only 50% of the penalty specified for standard burner design, provided the air intake is 10 ft (3 m) or more above grade and is not exposed to potential sources of spills from overhead. However, the 50% penalty cannot be applied when the fired heater itself is the Process Unit being evaluated. K. Hot Oil Heat Exchange System Since most hot oil (heat exchange) fluids will bum and are frequently used above their flash points or boiling paints, they represent an additional hazard in any Process Unit that uses them. The penalties in this section are based on the quantity and temperature of the heat exchange fluid used in the unit being evaluated. No penalty is applied if the hot oil is non-combustible or, if a combustible fluid, is always used below its flash point However, the possible formation of mists should be considered. (See page 12.) The quantity to be used with Table 5 to determine the penalty is taken to be the lesser of 1. a 15-minute spill caused by a break in the line servicing the Process Unit or 2. the hot oil inventory within the active circulating hot oil system. The portion of the hot oil heat exchange system that can be classified as "storage" is not used in determining the active capacity unless it is connected much of the time to the Process Unit. 35 It is recommended that the F&EI for the hot oil circulating system itself be determined, including the active (not storage) tank, pumps and distribution/retum piping. These determinations have histori cally led to large F&EI values. If the hot oil exchange system itself is the Process Unit being evalu ated, no penalty is taken for this section. However, if a fired hot oil heat exchange system is actually located in the area of the Process Unit being evaluated, the penalty for Section J will apply. TABLE 5 HOT OIL HEAT EXCHANGE SYSTEM PENALTY Quantity Above Flash At or Above Boiling Gallons (m^) Point Penalty Point Penalty < 5,000 (< 18.9) 0.15 0.25 5,000 to 10,000 (18.9 to 37.9) 0.30 0.45 10,000 to 25,000 (37.9 to 94.6) 0.50 0.75 > 25,000 (94.6) 0.75 1.15 L. Rotating Equipment This section recognizes the hazard exposure of Process Units incorporating large pieces of rotating equipment. Although formulas have not been developed for evaluating all types and sizes of rotating equipment, there is statistical evidence indicating that pumps and compressors beyond a certain size are likely to contribute to a loss incident A penalty of 0JO is applied to Process Units that utilize or are: 1. A compressor in excess of 600 hp. 2. A pump in excess of 75 hp. 3. Agitators (mixers) and circulating pumps in which failure could create a process exotherm due to lack of cooling from interrupted mixing or circulation of coolant or due to interrupted and resumed mixing. 4. Other large high speed rotating equipment with a significant loss history; for example, centrifuges. Once all of the special process hazards have been evaluated, a calculation is to be made of the sum of the base factor and all penalty factors applied in this sectioa The total is to be altered in the box labeled "Special Process Hazards Factor (F2)" on the F&EI Form, page 5. DO A 044648 CONFIDENTIAL. 36 DETERMINATION OF PROCESS UNIT HAZARDS FACTOR The Process Unit Hazards Factor (F3) is the product of the General Process Hazards Factor (Fi) and the Special Process Hazards Factor (F2). The product is used rather than the sum because the "contributing hazards" included in Fi (General Process Hazards) and F2 (Special Process Hazards) are known to have a compounding effect on each other. For example, a penalty for poor drainage in Fj is compounded by the magnitude of the quantity in F2. The Process Unit Hazards Factor (F3), which has a normal range of 1 to 8, is used to determine the Fire & Explosion Index, page 5, and to compute the Damage Factor (Figure 8, page 52). When penalties are properly applied to various Process Hazards, F3 is normally not in excess of 8.0. If a higher value is obtained, use a maximum of 8.0. The Process Unit Hazards Factor is to be entered at die bottom of the Fire & Explosion Index Form as shown on page 5. DO 37 conf DETERMINATION OF FIRE AND EXPLOSION INDEX The Fare and Explosion Index calculation is used for estimating the damage that would probably result from an incident in a process plant The various contributing factors, such as type of reaction, process temperatures, pressures, quantities of fuel, etc., indicate the probability and potential magnitude of a fuel or energy release resulting from process control failures, equipment failures or from vibration or other sources of stress fatigue. Effects of a fire and/or fuel-air explosion following the release of a flammable material and its ignition are categorized according to the immediate causes: a. The blast wave or deflagration, b. Fire exposure from the original release, c. Missile impact on piping and equipment from vessel explosion, d. Other fuel releases as secondary events. The secondary events become more significant as the Process Unit Hazards Factor and Material Factor increase. The Fire and Explosion Index (page 5) is the product of the Process Unit Hazards Factor (F3) and the Material Factor (MF). The F&EI will be related later to a Radius of Exposure (Figure 7, page 48). Table 6 is a listing of the F&EI values versus a description of the degree of hazard that gives sane relative idea of the severity of the F&EI. TABLE 6 DEGREE OF HAZARD FOR F&EI F&EI INDEX RANGE 1-60 DEGREE OF HAZARD Light 61-96 97-127 128 -158 159-up Moderate Intermediate Heavy Severe The F&EI is summarized on the Fire & Explosion Index Form which is presented cm page 5. It is recanmended that any backup calculations or documentation be filed with the original F&EI so it is possible to review and reconstruct how the original determination was made. DO A 044650 38 CONFIDENTIAL LOSS CONTROL CREDIT FACTORS In the construction of any chemical Process Unit (plant) consideration must be given to a number of basic design features (Appendix C, page 74) including compliance with various codes such as building codes or the codes of ASME, NFPA, ASTM, ANSI (see Appendix F) and requirements of local governments. In addition to these basic design requirements, certain loss control features based on experience have proven beneficial both in preventing serious incidents and in reducing the probability and magnitude of a particular incident. There are three categories of loss control features: Ci Process Control C2 Material Isolation C3 Fire Protection The Loss Control Credit Factors Form (page 6) is to be used to summarize the Loss Control Credit Factors using the following procedure: 1. Enter the appropriate credit factor immediately to the right of each credit item chosen. 2. If no credit factor is applicable, enter 1.00 for the Credit Factor Used. 3. Note that each category's Loss Control Credit Factor is the product of all factors used in that category. 4. Perform the calculation (Ci x C2 x C3) to determine the overall Loss Control Credit Factor. 5. Enter the Loss Control Credit Factor on Line 7 of the Process Unit Risk Analysis Summary on page 6. Loss Control features should be selected for the contribution they will actually make to reducing or controlling the unit hazards being evaluated. Selecting credit features to accumulate credits is not the intent of the Risk Analysis approach; the intent is to reduce the dollars at risk or the base MPPD to a more probable, realistic value. The local loss prevention specialist can help determine the appropriateness of various loss control features. The loss control features and their respective credit factors are listed and explained as follows: 1. Process Control Credit Factor (Ci) a. Emergency Power - 0.98 This credit is given for the provision of emergency power for essential services (instrument air, control instrumentation, agitators, pumps, etc.) with automatic changeover from normal to emer gency. The emergency power credit should be taken only if it is relevant to the control of an in cident in the specific Process Unit being evaluated. For example, maintaining agitation in certain chemical process reactors is a critical factor in avoiding a runaway reaction, and emergency power supply to such agitators is clearly a protective feature which justifies the credit In other cases, such as agitation in a rubber slurry tank in the polystyrene process, availability of emergency power is not needed either to prevent or to control a possible fire/explosion incident However, it may be a desirable feature because it permits continued operation when the normal power supply is unreliable. In such cases, no credit should be claimed for the availability of emergency power. A credit factor of 0.98 is to be given if applicable or else a factor of 1.00 is to be used which indicates no credit DO A 044651 39 CONFIDENTIAL b. Cooling - 0.97 to 0.99 If process cooling systems are designed with the capability of maintaining normal cooling for at least 10 minutes during an abnormal condition, use a credit factor of 0.99. If a backup cooling system is designed to provide 150% of the cooling requirement for at least 10 minutes, use 0.97. c. Explosion Control - 0.84 to 0.98 For explosion suppression systems installed on dust or vapor-handling equipment or equipment designed to contain a deflagration, use a credit factor of 0.84. For overpressure relief systems using rupture diaphragms or explosion-relieving vents designed to protect the equipment from possible abnormal conditions, use a credit factor of 0.98. The credit is applied for any relief device that protects the equipment or building from damage due to rapid overpressure, such as from a deflagration. This credit is not intended to be applied for typical overpressure relief systems such as safety relief valves that are required for all pressure vessels or emergency relief vents on storage tanks. d. Emergency Shutdown - 0.96 to 0.99 For a redundancy system that activates when conditions become abnormal, initiating a shutdown sequence, use 0.98. For critical rotating equipment such as compressors, turbines, fans, etc., that are provided with vibration detection equipment, use a credit factor of 0.99 if the equipment only activates an alarm and a credit factor of 0.96 if it initiates a shutdown. e. Computer Control - 0.93 to 0.99 When an on-line computer functions as an aid to operators and is not directly in control of key operations, or where the plant is frequently operated without the computer, use a credit factor of 0.99. When a computer with "fail-safe" logic is in direct control of a process, a credit factor of 0.97 is used. If any one of the following options are used, the credit factor will be 0.93: 1. Redundant critical field inputs 2. Abort feature on critical inputs 3. Backup capability for control system f. Inert Gas - 0.94 to 0.96 When equipment containing flammable vapors is continuously padded with an inert gas, use a credit factor of 0.96. If the inert gas system has sufficient capacity to purge the total volume of the unit automatically, use a credit factor of 0.94. This credit is not applicable if there is an inert purge connection that must be turned on or controlled manually. I DO A 044652 CONFIDENTIAL 40 g. Operating Instructions/Procedures - 0.91 to 0.99 Adequate written operating instructions and/or a fully documented operating discipline are an important part of maintaining satisfactory control of a unit The following conditions, listed with point ratings, are considered to be the most important: 1. Startup -0.5 2. Routine shutdown - 0.5 3. Normal operating conditions - 0.5 4. Turndown operating conditions - 0.5 5. Standby running conditions (unit running on total recycle or reflux) - 0.5 6. Uprated operating conditions (above flowsheet capacity) -1.0 7. Restarting shortly after a shutdown -1.0 8. Restarting plant from a post-maintenance condition -1.0 9. Maintenance procedures (work permits, decontamination, lockout, system clearance) -1.5 10. Emergency shutdown -1.5 11. Manufacturing unit equipment/piping modifications and additions - 2.0 12. Foreseeable abnormal fault situations - 3.0 To obtain a credit factor, add all the points for the conditions that have operating instructions. The total points are represented by "X" in the following formula: If all conditions have been covered, the credit factor will be: 13 5 1.0--- = 0.91 150 As an alternative, it may be determined what value in the range of 0.91 to 0.99 the engineer thinks best represents the completeness and accuracy of the operating instructions. h. Reactive Chemical Review - 0.91 to 0.98 The documented use of a total Reactive Chemical Program for reviewing existing and new proc esses, including process changes and storage and handling of chemicals, is an important loss control function. Where this program is a continuing part of the operations, a credit factor of 0.91 is used. If the review is done only on an occasional basis, use a credit factor of 0.98. As a "minimum requirement" for credit, operators must receive an orientation in Reactive Chemicals as applied to the operator's job at least annually. Unless this orientation is provided regularly, no credit can be taken. i. Other Process Hazard Analysis - 0.91 to 0.98 Several other process hazard analysis tools can be used in addition to the F&EI evaluation. These include Quantitative Risk Assessments (QRA), Detailed Consequence Analysis, Fault Tree Analysis, Hazard and Operability (HAZOP) Studies, Failure Modes and Effects Analysis (FMEA), Environmental, Health, Safety, and Loss Prevention Reviews, "What If' Studies, Greek List Evaluations and Management of Change Reviews. For descriptions of these hazard analysis tools, refer to the Corporate S/LP/S Process Risk Management Guidelines for Facilities and Distribution. 41 DO A 044653 CO NFTDFNTTAl The credit factors to be used for this area are as follows: Quantitative Risk Assessment (QRA) Detailed Consequence Analysis Fault Tree Analysis Hazard and Operability (HAZOP) Studies Failure Modes and Effects Analysis (FMEA) Environmental, Health, Safety, and Loss Prevention Reviews "What If' Studies Check List Evaluations Management of Change Review 0.91 0.93 0.93 0.94 0.94 0.96 0.96 0.98 0.98 When any of these process hazard risk analysis programs are done cm a regular part of operations, the full credit factor is to be used. The process hazard risk analysis must be consistent with the Corporate S/LP/S Process Risk Management Guidelinesfor Facilities and Distribution. If these analyses are only done on an occasional basis, a higher factor is to be used based on good engineering judgment For full credit, the results should be shared with employees as is appropriate. Material Isolation Credit Factor (C2) a. Remote Control Valves - 0.96 to 0.98 If the unit is provided with remotely operated isolation valves so that storage tanks, process vessels or major sections of transfer lines can be quickly isolated in an emergency, use a credit factor of 0.98. If such valves are cycled at least annually, use a credit factor of 0.96. b. Dump/Blowdown - 0.96 to 0.98 Where an emergency process dump tank can be used directly to receive the contents of the Process Unit safely with adequate quenching and venting, use a credit factor of 0.98. If the dump tank is located outside the unit area, use a credit factor of 0.96. For emergency venting, if gas/vapor material is piped to a flare system or to a closed vent receiver, use a credit factor of 0.96. Credit is given for a normal venting system that reduces the exposure of surrounding equipment to released gases or liquids. A vent tied into a flare system or receiver would receive a credit of 0.98. An example would be blowdown from a polystyrene reactor to a tank or receiver. c. Drainage - 0.91 to 0.97 To remove a large spill from a process or storage unit, it is considered necessary to provide a slope of at least 2% (1% on a hard surface) leading to a drainage trench of adequate size, assuming that 100% of the contents of the largest tank plus 10% of the next largest tank could be released plus 1 hr of deluge/sprinkler fire water. Where this requirement is met, use a credit fac tor of 0.91. If drainage conditions are good such as to drain the contents away from under or near tanks and equipment, a credit factor of 0.91 can also be used. DO A 044654 42 CONFIDENTIAl If the drainage design would allow a pooling of a large spill but could handle small spills (about 50% of the largest tanks contents), use a credit factor of 0.97. Many drains are capable of handling moderate spills, and many process areas would qualify for a credit factor of 0.95. Storage tanks that are diked on four sides to retain spills receive no credit. If the diking design directs the spill to an impounding basin located at least 50 ft (15 m) away and capable of receiving the contents of the largest diked tank plus 10% of the next largest tank plus sprinkler water, a credit factor of 0.95 is used. If the slope is doubtful, or if the impounding basin is closer than 50 ft (15 m) away, no credit is given for drainage. d. Interlock - 0.98 If a process is provided with an interlock system which prevents incorrect material flow that could produce undesirable reactions, use a credit factor of 0.98. This credit can also be taken for a burner management system that meets the Loss Prevention Principles and code requirements. Fire Protection Credit Factor (C3) a. Leak Detection - 0.94 to 0.98 If gas detectors have been installed that alarm only and identify a zone in the plant area, use a credit factor of 0.98. When a gas detector both alarms and activates a protective system before the lower flammability limit is reached, use a credit factor of 0.94. b. Structural Steel - 0.95 to 0.98 The time duration rating of a fireproof coating application is related to the quantity of fuel in the area and the drainage design. Where fireproofing is used, it should be applied to all load-bearing steel to a minimum height of 15 ft (5 m). Where this has been done, use a credit factor of 0.98. If fireproofing extends above 15 ft (5 m) but less than 30 ft (10 m), use a credit factor of 0.97. For fireproofing above 30 ft (10 m), use a credit factor of 0.95 but only if such fireproofing is necessary. Fireproofing systems must be in sound repair, or no credit is to be taken. Reinforced concrete construction qualifies for the ``fireproofing" credit and is the preferred method for fireproofing. Another approach is to install a deluge water spray for cooling the structure only. This should receive a credit factor of 0.98 under the "Structural Steel" category (although water spray cooling of a structure is not specifically mentioned), rather than a credit factor of 0.97 under "Sprinkler Systems." c. Fire Water supply - 0.94 to 0.97 When the delivery pressure is 100 psig (690 kPa) or more, use a credit factor of 0.94. If the delivery pressure is less than 100 psig (690 kPa), use a credit factor of 0.97. A plant's supply of fire fighting water should be capable of delivering the maximum calculated demand for a period of four hours. Less than four hours of fire water may be appropriate for low hazard operations. If this requirement is satisfied, use a credit factor of 0,97. 43 pom A 044655 confidential Unless the fire water supply can be provided by alternative power sources which are independent of normal electric service and capable of delivering the maximum calculated demand, no credit factor can be applied. A diesel-driven fire pump is an example of an alternative power source. d. Special Systems - 0.91 Special systems include CO2, halon, smoke and flame detectors and blast walls or cubicles. The installation of new halon systems is discouraged because of potential harm to the environment. Credit can be given to existing halon systems if deemed appropriate for life safety or other special situations. It is important to be certain that the loss control credits taken for the Process Unit being studied are those that truly apply to that particular Process Unit A credit factor of 0.91 can be used for special systems. If a double wall, above ground tank is designed so that the outer wall will contain the total con tents after a leak in the primary wall, a credit factor of 0.91 can be used. However, double wall tanks are usually not cost effective and additional integrity in the primary wall is often a better answer to minimizing risk. Formerly, a credit was given for underground buried and double wall tanks. There is no doubt that from die standpoint of fire protection that a buried tank is safer; however, a more important concern is the possibility for leakage of buried tanks and the difficulty of being able to detect and control leakage. Due to this environmental concern, the construction of new buried tanks is discouraged. e. Sprinkler Systems - 0.74 to 0.97 Deluge systems receive a credit factor of 0.97. A deluge system (open head) gets the minimum credit because such systems have many components, any one of which could fail completely or partially, producing a negative effect cm the operation and effectiveness of the system. Also the deluge system is used in combination with other loss control features on relatively hazardous unit operations so its individual benefit is less. Credit factors for wet pipe or dry pipe systems used in indoor manufacturing areas and ware houses are calculated as follows: Occupancy Light Ordinary Extra Hazard Design gpm/ft2 Ipm/m2 0.15-0.20 6.11-8.15 0.21-0.34 8.56-13.8 >0.35 S 14.3 Credit Factor Wet Pipe Dry Pipe 0.87 0.87 0.81 0.84 0.74 0.81 DO A 044656 CONFIDENT!AL 44 Wet and dry pipe sprinkler systems (closed head) are 99.9%-plus reliable, with very few of the variables encountered with deluge valves, which are subject to failure. Multiply the above factors by the following penalty factors, which are based on the size of fee floor area confined within firewalls: Area > 10,000 ft2 (929 m2) = 1.06 Area > 20,000 ft2 (1,858 m2) = 1.09 Area > 30,000 ft2 (2,787 m2) = 1.12 Note that as the possible fire area is increased (e.g., a warehouse), the credit factor is increased by a penalty factor (1.06 to 1.12), which increases the loss control credit factor and increases fee MPPD, as it should. Large fire areas offer greater exposure to fire loss than small fire areas. f. Water Curtains - 0.97 to 0.98 The use of automatic water spray curtains between a source of ignition and a potential vapor release area can be effective in reducing the vapor cloud ignition potential. To be effective, the curtain should be located at least 75 ft (23 m) from the vapor release point to allow time for detection of the release and automatic activation of the water curtain. A single tier of nozzles at a maximum elevation of 15 ft (5 m) will receive a credit factor of 0.98. A second tier of nozzles, not exceeding 6 ft (2 m) above fee first tier, will receive a credit factor of 0.97. g. Foam - 0.92 to 0.97 If fee area protection system includes fee capability of injecting foam liquid into a standard deluge sprinkler system from a remote manual control station, use a credit factor of 0.94. This credit is in addition to the credit taken for the deluge system itself. A totally automatic foam system re ceives a credit of 0.92. Totally automatic means the foam valve is automatically actuated when fire is detected. Manual foam application systems for fee protection of seal rings on open-top floating roof tanks receive a credit of 0.97. Use a factor of 0.94 when fire detection devices are used for actuating the foam system. Subsurface foam systems and foam chambers on cone roof tanks receive a credit factor of 0.95. Foam application around fee outer shell of a flammable liquid tank receives a credit factor of 0.97 if manually applied, 0.94 if automatic. h. Hand Extinguishers/Monitors - 0.93 to 0.98 If there is an adequate supply available of hand and portable fire extinguishers suitable for the fire risk involved, use a credit factor of 0.98. Where there is potential for a large spill of flammable material that, if ignited, could not be controlled effectively with hand extinguishers, do not take a credit. Hand extinguisher credit is not appropriate for process areas where large quantities of flammable or combustible liquids can be spilled. DO A 044657 45 CONFIDENTIAL If monitor guns have also been installed, use a credit factor of 0.97. Monitor guns that can be remotely operated from a safe vantage point receive a credit factor of 0.95. Monitors equipped with foam injection capability receive a credit factor of 0.93. i. Cable Protection - 0.94 to 0.98 Instrument and electrical cable trays are very vulnerable to damage from fire exposure when installed in pipeways and operating structures. The use of 14 to 16 gauge metal sheet below the tray with a water spray directed onto the top side will provide reasonable protection which justifies a credit of 0.98. The use of fireproofing material rat the metal sheet in lieu of the water spray also receives a credit of 0.98. If the cable raceway is buried below grade in a trench (either flooded or dry), use a credit of 0.94. The product of Cj x C2 x C3 constitutes the Loss Control Credit Factor for the Process Unit and is to be entered into line 7 of the Process Unit Analysis Summary, page 6. DO A 044658 CONFIDENTIAL 46 PROCESS UNIT RISK ANALYSIS SUMMARY The Process Unit Risk Analysis Summary, page 6, gives a summary of all of the important Process Unit Risk Analysis information This starts with the F&EI and gives additional risk information which is determined from the F&EI, the Loss Control Credit Factor, the Area of Exposure, the Damage Factor and the Value of Production for the Month. The Process Unit Risk Analysis Summary, along with the F&EI, is a good risk analysis tool to be used in making decisions regarding the risk management program for the Manufacturing Unit of which the Process Unit is a part The remainder of this guideline presents the process for determination of the additional risk factors which are to be considered for the Process Unit which then leads to an overall view of the risk factors for the total Manufacturing Unit 1. The Fire and Explosion Index (F&EI) The Fire and Explosion Index calculation is used for estimating the damage that would probably result from an incident in a process plant. A summary of a description of the F&EI is given on page 38 along with Table 6 which lists the degree of hazard for the various ranges of F&EI. All of the key information and calculations which go to determine the F&EI are list in the form on page 4. The F&EI value is to be entered on line 1 of the Process Unit Risk Analysis Summary, page 6, and in the Manufacturing Unit Risk Analysis Summary, page 7. 2. The Radius Of Exposure The F&EI, which was determined on page 5, is converted to a Radius of Exposure by multiplying the F&EI by a factor of 0.84 or by using Figure 7, page 48. This is determined in either feet or meters. This radius of exposure is to be shown on plot plans for the Manufacturing Unit with the primaiy item of process equipment as the center of a circle using the Radius of Exposure. Grcles should be drawn for each of the Process Units being analyzed in the Manufacturing Unit The Radius of Exposure should be entered in the Process Unit Risk Analysis Summary on page 6, line 2. When the Process Unit being evaluated is a small piece of equipment, the Radius of Exposure can be considered to start at the center of the item concerned. The Radius of Exposure for large pieces of equipment would extend outward from the equipment surface for a distance equal to what should be considered as the "radius." The additional area is added to the original area of the Process Unit being evaluated to determine the Area of Exposure. For specific cases, the center of the Area of Exposure is very often a leak point. Examples of likely leak points include vents, expansion joints, loading^ unloading connections, etc. These would be the center of the Area of Exposure circle. FIGURE 7 - RADIUS OF EXPOSURE o oo 2n O o>-* > nr? o H2 & X*->< O' 'O FIRE & EXPLOSION INDEX For Exposure Radius in meters multiply by 0.3048. 3. The Area Of Exposure The Radius of Exposure defines an Area of Exposure. The Area of Exposure is calculated with the equation: Area = JcR2 or Area = tc(Ra2) ft2 or m2 The Area of Exposure should be entered in the Process Unit Risk Analysis Summary on page 6, line 3. The area is that which contains equipment that could be exposed to a fire or to a fuel-air explosion generated in the Process Unit being evaluated. For evaluation of equipment that could be damaged in a fire or explosion, actually a volume is considered. This volume is a cylindrical volume of the plant surrounding the Process Unit with the area being the Area of Exposure and the height being equal to the Radius of Exposure. In some cases a spherical volume is appropriate. The volume is expected to be the amount of the Manufacturing Unit at risk in the event of a fire or explosion caused by an incident in the Process Unit under study. Below is a sketch of a vertical tank considered as a Process Unit; and the Radius of Exposure, Area of Exposure and volume are shown as an example. 4 Volume t A Height = Radius of Exposure T F&EI = 100 Radius of Exposure = 84 ft (25.6 m) Area of Exposure = 22,170 ft2 (2,060 m2) Height of Cylindrical Volume = 84 ft (25.6 m) It is recognized that a fire and/or explosion incident does not spread out into a perfect circle producing equal damage in all directions. The actual damage can be affected by positioning of the equipment, wind direction and drainage layout, all of which are important factors influencing loss prevention design. However, the circle affords a good basis for later calculation of values. As a matter of interest, the Radius of Exposure was computed in early studies for the F&EI by considering the probable effects of spills of various flammable materials 3 in (8 cm) deep as well as the potential effects of vapor air mixtures and fire, considering several different sets of ambient conditions. n0 ft OA4661 49 confidential If the Area of Exposure is external to, but includes walls of buildings that are resistant to fire or explosion or both, the building may not be at risk and may be excluded from the Area of Exposure. If there is a blast wall or fire wall within the Area of Exposure, the area behind the wall would not be included. When the material is stored in a warehouse or other building, the above reasoning leads naturally to the conclusion that only the volume of that building itself is at risk, provided the risk is fire only, not explosion, and the construction is such that the walls and roof will not propagate fire. If the building does not have fire-resistant or at least non-combustible construction, the Area of Exposure will extend beyond its walls. Some additional considerations are: 1. The entire area of a single building containing a Process Unit is considered to be an Area of Exposure unless various parts of the building are separated from each other by vertical fire walls. If the risk of explosion exists, the entire building is considered to be an exposure area, even if its parts are separated by fire walls. 2. A multi-story building containing fire-resistant floors would be divided into exposure areas by floor levels. 3. Fire-resistant walls are an adequate barrier to exclude a building from fire exposure penalties if the fire source is external. However, where an explosion hazard exists, a fire-resistant wall cannot be considered an adequate barrier. 4. Blast resistant walls are considered adequate for establishing any Area of Exposure boundaries provided the protection from blasts is oriented in the correct direction. The real effect of the F&EI on the final evaluation can be seen by referring to the following: Example: Process Unit "A" Process Unit "B" Process Unit Hazards Factor = 4.0 Material Factor = 16 Damage Factor = 0.45 F&E Index = 64 Radius of Exposure = 54 ft (16.4 m) Area of Exposure = 9,161 ft2 (845 m2) Process Unit Hazards Factor = 4.0 Material Factor = 24 Damage Factor = 0.74 F&E Index = 96 Radius of Exposure = 81 ft (24.6 m) Area of Exposure = 20,612 ft2 (1,901 m2) Although both Process Units have a Process Unit Hazards Factor (F3) of 4.0, the final measurement of their probable loss exposure must include the hazard of the material being processed or handled. The conditions in Process Unit "A" represent 45% damage to 9,161 ft2 (845 m2) of surrounding area. The conditions in Process Unit "B" represent 74% damage to 20,612 ft2 (1,901 m2) of surrounding area. If Process Unit "B" had a Process Unit Hazards Factor of 2.7 instead of 4.0, the F&EI would be the same as that of Process Unit "A," 64. However, the Damage Factor for Process Unit "B" would be 0.64 (based on a Material Factor of 24), compared to a Damage Factor of 0.45 (based cm a Material Factor of 16) for Process Unit "A." 50 4. Value Of the Area Of Exposure The value of the Area of Exposure is obtained from the Replacement Value of the property contained within it, including the inventory of material. Replacement Value = Original Cost X 0.82 X Escalation Factor The factor 0.82 is an allowance for items of cost not subject to loss or replacement, such as site preparation, roads, underground lines and foundations, engineering expenses, etc. This factor may be changed if a more accurate estimate exists. The Escalation Factor is determined from the value obtained from an engineering estimator who keeps the most currently accepted values. See page 54 for escalation values from 1986. The Value of the Area of Exposure is to be entered on line 4, Process Unit Risk Analysis Summary, page 6, and in the Manufacturing Unit Risk Analysis Summary on page 7. The Replacement Value may be calculated in several ways: 1. Use Replacement Value of the equipment in the Area of Exposure. The current value may be de termined as outlined above. Accounting records, if properly constructed, can provide this information. Note: Accounting may have an insurable value or Actual Cash Value (ACV), which is computed from current Replacement Value. While the dollars recovered in the event of loss are based on insurable value, the best estimate of risk is based on the current Replacement Value. 2. Make a current engineering cost estimate of the Replacement Value (excluding foundations and other cost items not subject to loss) of everything within the Area of Exposure. This can be quite time-consuming for all but new plants. To simplify the procedure, use major equipment cost only in estimating and correct to installed cost using Engineering Estimating Installation Factors. Technology Centers may have the most current cost data on both existing and recently constructed plants. 3. Derive an equipment cost per square foot from the overall manufacturing unit Replacement Value. Multiply this cost by the ground floor area within the plan view of the Area of Exposure. While this is likely to be the least accurate method, it may be the most practical for older plants. When the Replacement Value for the Area of Exposure is computed, it is necessary to use the value of the product inventory along with the equipment value. For storage tanks, use 80% of tank capacity: for columns, towers, pumps, reactors, etc., use the product inventory or connected source of supply. Use 15 min flow process or the volume available, whichever is less. The product value should be based on cost of manufacture for work-in-process, cm the sales value of saleable products or on the cost for scrap. All products within the Area of Exposure are to be included. Note: When this Area of Exposure encompasses part of another Area of Exposure, the values for the two areas are not additive. DO A 044663 CONFIDENTIAL 51 5. Determination OfDamage Factor The Damage Factor is detennined from the Process Unit Hazards Factor (F3) and the Material Factor (MF) with the use of Figure 8, page 53. The Damage Factor represents the overall effect of fire plus blast damage resulting from a release of fuel or reactive energy from a Process Unit. For any calculation in which F3 exceeds 8.00, do not extrapolate from Figure 8. Use 8.00 as the F3 for obtaining the Damage Factor. As the Material Factor (MF) and the Process Unit Hazards Factor (F3) increase, the Damage Factor will increase from 0.01 to 1.00. The Damage Factor is to be listed on line 5, page 6. For example, two Process Units, A and B, may be found to have a Process Unit Hazards Factor (F3) of 4.00. Unit A has an MF of 16 and Unit B has an MF of 24. Using Figure 8, it can be detennined that the Damage Factor for Unit A is 0.45 and the Damage Factor for Unit B is 0.74. The equations for the data presented in Figure 8 are given in Appendix E, page 81. Note that there is no meaning for the intermediate Material Factors other than the nine defined cases of Material Factors that equal 1, 4, 10, 14, 16, 21, 24, 29, and 40 for which nine equations have been defined. See Appendix E for additional information. 6. Base Maximum Probable Property Damage (Base MPPD) With the Area of Exposure, the Value of the Area of Exposure and the Damage Factor determined, it is necessary to obtain some appropriate dollar value for the plant equipment within the theoretical Area of Exposure (really volume of exposure) which represents the Base Maximum Probable Property Damage (Base MPPD). The Base MPPD is obtained by multiplying the values of lines 4 and 5 of the Process Unit Risk Analysis Summary, page 6. This gives a result which is based on loss experiences from many years of data. The Base MPPD is to be entered on line 6, page 6 and in the Manufacturing Unit Risk Analysis Summary, page 7. The Base MPPD assumes none of the loss control features mitigates the loss. 7. Loss Control Credit Factor The Loss Control Credit Factor is entered as determined from the top of page 6 of the forms. This is the product of numerous credit factors which are described in tire previous section on Loss Control Credit Factors, pages 39 to 46. The final Loss Control Credit Factor is to be entered cm line 7 of the Process Unit Risk Analysis Summary, page 6. 8. Actual Maximum Probable Property Damage (Actual MPPD) The product of tire Base MPPD and the Loss Control Credit Factor from tire Loss Control Credit Factors Section, page 6, will provide the Actual Maximum Probable Property Damage (Actual MPPD). This product represents the property damage loss that could result from an incident of reasonable magnitude with adequate (but not perfect) functioning of protective features as listed on page 6. If any of these protective systems were to fail, the loss might approach the Base MPPD. The value of the Actual MPPD is to be entered on line 8 of the Process Unit Risk Analysis Summary, page 6, and in the Manufacturing Unit Risk Analysis Summary, page 7. DO A 044664 52 CONFIDENTIAL DAMAGE FACTOR FIGURE 8 - DAMAGE FACTOR oo . o> MATERIAL FACTOR (MF) < O' See Appendix E for data equations. >- OU'1 9. Maximum Probable Days Outage (MPDO) As noted in the introduction, the estimate of Maximum Probable Days Outage (MPDO) is a necessary step in assessing the potential Business Interruption (BI) from a loss incident. The dollar impact of Business Interruption can often times equal or exceed that of property damage, depending on inventory levels and product demand. A number of different conditions can cause variations in the relationship of MPDO to property damage. For example: 1. Repair of damaged cable in a cable tray could require as much time as the repair or replacement of small electric motors, pumps and instruments, although the property damage would be smaller. 2. Failure of a vital raw material supply line, such as a brine line or a hydrocarbon line, would be a low property damage incident with a high MPDO. 3. Availability of hard-to-get or one-of-a-kind items will have an impact chi the number of days a process will be down. 4. Ability to make up the lost product at a remote production facility. 5. Plant interdependence: loss of profit and continuing costs of a plant due to lack of material from the plant in question. To obtain the MPDO value, it is necessary to have determined the Actual MPPD of the area and then to refer to Figure 9, page 55. Figure 9 gives a correlation between MPDO and Actual MPPD. The data are derived from historical fire and explosion loss incidents, which also provided a basis for the Damage Factor. Such a correlation is imprecise because there is a considerable spread of data. Many times, people have simply read the MPDO value directly from the central correlation line. The intention is that judgment should be used in selecting the MPDO and that the value will generally fall within the upper and lower 70% probability levels in the absence of any other controlling factor. However, the value for the MPDO could deviate considerably from 70% if there were clearly some strong overriding consideration. If there is a better estimate of days outage based on delivery times or engineering schedules, use the better estimate of MPDO instead of Figure 9. In sane instances, the MPDO may not be realistic for the known conditions. For example, critical component parts for a compressor might be kept in stock or a spare pump or rectifier might be in stock. This would justify using the MPDO obtained from the lower line of the normal range bracketing the 70% probability level. On the other hand, hard-to-get or one-of-a-kind items would usually require using an MPDO near the upper line of that range. Alternatively, an individual analysis of the effect of fire and/or explosion might be substituted for the use of Figure 9, page 55. The value of the Actual MPPD is given in 1986 dollars in Figure 9. Escalation needs to be made to present day values. The current relative escalation values from Chemical Engineering Plant Cost Index is as follows: 1986 1987 1988 1989 1990 Based on August 1993 index Best Estimate 318.4 323.8 342.5 355.4 357.6 54 1991 1992 1993 1994 1995 361.3 358.2 359.9* 368.4** 378.3** C>0 A 044666 confidential MAXIMUM PROBABLE DAYS OUTAGE FIGURE 9 - MAXIMUM PROBABLE DAYS OUTAGE (MPDO) MAXIMUM PROBABLE PROPERTY DAMAGE (ACTUAL MPPD $MM, 1986 BASIS) For update to 1993 basis multiply by 359.9/318.4 = 1.130, based on Chemical Engineering Plant Cost Index. WP Thus, for an escalation from 1986 to 1994 the following factor would be used: 368.4 1.157 318.4 These values many need to be adjusted in the future for the best possible estimate of Actual MPPD. The equations for the curves in Figure 9 for MPPD (X) versus Days Outage (Y) are as follows: Curve for UPPER 70% PROBABILITY LIMIT log Y = 1.550233 + 0.598416(logX) or log Y = 1.550233 + 0.598416*logX Curve for NORMAL PROBABILITY LIMIT log Y * 1.325132 + 0.59247l(logX) or log Y = 1.215132 + 0.592471*logX Curve for LOWER 70% PROBABILITY LIMIT log Y = 1.045515 + 0.610426(logX) or log Y - 1.045515 + 0.610426*logX The MPDO is to be entered on line 9 of the Process Unit Risk Analysis Summary, page 6 and in the Manufacturing Unit Risk Analysis Summary, page 7. 10. Business Interruption (BI) The calculation for Business Interruption (BI) in U. S. dollars is done as follows: BI = MFDxVPMx0.70 30 VPM is the Value of Production for the Month, and 0.70 represents the fixed costs plus profits. The BI loss is to be entered cm line 10 of the Process Unit Risk Analysis Summary, page 6 and in the Manufacturing Risk Analysis Summary, page 7. DO A 044668 CONFIDENTIAL 56 DISCUSSION OF MPPD, BI AND PLANT LAYOUT What is an acceptable Maximum Probable Property Damage (MPPD) and Business Interruption (BI) risk? This is not an easy question to answer. It depends on the type of plant. For example, the potential loss from a hydrocarbon plant will always exceed the loss of a STYROFOAM plant The best approach is to compare plants in similar technology areas. The predicted loss from a new plant should not exceed that of similar plants in the same technology. Another approach would be to set an acceptable MPPD value at 10% of the Manufacturing Unit (Plant) Replacement Value. Another issue is that of market conditions and the ability to supply product if a plant is down. With mul tiple plants making the same product, Business Interruption can be minimal. If the damaged plant is a sin gle source of the product and market position is vulnerable, the potential business impact can be great. Plants relying on a critical unit operation, e.g., waste water treatment facilities, thermal oxidizers, etc., can also have large business interruption impact if there is a significant property damage incident. The important consideration is what action will or can be taken if the MPPD is not acceptable. A. The risk analysis should be carried out during the design phase of a new capital project, and there should be opportunity for action to reduce MPPD. The most effective way to achieve this is by a change in layout, an increase in separation distances and a reduction of total capital within the Area of Exposure. In certain cases, where the inventory penalty is a major item in the F&EI, a reduction in inventory may be feasible and effective. Other possibilities may be found in specific cases. It will quickly become apparent that preventative measures that eliminate or reduce hazards and reduce the F&EI have more impact on the MPPD than the addition of more protective features (credit factors). B. When the review is carried out cm an existing operating plant, changes in layout or inventory are much less likely to be economically feasible, and the opportunities to achieve a significant reduction in MPPD may be limited. Emphasis should be placed on the addition of appropriate loss control features. Plant Layout The Fire and Explosion Index evaluation can be very useful in developing new plant layouts or adding equipment and buildings to existing plants. The F&EI can be used in conjunction with Loss Prevention Principle, 2.2, to assure adequate separation between process units and critical buildings and equipment The more severe the F&EI rating, the greater the separation distance required between facilities. Also, F&EI circles can be superimposed cm preliminary plot plans to evaluate the potential impact of a fire or explosion cm adjacent buildings and equipment If the risk appears unacceptable, the separation dis tances should be increased or consideration given to more sophisticated engineering estimates of the conse quences. Evaluation of the F&EI calculations and other layout considerations will result in a safe, main tainable, operable and cost-effective arrangement of equipment and buildings. DO A 044669 57 CONFIDENTIAL MANUFACTURING UNIT RISK ANALYSIS SUMMARY The Manufacturing Unit Risk Analysis Summary, page 7, documents the probable loss impact of both Base and Actual Maximum Probable Property Damage and Business Interruption for the Manufacturing Unit (plant) being evaluated In the first column the name of the Process Unit is to be given Mowed by the major material of concern from which the Material Factor was determined An example for a latex plant would be - Reactor Unit/ butadiene. The other values are to be entered from the F&EI Sheet (page 5) and the Process Risk Analysis Summary Sheet (page 6). These include the F&EI, Value of Area of Exposure, Base MPPD, Actual MPPD, MPDO, and BI. Separate F&EI, Loss Control Credit Factors, and Process Unit Risk Analysis Summary forms are to be completed for all of the pertinent Process Units. The Manufacturing Unit Risk Analysis Summary gives the key information from these forms and is to be included in the Risk Analysis Package. D0 ft 044670 58 confidENTTA RISK ANALYSIS PACKAGE It is necessary to provide fire and extended coverage insurance carriers with a summary of the loss and prevention features on manufacturing units. This summary is called a Risk Analysis Package and includes the following: 1. Manufacturing Unit Risk Analysis Summary 2. F&EI Forms completed for: a. The highest Actual MPPD b. The highest MPDO and BI c. The highest F&EI necessary for the Process Risk Management Guidelines for Facilities and Distribution 3. Simplified Block Flowsheet 4. Plot plan showing Areas of Exposure, Gas Detection, Fire Equipment, Emergency Block Valves (EBVs), etc. 5. Business Interruption data, including: a. Sources of raw materials and alternates b. Packaging and shipping of product or products c. Essential utilities and reliability d. Critical equipment and plans for coping with breakdowns e. Capability of loss control systems such as fire fighting, water supply, deluge water spray, explo sion suppression, fire department response, etc. f. Interdependencies with Dow and non-Dow facilities. 6. Chemical Exposure Index (CEI) Summary 7. Site Loss Prevention Insurance Report 8. Unit Loss Prevention Insurance Report Each site needs to maintain a current Risk Analysis Package for each of its manufacturing units. The Risk Analysis Package is used by many sites as a part of the Consolidated Audit DO td^tXAL' 59 CONF DO A 0 4 4 6 7 2 CO NFIDENTIAL APPENDIX A COMPOUND Acetaldehyde Acetic Acid Acetic Anhydride Acetone Acetone Cyanohydrin Acetonitrile Acetyl Chloride Acetylene Acetyl Ethanolamine Acetyl Peroxide Acetyl Salicylic Acid [8] o Acetyl Tributyl Citrate Acrolein Acrylamide Acrylic Acid Acrylonitrile Ally! Alcohol Allylamine Allyl Bromide Allyl Chloride Allyl Ether Aluminum Chloride Ammonia Ammonium Nitrate Amyl Acetate Amyl Nitrate 7 ) Aniline Barium Chlorate MATERIAL FACTORS AND PROPERTIES He 1 BTU/LB NFPA Classification Flash MF X 10A3 N(H) N(F) | N(R) Point (deg F) 24 10.5 342 14 5.6 32 1 14 7.1 32 1 16 12.3 1 30 24 11.2 422 16 12.6 3 30 24 2.5 332 29 20.7 04 3 14 9.4 111 40 6.4 1 24 16 8.9 1 10 4 10.9 0 1 0 29 11.8 4 33 24 9.5 322 24 7.6 322 24 13.7 432 16 13.7 43 1 16 15.4 43 1 16 5.9 33 1 16 9.7 33 1 24 16.0 332 24 (2) 302 4 8.0 310 29 12.4(7) 0 0 3 16 14.6 1 30 10 11.5 220 10 15.0 320 14 (2) 20 1 -36 103 126 -4 165 42 40 Gas 355 - - 400 -15 - 124 32 72 -4 28 -20 20 - Gas - 60 118 158 - Boiling Pointed g F) 69 244 282 133 203 179 124 -118 304 - 308 (4) - 343(1) 127 257(1) 286 171 207 128 160 113 203 (3) -28 410 300 306 - 315 364 - APPENDIX A MATERIAL FACTORS AND PROPERTIES COMPOUND Barium Stearate Benzaldehyde Benzene Benzoic Acid Benzyl Acetate Benzyl Alcohol Benzyl Chloride Benzyl Peroxide Bisphenol A Bromine Bromobenzene o-Bromotoluene 1,3-Butadiene Butane 1-Butanol (Butyl alcohol) 1 -Butene Butyl Acetate Butyl Acrylate n-Butylamine Butyl Bromide Butyl Chloride 2,3-Butylene Oxide Butyl Ether t-Butyl Hydroperoxide <-> z Butyl Nitrate -h t-Butyl Peracetate t-Butyl Perbenzoate t-Butyl Peroxide ^ ^ E^ MF 4 10 16 ' 14 4 4 14 40 14 1 10 10 24 21 16 21 16 24 16 16 16 24 16 40 29 40 40 29 He BTU/LB X 10A3 8.9 13.7 17.3 11.0 12.3 13.8 12.6 12.0 14.1 0.0 8.1 8.5 19.2 19.7 14.3 19.5 12.2 14.2 16.3 7.6 11.4 14.3 16.3 11.9 11.1 10.6 12.2 14.5 1 NFPA Classifycation N(H) N(F) N(R) 0i0 220 230 21 1 1 10 210 22 1 1 34 21 1 300 220 220 24 2 1 40 1 30 140 1 30 22 2 330 230 230 232 23 1 144 133 234 1 34 1 33 Flash Point (deg F) - 148 12 250 195 200 162 - 175 - 124 174 -105 -76 84 Gas 72 103 10 65 15 5 92 < 80 or above 97 <80 > 190 64 Boiling Point (deg F) - 354 176 482 417 403 387 428 138 313 359 24 31 243 21 260 300 171 215 170 149 288 (9) 2T7 (4) (4) 176 APPENDIX A COMPOUND Calcium Carbide Calcium Stearate [6] Carbon Disulfide Carbon Monoxide Chlorine Chlorine Dioxide Chloroacetyl Chloride Chlorobenzene Chloroform Chloro Methyl Ethyl Ether 1-Chloro 1-Nitroethane o-Chlorophenol Chloropicrin 2-Chloropropane Chlorostyrene Coumarin Cumene Cumene Hydroperoxide Cyanamide Cyclobutane Cyclohexane Cyclohexanol Cyclopropane DER* 331 Dichlorobenzene 1,2-Dichloroethylene o 1,3-Dichloropropene z o 2,3-Dichloropropene ^ ^ MATERIAL FACTORS AND PROPERTIES He BTU/LB |1 NFPA Classification Flash MF X 10A3 N(H) N(F) N(R) Point (deg F) 24 9.1 332 - 421 6.1 21 4.3 1 0.0 40 0.7 14 2.5 16 10.9 010 340 340 4 00 314 30 1 2 30 - -22 Gas Gas Gas 84 1 1.5 2 0 0 14 5.7 21 1 29 3.5 323 10 9.2 320 29 5.8C7) 4 0 3 21 10.1 240 24 12.5 21 2 - 133 147 -26 165 24 12.0 16 18.0 40 13.7 29 7.0 21 19.1 16 18.7 10 15.0 21 21.3 14 13.7 10 8.1 24 6.9 16 6.0 16 5.9 212 23 1 1 24 413 1 40 1 30 1 20 1 40 111 220 232 330 230 - 96 175 286 Gas -4 154 Gas 485 151 36-39 95 59 Boiling Point (deg F) 115 -313 -29 50 223 270 143 - 344 47 234 95 372 554 306 (4) 500 55 179 322 -29 878 357 140 219 201 APPENDIX A MATERIAL FACTORS AND PROPERTIES COMPOUND 3,5-Dichloro Salicylic Acid Dichlorostyrene Dicumyl Peroxide Dicyclopentadiene Diesel Fuel Diethanolamine Diethylamine m-Diethyl Benzene Diethyl Carbonate Diethylene Glycol Diethyl Ether Diethyl Peroxide Diisobutylene Diisopropyl Benzene Dimethylamine 2,2-Dimethyl-1 -Propanol 1,2-Dinitrobenzene 2,4-Dinitro Phenol 1,4-Dioxane Dioxolane Diphenyl Oxide Dipropylene Glycol Di-tert-butyl Peroxide Divinyl Acetylene n Divinylbenzene Divinyl Ether m& DOWANOL* DM mo LD---O--W---A---N--O---L-*---E--B-------------- r*-h--a---------M f Oi MF 24 24 291 16 10 4 16 10 16 4 21 40 16 10 21 16 40 40 16 24 4 4 40 29 24 24 10 10 He BTU/LB X 10A3 5.3 9.3 15.4 17.9 18.7 10.0 16.5 18.0 9.1 8.7 14.5 12.2 19.0 17.9 15.2 14.8 7.2 6.1 10.5 9.1 14.9 10.8 14.5 18.2 17.4 14.5 10.0 12.9 NFPA Classification N(H) N(F) N(R) 0l2 212 013 131 0 20 1 10 3 30 220 231 1 10 24 1 - 44 1 30 020 340 2 30 3 14 3 14 231 232 1 10 0 10 324 - 33 222 232 220 1 20 Flash Point (deg F) - 225 ' 90 100- 130 342 -18 133 77 255 -49 (4) 23 170 Gas 98 302 - 54 35 239 250 65 < -4 157 <-22 197 (Seta) 150 Boiling Point (d g F) - - - 342 315 514 132 358 259 472 94 (4) 214 401 44 237 606 - 214 165 496 449 231 183 392 102 381 340 APPENDIX A COMPOUND DOWANOL* PM DOWANOL* PnB DOWICIL* 75 DOWICIL* 200 DOWFROST* DOWFROST* HD DOWFROTH* 250 DOWTHERM* 4000 DOWTHERM* A DOWTHERM* G DOWTHERM* HT DOWTHERM* J DOWTHERM* LF DOWTHERM* Q DOWTHERM* SR-1 DURSBAN* Epich lorohydrin Ethane Ethanolamine Ethyl Acetate Ethyi Acrylate Ethyl Alcohol Ethylamine Ethyl Benzene 0 Ethyl Benzoate io Ethyl Bromide m> Ethylbutylamine Ethyl Buty(carbonate TM I> SJ r O' MATERIAL FACTORS AND PROPERTIES He BTU/LB MF X 10A3 16 li.i 10 24 7.0 24 9.3 4 9.1 114 7.0 4 15.5 4 15.5 410 17.8 4 16.0 4 17.3 4 7.0 14 19.8 24 7.2 21 20.4 10 9.5 16 10.1 24 11.0 16 11.5 21 16.3 16 17.6 4 12.2 4 5.6 16 17.0 14 10.6 | NFPA Classifiication N(H) N(F) N(R) 030 020 222 222 010 000 000 1 10 210 1 10 1 10 1 20 1 10 1 10 1 10 121 332 1 40 2 20 1 30 232 030 340 2 30 1 10 210 330 22 1 Flash Point (deg F) 90 (Seta) 138 - - 215 (TOC) None 300 (Seta) 252 (Seta) 232 266 (Seta) 322 (TOC) 136 (Seta) 240 249 (Seta) 232 81 - 110 88 Gas 185 24 48 55 <0 70 190 None 64 122 Boiling Point (d g F) 248 338 - - 370 240 473 330 495 551 650 358 550-558 513 325 . 241 -128 339 171 211 173 62 277 414 100 232 275 APPENDIX A MATERIAL FACTORS AND PROPERTIES COMPOUND Ethyl Butyrate Ethyl Chloride Ethyl Chloroformate Ethylene Ethylene Carbonate Ethylenediamine Ethylene Dichloride Ethylene Glycol Ethylene Glycol Dimethyl Ether Ethylene Glycol Monoacetate Ethylenimine Ethylene Oxide Ethyl Ether Ethyl Formate 2-Ethylhezanal 1,1 -Ethylidene Dichloride Ethyl Mercaptan Ethyl Nitrate Ethyl Propyl Ether p-Ethyl Toluene Fluorine Fluorobenzene Formaldehyde (Anhydrous Gas) Formaldehyde, solutions (37 - 56%) Formic Acid Fuel Oil #1 o Fuel Oil #2 2 Fuel Oil #4 %o MF 16 21 161 24 14 10 16 4 10 4 29 29 21 16 14 16 21 40 16 10 40 16 21 10 10 10 10 10 He BTU/LB X 10A3 12.2 8.2 5.2 20.8 5.3 12.4 4.6 7.3 11.6 8.0 13.0 11.7 14.4 8.7 16.2 4.5 12.7 6.4 15.2 17.7 - 13.4 8.0 3.0 18.7 18.7 18.7 |1 NFPA Classification N(H) N(F) N(R) 030 1 40 33 i 142 21 1 320 230 1 10 220 010 433 343 24 1 230 22 1 230 240 234 ! 30 320 404 330 340 320 320 020 020 1o 2 0 Flash Point (deg F) 75 -58 61 Gas 290 110 56 232 29 215 12 -4 -49 -4 112 2 <0 50 < -4 887 Gas 5 Gas 140-181 122 100-162 126 - 204 I 142-240 Boiling Point (deg F) 248 54 203 -155 351 239 181 - 183 387 174 347 135 51 94 130 325 135-138 95 190 147 324 -307 185 -6 206-212 213 304-574 - APPENDIX A MATERIAL FACTORS AND PROPERTIES COMPOUND Fuel Oil #6 Furan Gasoline Glycerine Glycolonitrile Heptane Hexachlorobutadiene Hexachloro Diphenyl Oxide Hexanal Hexane Hydrazine (anhydrous) Hydrogen Hydrogen Cyanide Hydrogen Peroxide (40 to 60%) Hydroqen Sulfide Hydro xylamine 2-Hydroxyethyl Acrylate Hydroxypropyl Acrylate Isobutane Isobutyl Alcohol Isobutylamine Isobutylchloride Isopentane Isoprene Isopropanol _ Isopropenyl Acetylene ^ Isopropyl Acetate Isopropvlamine o^ 22 He BTU/LB NFPA Classification Flash MF X 10A3 N(H) N(F) N(R) Point (deg F) 10 18.7 21 12.6 020 i 4l 150 - 270 <32 16 18.8 i 30 -45 4 6.9 14 7.6 i 10 l 11 390 - 16 19.2 i 30 25 14 2.0 21 1 - 14 5.5 211 - 16 15.5 23 1 90 16 19.2 1 30 -7 29 7.7 3 33 100 21 51.6 040 Gas 24 10.3 442 0 14 (2) 201 - 21 6.5 4 40 Gas 29 3.2 2 03 (4) 24 8.9 212 214 24 10.4 3 12 207 21 19.4 1 40 Gas 16 14.2 1 30 82 16 16.2 2 30 15 16 11.4 2 30 <70 21 21.0 1 40 <-60 24 18.9 242 -65 16 13.1 1 30 53 24 - 242 < 19 16 11.2 1 30 34 21 15.5 340 -15 r~ 03 Boiling Point (deg F) - 88 100 - 400 340 - 209 - - 268 156 236 -423 79 226 - 237 -76 158 410 410 11 225 150 156 82 93 181 92 194 93 uu A 044679 CONFIDENTIAL APPENDIX A COMPOUND Isopropyl Chloride Isopropyl Ether Jet Fuel A & A-1 Jet Fuel B Kerosene Lauryi Bromide Lauryl Mercaptan Lauryi Peroxide LORSBAN* 4E Lube Oil (mineral) Magnesuim Maleic Anhydride Methacrytic Acid Methane Methyl Acetate Methylacetylene Methyl Acrylate Methyl Alcohol Methylamine Methyl Amyl Ketone Methyl Borate Methyl Carbonate Methylcellulose (bag storage) Methylcellutose Dust [8] Methyl Chloride Methyl Chloroacetate Methylcyclohexane Methyl Cyclopentadiene MATERIAL FACTORS AND PROPERTIES He BTU/LB MF X 10A3 21 116 10 16 10 4 4 40 14 4 14 14 24 21 16 24 24 16 21 10 16 16 4 16 21 14 16 14 I 10.0 15.6 21.7 21.7 18.7 12.9 16.8 15.0 3.0 19.0 10.6 5.9 9.3 21.5 8.5 20.0 18.7 8.6 13.2 15.4 - 6.2 6.5 6.5 5.5 5.1 19.0 17.4 1 NFPA Classifi cation N(H) N(F) N(R) 24 0 23 1 020 1 30 02 0 1 10 210 014 121 010 01 1 31 1 32 2 140 1 30 242 332 1 30 340 1 20 23 1 23 1 010 01 0 l40 22 1 230 121 Flash Point (deg F) -26 -18 no-150 -10 to +30 100- 162 291 262 - 85 300 - 450 - 215 171 Gas 14.............. Gas 27 52 Gas 102 <80 66 - -50 135 25 120 Boiling Point (d g F) 95 156 400 - 550 - 304 - 574 356 289 - 165 680 2025 395 325 -258 140 -10 177 147 21 302 156 192 - -12 266 214 163 DO A 0 4 4 6 8 0 CO NFIDENTIAL APPENDIX A MATERIAL FACTORS AND PROPERTIES COMPOUND Methylene Chloride Methylene Diphenyl Diisocyanate Methyl Ether Methyl Ethyl Ketone Methyl Formate Methyl Hydrazine Methyl Isobutyl Ketone Methyl Mercaptan Methyl Methacrylate 2-Methytpropenal Methyl Vinyl Ketone O Mineral Oil Mineral Seal Oil Monochlorobenzene Monoethanolamine Naphtha, V.M. & P, Regular Naphthalene Nitrobenzene Nitrobiphenyl Nitrochlorobenzene Nitroethane Nitroglycerine Nitromethane Nitropropanes p-Nitrotoluene N-SERV* Octane t-Octyl Mercaptan He 1 BTU/LB NFPA Classifi cation Flash MF X 10A3 N(H) N(F) N(R) Point (deg F) 4 2.3 14 12.6 21 12.4 16 13.5 21 6.4 2l0 2l 1 24 1 1 30 24 0 - 460 Gas 16 -2 24 10.9 432 21 16 16.6 21 10.0 24 11.9 24 15.4 24 13.4 4 17.0 23 1 440 232 332 432 010 64 Gas 50 35 20 380 10 17.6 16 11.3 10 9.6 16 18.0 10 16.7 14 10.4 4 12.7 4 7.8 29 7.7 020 230 220 1 30 220 32 1 210 310 1 33 275 84 185 28 174 190 290 261 82 40 7.8 40 5.0 24 9.7 14 11.2 14 15.0 16 20.5 10 16.5 224 1 34 1 32 31 1 22 1 030 220 (4) 95 75-93 223 102 56 115 Boiling Point (deg F) 104 (9) -11 176 89 190 242 43 213 154 179 680 480 - 680 270 339 212-320 424 411 626 457 - 475 237 {4) 213 249 - 269 460 300 258 318-329 DO A 0 4 4 6 8 1 CO NFIDENTIAL APPENDIX A COMPOUND Oleic Acid Pentamethylene Oxide Pentane Peracetic Acid Perchloric Acid Petroleum - Crude Phenoi 2-Picoline Polyethylene Polystyrene Foam Polystyrene Pellets Potassium (metal) Potassium Chlorate Potassium Nitrate Potassium Perchlorate Potassium Peroxide Propanal Propane 1,3-Propanediamine Proparpyl Alcohol Propargyl Bromide Proprionic Nitrile Propyl Acetate Propyl Alcohol Propylamine Propylbenzene Propylchloride Propylene MATERIAL FACTORS AND PROPERTIES MF 4 16 ' 21 40 29 16 10 10 10 16 10 24 14 29 14 14 16 21 16 29 40 16 16 16 16 16 16 21 He BTU/LB X 10A3 16.8 13.7 19.4 4.8 (2) 21.3 13.4 15.0 18.7 17.1 - (2) (2) - - 12.5 19.9 13.6 12.6 13.6 (7) 15.0 11.2 12.4 15.8 17.3 10.0 19.7 |1 NFPA Classification N(H) N(F) N(R) 0l0 23l 1 40 324 303 1 30 4 20 2 20 - -- - - 3 1 1 1 3 2 1 2 4 4 4 1 1 3 2' 2 1 - 3 0 0 0 0 3 4 3 3 3 3 3 3 3 3 3 4 - 2 1 3 1 1 1 0 0 3 4 1 0 0 0 0 0 1 Flash Point (deg F) 372 -4 <-40 105 - 20-90 175 102 NA NA NA - - -22 Gas 75 97 50 36 55 74 -35 86 <0 -162 Boiling 1 Point (deg F) 1 547 178 97 221 66(9) - 358 262 NA NA NA 1410 752 752 - (9) 120 -44 276 237 - 239 192 207 215 207 120 319 115 -54 DO A 0 4 4 6 8 2 CO NFIDFNTIAL m APPENDIX A COMPOUND Propylene Dichloride Propylene Glycol Propylene Oxide n-Propyl Ether n-Propyl Nitrate Pyridine Sodium Sodium Chlorate Sodium Dichromate Sodium Hydride Sodium Hydrosulfite Sodium Perchlorate Sodium Peroxide Stearic Acid Styrene Sulfur Chloride Sulfur Dioxide SYLTHERM* 800 SYLTHERM* XLT TELONE* II TELONE* C-17 Toluene Toluene 2,4-Di isocyanate Tributylamine 1,2,4-Trichlorobenzene 1,1,1 -Trichloroethane Trichloroethylene 1,2,3-Trichloropropane m MATERIAL FACTORS AND PROPERTIES He BTU/LB 11 NFPA Classification Flash MF X 10A3 N(H) N(F) N(R) Point (deg F) 16 6.3 230 60 4 9.3 010 210 24 13.2 342 -35 16 15.7 1 30 70 29 7.4 233 68 16 5.9 230 68 24 - 332 - 24 - 1 02 - 14 - 101 - 24 - 332 - 24 - 212 - 14 - 20 1 - 14 - 30 1 - 4 15.9 1 10 385 24 17.4 232 88 14 1.8 3 1 1 (5) 245 1 0.0 300 Gas 4 12.3 1 10 >320(10) 10 14.1 1 20 108 16 3.2 2 30 83 16 2.7 33 1 79 16 17.4 230 40 24 10.6 312 270 10 17.8 320 145 4 6.2 210 222 4 3.1 210 None 10 2.7 2 10 None 10 4.3 320 160 > Boiling Point (d g F) 205 370 94 194 230 240 1619 (4) (4) (4) (4) (4) (4) 726 293 280 14 398 345 220 200 232 484 417 415 165 189 313 APPENDIX A MATERIAL FACTORS AND PROPERTIES n bo -n o 5 3^ co He 1 BTU/LB NFPA Classifynation Flash Boiling COMPOUND MF X 10A3 N(H) N(F) N(R) Point (deg F) Point (deg F) Triethanolamine 14 10.1 21 i 354 650 Triethylaluminum Triethylamine Triethylene Glycol Triisobutylaluminum Triisopropylbenzene Trimethylaluminum Tripropylamine Vinyl Acetate Vinyl Acetylene Vinyl Ally! Ether 29 i 16 4 29 4 29 10 24 29 24 16.9 17.8 9.3 18.9 18.1 16.5 17.8 9.7 19.5 15.5 343 330 1 10 343 010 - 33 220 232 24 3 232 - 365 16 193 350 546 32 414 207 495 Ignites spontaneously in air 105 313 18 163 Gas 41 <68 153 Vinyl Butyl Ether Vinyl Chloride 4-Vinyl Cyclohexene Vinyl Ethyl Ether Vinylidene Chloride Vinyl Toluene p-Xylene 24 15.4 24 8.0 24 19.0 24 14.0 24 4.2 24 17.5 16 17.6 232 24 2 032 24 2 242 222 230 15 -108 61 <-50 0 125 77 202 7 266 96 89 334 279 Zinc Chlorate 14 (2) 101 - - Zinc Stearate [81 4 10.1 010 530 - Footnotes: The net Heat of Combustion (He) is the value obtained when the water formed in the combustion is considered to be in the vapor _ _staie. .When He isjjjyen injtcal/gmjnoje^ it ca_n_bejponyertedjo BTU/jbJby muh>Qt^ing_by_l_800_and_dividmg by molecular weighty (1) Vacuum distillation. 16] MF is packaged material. [2] Material oxidized to higher level of oxid; [7] He equivalent to 6 times heat of decomposition. (Hd) {3] Sublimes. [6] Evaluate as a dust. [4J Explodes on heating. [9] Decomposes. J5]_ Decomposes^in water.]10]_ After extended use_>_600 deq. FJhe flash point car^potentiaMy drop to_95 deg. _E_ Seta = Setaflash Method 7See NFPA 321) NA= Not Applicable TOC = fag Open Cup Method Other Rash Points determined by Tag Closed Cup Method (TCC). * Trademark of the Dow Chemical Company APPENDIX B________________________________________________________ SPECIAL MATERIAL FACTOR CONSIDERATIONS FOR MIXTURES The Material Factor (MF) has two components, flammability and reactivity, and represents the hazard of both. Once these two are established, the Material Factor can be determined, as described in the text and using Table 1, page 13. The selection of the significant material for determining the Material Factor can be a problem. Pure mate rials are straightforward. Problems arise when the process has a mixture of materials, particularly in batch reactors where many sequential reactions are done. For example, in a batch process where the composition changes during the batch cycle, it is valid to select the worst condition which normally occurs during the cycle. If there is a mixture of materials in a Process Unit with MFs of 10,16 and 24, usually the material with the highest MF, which is of significant concentration (about 5%), should be used as the basis for the MF. The best way to determine the MF of the mixture is to obtain the flash point, boiling point, DTA/DSC exotherm peak temperature of the mixture, thermal and mechanical shock sensitivity and water reactivity by reactive chemicals testing and to use the appropriate data to find MF from Table 1, page 13. The Reactive Chemicals program requires that the flash point, DTA/DSC and other pertinent data be obtained before scale-up. See Guidelinesfor a Reactive Chemicals Program, latest editioa Some examples of special Material Factor situations are: 1. Ethylene and Chlorine in an Ethylene Dichloride Reactor to Produce Ethylene Dichloride MF The material factor should be selected based on ethylene dichloride and not for ethylene or chlorine. Because the reaction is very fast between the ethylene and chlorine being sprayed into liquid ethylene dichloride, the reactor contains only ethylene dichloride. The hazard is ethylene dichloride in the reactor. 2. Ethane Cracked in a Furnace to Make Ethylene - The material factor for ethylene should be used. The most likely leak of contents is a mixture of ethane and ethylene, with the ethylene content signifi cant enough to make the mixture much like ethylene in its reactivity. 3. Continuous Benzene Alkylation Reactor - The feed streams to the reactor are ethylene (MF = 24) and benzene (MF = 16), while the bulk of inventory in the reactor is ethyl benzene (MF - 16). There is a minimum of unreacted ethylene present in the reactor. The recommended material factor of use is 16. Although this process involves the potential for release of an ethylene vapor cloud external to the reactor, there is no connection between this and penalty factors applied for conditions in the reactor. It would be wise to consider something in the ethylene feed system as a separate Process Unit and calculate the F&EI for the feed system Process Unit to determine the worst case. 4. Polyol Reactor (Batch Process) - The initial charge to the reactor is glycerine (MF = 4). Propylene oxide (MF = 24) and/or ethylene oxide (MF = 29) are added progressively during the batch and react with the glycerine to form the polyol (MF = 4). The reaction depends on the addition of catalyst. If there is a significant chance that none or insufficient catalyst may be added to the reactor, a Material Factor of 29 is appropriate. When ethylene oxide alone is used, it reacts relatively quickly, when catalyst is present, so that there are oily small amounts of unreacted ethylene oxide present in the reactor at any time: hence, the reactor MF = 4. However, the propylene oxide reaction is slower and there may be up to about 15% of unreacted propylene oxide present at sane stage. The suggested material factor, then, for the F&EI calculation is the factor for the worst case reaction mixture containing 15% propylene oxide (MF = 24). DO A 044684 72 CONFIDENTIAL za A P P E I X It This is a typical case where it is not appropriate to take a weighted average of factors for individual components in determining the factor for the mixture. This is due to the wide disparity in the properties of components and the high molecular weight of the polyol. It is necessary to consider the actual properties of the mixture which arc equivalent to Np = 3 and Nr = 2 for a material factor of 24. This compares with a value of about 6.6 which would be wrongly obtained as a weighted average factor. If the properties of the mixture are not known, the approach taken in 3. above may be appropriate while awaiting results of reactive chemicals testing of the mixture. 5. Electrolytical Production of Chlorine - Electrolytic production of chlorine presents the need for an atypical approach. The process is endothermic and not theoretically hazardous; the hazards present are due to the presence of flammable hydrogen and reactive chlorine. The MF for hydrogen would be correct for this evaluation, as the MF for hydrogen is the higher. 6. "Burner-Type" Reactor - When feeding two reactants continuously, such as in burners, consider the "burner-type" reactor. An example is an HQ (hydrogen chloride) synthesis reactor, which, as a Proc ess Unit reacts hydrogen with chlorine but normally contains oily HD, a completely non-reactive and non-combustible gas (MF - 1). However, the slightest upset can result in flameouts and reaction ceases, resulting in the Process Unit filling with reactants. The explosion hazards of HD synthesis reactors are so well known that they are always provided with explosion relief. MF should be based on the higher MF of the two reactants, hydrogen (MF = 21) and chlorine (MF = 1); that is, the MF should be 21. Fired boilers and furnaces are subject to flameout and explosive re-ignition of the reactants, fuel and air. They should be treated similarly to the example in the previous paragraph. 7. Mixtures with Mostly Water Composition - If a mixture is mostly water, consider carefully the condition of the water in determining the "material factor" to avoid an unrealistically low value. For example, water saturated with butadiene will have a true flash point equal to that of butadiene but will not have a DTA/DSC exotherm. The vapor above such water is mostly butadiene. Thus Np= 4 and Nr = 0 for the vapor space and therefore MF - 21. In summary, the Process Unit should be examined over its cycle of operation for the most hazardous state. This most hazardous state is when the worst possible materials may escape from or exist in the process equipment during normal starting up, operating or shutting down. 73 DO A 0446.85 CONFIDENTIAL APPENDIX C________________________________________________ BASIC PREVENTIVE AND PROTECTIVE FEATURES Many of the features below should be provided regardless of the type of operation or the magnitude of die Fire and Explosion Index. When they are not provided, the existing hazard exposure may be greater than the F&EI indicates. This list is not all-inclusive as other features may be needed, depending upon the specific installation. A. Adequate water supply for fire protection. This is determined by multiplying its water demand by the length of time that the worst possible fire can be expected to last. The supply deemed adequate will vary with different authorities and may range from enough for a two-hour fire to enough for one lasting eight hours. (See Loss Prevention Principle (LPP) 45.) B. Structural design ofvessels, piping, structural steel, etc. C. Overpressure relief devices. (See LPP 14.3) D. Corrosion resistance and/or allowances. E. Segregation of reactive materials in process lines and equipment F. Electrical equipment grounding. G. Safe location of auxiliary electrical gear (transformers, breakers, etc.) (See LPP 3.5) H. Normal protection against utility loss (alternate electrical feeder, spare instrument air compressor, etc.) I. Compliance with various applicable codes (ASME, ASTM, ANSI, Building Codes, Fire Codes, etc.) J. Fail-safe instrumentation. (See LPP 15.2) K. Access to area for emergency vehicles and exits for personal evacuation. (See LPP 2.3) L. Drainage to handle probable spills safely plus fire fighting water from hose nozzles and sprinkler heads and/or chemicals. (See LPP 2.4) M. Insulation of hot surfaces that heat to within 80% of the autoignition temperature of any flammable in the area. N. Adherence to the National Electrical Code. The Code should be followed except where variances have been requested/approved. (See LPP 3.1) O. Limitation of glass devices and expansion joints in flammable or hazardous service. Such devices are not permitted unless absolutely essential. Where used, they must be registered and approved by the production manager and installed in accordance with Dow standards and specifications. (See LPP 6.9) P. Building and equipment layout. Separation of high-hazard area must be recognized especially as it relates to both property damage and interruption of business. Separation of tanks must be at least in accordance with NFPA 30. (See LPP 2.2) Q. Protection of pipe racks and instrument cable trays as well as their supports from exposure to fire. (See LPP 3.2) R. Provision of accessible battery limit block valves. S. Cooling tower loss prevention and protection. (See LPP 6.1) T. Protection of fired equipment against accidental explosion and resultant fire. (See LPP 13.1-13.4) U. Electrical classification. Division 2 electrical equipment will be required for outside flammable liquid handling where congestion is minimal and natural ventilation is unobstructed. Division 1 equipment is required only for special chemicals and/or special building or process handling conditions or where ventilation is inadequate. (See LPP 3.1) V. Process control rooms shall be isolated by one hour fire walls from process control laboratories and/or electrical switch-gear and transformers. (See LPP 12.2) W. A process review shall determine a need for reactive chemicals testing. (See Guidelines For A Reac tive Chemicals Program.) X. A HAZOP review is recommended in high hazard areas. DO A 044686 CONFIDENTIAL 74 APPENDIX D LOSS PREVENTION CHECKLIST 1. Scope This checklist outlines most engineering topics needing consideration for possible loss prevention requirements. Such topics include: Location, Buildings, Fire Protection, Electrical, Sewers, Storage, Inert Gas Blanketing, Materials Handling, Machinery. Process, Process Computers, and General Safety Equipment 2. Introduction This checklist is intended as a guide for use when assessing the fire hazards and reviewing the loss prevention requirements of a chemical plant It may also be of particular advantage in planning new facilities. No such'checklist can ever be entirely complete or meet the needs of every situation. Care should be taken in using such a list to make sure that other pertinent items not included here are not overlooked. 3. Location A. Plant layout; separation of units per hazard evaluation B. Accessibility C. Traffic - vehicular and pedestrian D. Parking areas - entrances, exits, drainage, lighting, enclosures E. Clearances - buildings for railroad traffic and vehicles (overhead turnarounds) F. Drainage, impounding areas G. Road locations, markings H. Entrances, exits - pedestrian, vehicular, and railroad I. Ignition sources - furnace location, flare stacks, boilers, burner management J. Prevailing wind K. Underground utility conduits L. Flood control or protection M. Loading/unloading facilities, avoid using main traffic area for this activity 4. Buildings A. Basic non-combustible construction B. Wind pressure, snow loads, floor loads, earthquake design C. Roof material, anchorage D. Roof vents and drains, smoke dispersal F. Stairwells, ramps, lighting F. Elevators and dumbwaiters G. Fire walls, openings, fire doors H. Explosion relief, blast design I. Exits - fire escapes, identification, safety treads J. Record storage K. Ventilation - fans, blowers, air conditioning, scrubbing of toxic vapors, location of exhaust inlets, smoke and heat ventilation dampers, fire curtains L. Lightning protection, structural and equipment grounding for electrical discharges M. Building heaters (Division 1 or 2 or standard areas'), vents N. Locker rooms including need for separate lockers for work and street clothes, required number of each and air changes O. Building drainage - inside and out, property trapped DO A 044687 CONFIDENTIAL 75 P. Structural steel and equipment fireproofing Q. Access ladders to roofs and outside level, escape ladders, fire escapes R. Bearing capacity of subsoil S. Heat and smoke detection T. Elevation - flood plain restrictions U. Wheel load on overhead crane 5. Fire Protection A. Water supply including secondary supplies, pumps, reservoirs and tanks B. Mains - adequate looping, cathodic protection, coated and wrapped when needed, sectional valves C. Hydrants - location, spacing, monitors D. Automatic sprinklers - occupancy classification, wet systems, dry systems, deluge systems E. Standpipes and tanks F. Type, size, location and number of fire extinguishers needed G. Fixed automatic extinguishing systems, CO2, foam, dry powder H. Special fire protection systems - rise in temperature alarms, sprinkler system flow alarms, photo electric smoke and flame alarms, snuffing steam I. Piping system - materials of construction, no cast iron if explosion is possible 6. Electrical A. Electrical hazard area classifications, intrinsically safe equipment B. Accessibility of critical circuit breakers and switchgear C. Polarized outlets and grounded systems D. Switches and breakers for critical equipment and machinery E. Lighting - Division 1 or 2 or standard areas, light intensity, approved equipment, emergency lights F. Telephones and intercoms - Division 1 or 2 or standard areas G. Type of electrical distribution system - voltage, grounded or ungrounded, overhead, underground H. Conduit, raceways, enclosures, corrosion considerations I. Motor and circuit protection J. Transformer location and types K. Fail safe control devices protection against automatic restarting L. Backup busses for critical loads M. Key interlocks for safety and proper sequencing, duplicate feeders N. Ughtran^protection O. Exposure of cable trays to fire damage P. Uninterruptible Power Supply (UPS) and emergency power system Q. Requirements for equipment grounding, methods and frequency of testing 7. Sewers A. Chemical sewers - trapped, accessible cleanouts, vents, locations, disposal, explosion possibili ties, trap tanks, forced ventilation, flammable vapor detectors and alarms, freezing or ice blocks B. Sanitary sewers - treatment, disposal, traps, plugs, cleanouts, vents C. Storm sewers D. Waste treatment, possible dangers from steam contamination including fire hazard from spills into streams and lakes E. Drain trenches - open, buried, accessible cleanouts, presence of required baffles, exposure to process equipment F. Ground water impairment prevention, air and surface water safeguards and proper disposal of waste G. Sewer drains connected to process drains QO A 044688 CONFIDENTIAL 76 8. Storage A. General 1. Accessibility - entrances and exits, sizes 2. Sprinklered 3. Aisle space 4. Floor loading 5. Racks and spacing 6. Height of piles 7. Roof venting 8. Spill containment 9. Adequate tank venting for both pressure and vacuum B. Flammable liquids - gases, dusts and powders, fumes and mists 1. Closed systems 2. Safe atmospheres throughout system 3. Areas to be sprinklered or provided with water spray 4. Emergency vents, flame arresters, relief valves, safe venting location including flares 5. Floor drains to chemical sewers properly trapped 6. Ventilation - pressurized controls, etc., and/or equipment 7. Tanks, bins, silos - safe distance separation, fireproofing supports or local deluge protection, dikes and drainage, inerting atmospheres, underground (not recommended) 8. Special extinguishing systems, explosion suppression - foam, dry chemicals, carbon dioxide 9. Dependable refrigeration systems for critical chemicals 10. Location of pumps, compressors, etc., away from spill potential 11. Weak roof seam construction on API tanks 12. Cross venting of source tanks and storage tanks C. Raw Materials 1. Danger of risk classification of material including shock sensitivity 2. Facilities for receiving and storing 3. Identification and purity tests 4. Provisions to prevent materials being placed in wrong tanks, tank overflow, etc. D. Finished Products 1. Identification and labeling to protect the customer 2. Conformance with shipping regulations 3. Segregation of dangerous materials 4. Protection from contamination, especially in the filling of tank cars and tank trucks 5. Placarding of shipping vehicles 6. Routing of dangerous shipments 7. Material Safety Data Sheets (MSDS) for safety information for customers 8. NFPA Hazard Ratings 9. Heat detection 10. Conveyers and their location in production areas 11. Flammable liquid storage - paints, oils, solvents 12. Reactive or explosive storage - quantities, distance separation, limited access 13. Disposal of wastes - incinerators, air and water pollution safeguards 14. Spill control 15. Safe shipping containers D0 A 044689 CONFIDENTIAL 77 9. Inert Gas Blanketing of All Flammable Products A. Consider raw material, intermediates and products B. Consider storage, materials handling and processes 10. Materials Handling A. Truck loading and unloading facilities B. Railroad loading and unloading facilities C. Industrial trucks and tractors - gasoline, diesel, liquefied petroleum gas, and battery powered D. Loading and unloading docks for rail, tank trucks, and truck trailer grounding systems for flammable liquids E. Cranes - mobile, capacity marking, overload protection, limit switches, inspection schedules F. Warehouse area - floor loading and arrangement, sprinklers, height of piles, ventilation, smoke and heat detection G. Conveyors and their location in production areas H. Flammable liquid storage - paints, oils, solvents I. Reactive or Explosive storage - quantities, distance separation, limited access J. Disposal of wastes - incinerators, air and ground water safeguards K. Spill control 11. Machinery A. Accessibility, maintenance and operations B. Remote emergency stop switches C. Vibration monitoring/shutdown D. Lubrication monitoring E. Overspeed protection F. Noise evaluation G. Do not use cast iron or other brittle construction materials on: 1. Hazardous materials 2. Equipment load bearing parts (e.g., pump casing frames) 12. Process A. Chemicals - fire and health hazards (skin and respiratory), instrumentation, operating rules, maintenance, compatibility of chemicals, stability, labeling of pipelines and equipment, etc. B. Critical pressures and temperatures C. Reliefdevices and flame arresters, properly registered D. Coded vessels made of suitable materials of construction E. Piping made to suitable specifications and codes and materials of construction F. Methods for handling runaway reactions G. Fixed fire protection systems - CO2, foam, sprinkler deluge H. Vessels properly vented, safe location, deadhead pump protection I. Permanent vacuum cleaning systems J. Explosion barricades and isolation K. Inert gas blanketing systems - listing of equipment requiring blanketing L. Emergency shutdown valves and switches, location from critical area, action time for relays, emergency block valves M. Fireproofing of structural steel beams and columns (or area deluge protection) N. Safety devices for heat exchange equipment - vents, valves and drains O. Expansion loops for steam lines P. Do not use expansion joints unless not alternative - register and maintain Q. Do not use sight glasses - if absolutely necessary register and maintain A 044690 CONFIDENTIAL 78 R. Steam and electrical tracing - provision for relief of thermal expansion in heated lines S. Insulation for personnel protection - hot process, steam lines and tracing - overheating protec tion of material in pipe T. Static grounding for vessels, piping and production equipment U. Geaning and maintenance of vessels and tanks - adequate manholes, platfoims, ladders, dean- out openings and safe entry permit procedures V. Provisions for corrosion monitoring and control W. Pipeline identification X. Radiation problems including personal protection for firefighters - processes and measuring instruments containing radioisotopes. X-rays, etc. Y. Redundant critical instruments with alarms, fail safe operation Z. Critical instrument designation and maintenance AA. Fixed flammable gas detection and alarm systems 13. Process Computers A. Control Room 1. Air handling - temperature, humidity, dust, positive pressure, etc. 2. Location - ground floor preferred, non-combustible construction 3. Floor covering - vinyl or laminated plastic to prevent static 4. Space requirements for accessibility 5. No paper or combustibles storage 6. Lighting and power receptacles 7. Fire protection - use CO2. smoke detectors, heat detectors 8. Purged control room B. Power Wiring and Grounding 1. Adequate power supply from special panel 2. Dual sources of power 3. Computer control system grounded at source, i.e., at step down transformer 4. Control room junction boxes connected to building ground C. Signal Wiring 1. Held wiring terminated in a control junction box or other interface device 2. Wiring protected by cable tray, metal wireway, conduit or run below raised floor 3. Ribbon cables or similar type fragile cables run in separate enclosure from field cables D. Control Systems 1. Fail safe conventions 2. Policies on parameter changes and manual control of outputs or input 3. Policies on control strategy changes and backup of current strategy 4. Documentation - inputs and outputs, operating discipline and control logic diagrams 5. Shutdown procedures for loss of utilities 6. Training 7. Alarm system 8. Regular audits 9. Control room integrity and location 10. Source of power for process controllers 11. Backup control systems DO A 044691 CONFIDENTIAL 79 14. Safety Equipment, General A. Dispensary and equipment B. Ambulance C. Fire truck D. Emergency alarm system - alert, gas release, evacuate, etc. E. Fire whistle and siren-departments, inside and outside F. Snow removal and ice control equipment G. Safety showers and eye wash fountains - operational alarms, indication of location H. Safety ladders and cages I. Emergency equipment locations - gas masks, protective clothing, inside hose streams, stretchers, flash suits, self-contained breathing apparatus, etc. J. Laboratory safety shields K. Instruments - continuous, portable analyzers for flammable vapors and gases, oxygen, toxic vapors, etc. L. Communications - emergency telephones, radio, public address systems, paging systems, safe location and continuous manning of communication center M. Guards on rotating equipment N. Combustion safeguards on furnaces, burner management system (see LPP 13.1) O. Fuel gas shutoff valves P. Spill/vapor release alarms Q. Flange protectors on acid lines DO A 044A92 CONFIDENTIAL 80 APPENDIX E EQUATIONS FOR DAMAGE FACTOR DATA The Damage Factor is to be determined using Figure 8, page 53. This data is different from the data in the other figures in this report inasmuch as the data was fit to equations giving the damage factors at Process Unit Hazards Factors from 1.0 to 8.0 for each of the discrete Material Factors. Since there are nine Material Factors - 1,4,10,14,16,21,24,29, and 40 - there are nine equations. It is important to note that there really is no meaning for the intermediate Material Factors other than the nine defined cases. The data points were joined by lines solely for the purpose of allowing it to be easier to follow along the lines of constant Process Unit Hazards Factors. The main value of this figure is to allow for the interpolation of the Damage Factors between different values of the Process Unit Hazards Factors. The nine equations derived for the nine Material Factors are as follows: For the Material Factor of 1 the equation for the Damage Factors (Y axis) based cm the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.003907 + 0.002957(X) + 0.004031CX2) - 0.00029(X3) or Y = 0.003907 + 0.002957*X + 0.004031*XA2 - 0.00029*XA3 For the Material Factor of 4 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.025817 + 0.019071(X) - 0.00081CX2) + 0.000108CX3) or Y = 0.025817 + 0.019071 *X - 0.00081*XA2 + 0.000108*XA3 For the Material Factor of 10 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.098582 + 0.017596(X) + 0.000809CX2) - 0.000013CX3) or Y = 0.098582 + 0.017596*X + 0.000809*XA2 - 0.000013*XA3 For the Material Factor of 14 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.20592 + 0.018938(X) + 0.007628CX2) - 0.00057CX3) or Y = 0.20592 + 0.018938*X + 0.007628*XA2 - 0.00057*XA3 For the Material Factor of 16 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.256741 + 0.019886(X) + O.OllOSSfX2) - 0.00088(X3) or Y = 0.256741 + 0.019886*X + 0.011055*XA2 - 0.00088*XA3 81 OO A 44693 OONFtdF^rr al For the Material Factor of 21 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from l through 8 is as follows: Y = 0.340314 + 0.076531(X) + 0.003912CX2) - 0.00073(X3) or Y = 0.340314 + 0.076531*X + 0.003912*XA2 - 0.00073*XA3 For the Material Factor of 24 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.395755 + 0.096443(X) - 0.00135(X2) - 0.00038(X3) or Y = 0.395755 + 0.096443*X - 0.00135*XA2 - 0.00038*XA3 For the Material Factor of 29 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors .from 1 through 8 is as follows: ' Y 0.484766 + 0.094288(X) - 0.00216CX2) - 0.0003l(X3) or Y = 0.484766 + 0.094288*X - 0.00216*XA2 - 0.00031*XA3 For the Material Factor of 40 the equation for the Damage Factors (Y axis) based on the Process Unit Hazards Factors from 1 through 8 is as follows: Y = 0.554175 + 0.080772(X) + 0.000332CX2) - 0.00044(X3) or Y = 0.554175 + 0.080772*X + 0.000332*XA2 - 0.00044*XA3 The equations are given in both word processing format and text format For reading this guide in text format only, the figures and the word processing format equations will not appear. However, the equation in text format will allow determination of the Damage Factor. D0 A 044694 82 confidential APPENDIX F ACRONYMS AND ABBREVIATIONS ACV AIChE ANSI API ARC ASME ASTM BI BTU CEI DRI DSC DTA EBV F&EI FMEA HAZOP LPG LPP MF MPDO MPPD MSDS NFPA QRA SI S/LP/S STP UPS US/British Units VPM Actual Cash Value American Institute of Chemical Engineers American National Standards Institute American Petroleum Institute Accelerating Rate Calorimeter American Society of Mechanical Engineers American Society for Testing and Materials Business Interruption British Thermal Unit Chemical Exposure Index Distribution Ranking Index Differential Scanning Calorimeter Differential Thermal Analysis Emergency Block Valve Fire and Explosion Index Failure Mode and Effect Analysis HAZard and OPerability Study Liquefied Petroleum Gas Loss Prevention Principle Material Factor Maximum Probable Days Outage Maximum Probable Property Damage Material Safety Data Sheet National Fire Protection Association Quantitative Risk Assessment International System of Units (Le Systeme International d'Unites) Safety/Loss Prevention/Security Standard Temperature and Pressure Uninterruptible Power Supply United States/British Units Value of Production for the Month DO A 044695 CONFIDENTIAL 83 CORPORATE SAFETY, LOSS PREVENTION, AND SECURITY PUBLICATIONS Minimum Requirements Minimum Requirements for S/LP/S June 1989 Guidelines Guidelines for A Contractor Safety, Loss Prev., & Security Program, 2nd Edition Guidelines for Safety, Loss Prevention and Security Audits, 3rd Edition Guidelines for Office Safety, Loss Prevention and Security, 2nd Edition Guidelines for Emergency Planning Guidelines for A Motor Vehicle Accident Prevention Program, 3rd Edition Guidelines for Safety on Non-Dow Premises (Reprinted OcL 1988) Guidelines for S/LP/S Reporting, 5th Edition Guidelines for Root Cause Incident investigation Fire and Explosion Index Hazard Classification Guide, 7th Edition Guidelines for Public Warehouse Rating & Risk Analysis Distribution Emergency Response Process2 Air Travel - Policy and Guidelines (Reprinted Jan. 1989) Guidelines for Safe Sample Shipping, 3rd Edition Guidelines for A Reactive Chemicals Program, 2nd Edition Guidelines for Handling Dow Proprietary Information, 2nd Edition Guidelines for Personal Safety & Security at Hotels/Motels and Other Off-Premises Facilities (Reprinted Nov. 1988) Guidelines for Determining Dust Hazard Potential Guidelines For Assessing Potential Acquisitions, 2nd Edition Program Requirements For Hearing Conservation1 Basic Requirements for an Industrial Hygiene Program3 Chemical Exposure Index Guide, 2nd Edition Chemical Hazard Engineering Guidelines Environmental Protection Guidelines for Operations Loss Prevention Self-Inspection Guideline Program Requirements for Respiratory Equipment1 Program Requirements and Guidelines for Research and Development Facilities or Support Laboratories3 Guidelines for Burner Management Systems for Boilers and Process Furnaces Global Hazardous Materials Distribution Guidelines4 Guidelines for Management of Change Program Requirements for Personal Protective Equipment1 Program Guidelines for Ergonomics and Ergonomic Program Guideline Resource Document1 Guidelines for Chemical Labeling (for the U.S. Area)5 Guidelines for Confined Space Entry Process Risk Management Guidelines for Facilities and Distribution January 1992 November 1989 April 1988 September 1985 May 1992 December 1980 June 1990 February 1993 January 1994 January 1990 1991 April 1980 June 1992 January 1987 March 1991 July 1981 October 1989 July 1992 July 1992 August 1987 September 1993 1993 1990 February 1991 October 1990 May 1991 June 1993 March 1991 February 1992 March 1992 September 1992 May 1992 June 1993 January 1994 Practices Loss Prevention Principles Loss Prevention Principles - Abstracts Operations Practices Biannuafly Biannually April 1990 Others Dow Safety Improvement System (DSIS) Dow Safety Improvement System User's Guide Fundamentals of Fire and Explosion - By Daniel R. Stull Topical Index of S&LP Standards & Specifications S&LP Audio/Visual Listing The Office Safety Handbook Security...In The Office & Data Handling Areas October 1991 April 1992 October 1986 September 1990 1977 1983 Publications Available from: Corporate Safety, Loss Prevention, and Security 2030 Dow Center - Midland, Ml (517) 636-3358 or -6821 DO A 044696 CONFIDENTIAL 10ccupational Health Guide 2US Area Distribution Guide industrial Hygiene Guide 4Corp. Product Dept. Guide 5Health and Environmental Sciences CHEC 01/94 LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (Ci) .98 f) Inert Gas .97 to .99 g) Operating Instructions/ .84 to .98 Procedures .96 to .99 h) Reactive Chemical Review .93 to .99 Ci Total * .94 to .96 .91 to .99 .91 to .98 a) Remote Control Valves b) Dump/Blowdown 2. Material Isolation (C2) .96 to .98 .96 to .98 c) Drainage d) Interlock C2 Total .91 to .97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply a) Special Systems 3. Fire Protection (C3) .94 to .98 .95 to .98 .84 to .91 .94 to .97 .91 0 Sprinkler Systems g) Water Curtains h) Foam i) Hand Extinguishers/Monitors j) Cable Protection C3 Value .74 to .97 .97 to .98 .92 to .97 .95 to .98 .94 to .98 Credit Factor - Ci X C2 X C3 =Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) ----------------------------------------- $MM-------------------------------------------------------------------- $MM--------------------------------------- ---------------------------- $MM-------------------------------------------------------------------------------------- ^ays, $MM---------------------------------------- ------ Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) w2 DO A 044697 CONFIDENT^ LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (C,) .98 .97 to .99 .84 to .98 .96 to .99 .93 to .99 0 Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review C, Total 1 .94 to .96 .91 to .99 .91 to .98 a) Remote Control Valves b) Dump/Blowdown 2. Material Isolation (C2) .96 to .98 .96 to .98 c) Drainage d) Interlock C2 Total 1 .91 to .97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .94 to.98 f) Sprinkler Systems .95 to.98 g) Water Curtains .84 to.91 h) Foam .94 to.97 i) Hand Extinguishers/Monitors .91 j) Cable Protection C3 Value .74 to .97 .97 to .98 .92 to .97 .95 to .98 .94 to .98 Credit Factor = C, X C2 X C3 =Enter on Line D Below UNIT ANALYSIS SUMMARY A-1.F&EI A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) ---------------------------------------- ^ $MM--------------------------------- --------- ---------------------- $MM----------------------------------------- -- ---------------------- $MM --- ------- --------------------------------------------------------------------------- $MM----------------------------------------------- 'Product of all factors used. BACK OF FORM C-22380 R-**7 (471 -036) W2 oo A 044698 CONFIDENTIAL. FIRE & EXPLOSION INDEX AREA/COUNTRY Kio Q-tugr>1 COL SITE DIVISION LA-O MANUFACTURING UNIT LOCATION PROCESS UNIT PREPARED BY: APPROVED BY: (Superintendent) REVIEWED BY: (Management) REVIEWED BY: (Technology Caniar) DATE L+* l\~r ( ^ lc I-IICO BUILDING t S Cl REVIEWED BY: (Safaty & Loss Pravantlon) MATERIALS IN PROCESS UNIT ?oc STATE OF OPERATION ___ DESIGN ___ STARTUP i/NnoOrRmMALOPSIATION SHUTDOWN BASIC MATERIALS) FOR MATERIAL FACTOR MATERIAL FACTOR (See Table 1 or Appendices A or B) Note requirements when unit temperature over 140 F (60 C) \<> 1. General Process Hazards Penalty Fac Penalty Ft tor Range tor Usedi Base Factor..................................................................................................... A. Exothermic Chemical Reactions B. Endothermic Processes C. Material Handling and Transfer D. Enclosed or Indoor Process Units E. Access F. Drainage and Spill Control _ fn ^ Go- a aal or cu.m. 1.00 0.30 to 1.25 0.20 to 0.40 0.25 to 1.05 0.25 to 0.90 0.20 to 0.35 0.25 to 0.50 1.00 -- -- -- -- ----. e. so General Process Hazards Factor (Fit ... ......................................................................... I.SO 2. Special Process Hazards Base Factor..................................................................................................... A. Toxic Material(s) = B. Sub-Atmospheric Pressure (< 500 mm Hg) C. Operation In or Near Flammable Range . `-"Inerted _ Not Inerted 1. Tank Farms Storage Flammable Liquids 2. Process Upset or Purge Failure 3. Always in Flammable Range D. Dust Explosion (See Table 3) E. Pressure (See Fiaure 21 ODeratina Pressure -- 1 DSia or kPa aauqe Relief Settina 5o Dsia or kPa gauge F, Low Temperature G. Quantity of Flammable/Unstable Material: QuantitvfoTCOlb or ka Hr: = k. 3>t6Tl3/lb or kcal/kg 1.00 0.20 to 0.80 0.50 0.50 0.30 0.80 0.25 to 2.00 o. Z5 0.20 to 0.30 1.00 O-MC O* Sc -- -- ----- - 13 f. Liquids or Gases in Process (See Figure 3) 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion 1. Leakage - Joints and Packing J. Use ot Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 5) L Rotating Equipment 0.10 to 0.75 0.10 to 1.50 0.15 to 1.15 0.50 a -- ----e--------- ------------ Soecial Process Hazards Factor (Fo) ..................................................................................... "2 , PmhASS llnli H979nt Factor (Fi y Fol - Fi ........ > ^ .......... ............................... 3.2.7 Fire and Fxol Si n Index (Fq y MF - F&EI1......................................................................... <5-2- FORM C-22360 HanDI-M (471-00036) (1) For no penalty use 0.00. 5 DO A 044699 CONFTDENTTAL LOSS CONTROL CREDIT FACTORS 1. Process Contr I Credit Factor (Ci) Feature a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Factor Range 0.98 0.97 to 0.99 0.84 to 0.98 0.96 to 0.99 0.93 to 0.99 Credit Factor Used(2) 1 l l \ 0,^7 Feature f. Inert Gas g. Operating tnstructions/Procedures h. Reactive Chemical Review i. Other Process Hazard Analysis Ci Valueo) 2. Material isolation Credit Factor {C2) O n<z~i Feature a. Remote Control Valves b. Dump/Blowdown Credit Factor Range 0.96 to 0.98 0.96 to 0.98 Credit Factor U$ed(2> O \ Feature c. Drainage d. Interlock Credit Fact r Rang 0.94 to 0.96 0.91 to 0.99 0.91 to 0.98 0.91 to 0.98 Credit Factor Range 0.91 to 0.97 0.98 3. Fire Protection Credit Factor (C3) Feature a. Leak Detection Credit Factor Range 0.94 to 0.98 b. Structural Steel 0.95 to 0.98 c. Fire Water Supply 0.94 to 0.97 d. Special Systems 0.91 e. Sprinkler Systems 0.74 to 0.97 C2 Value(3) O. clh Credit Factor Used(2) \ O1 G . Ft "7 Feature f. Water Curtains g. Foam h. Hand Extinguishers/Monitors I. Cable Protection C3Value(3) I Q Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Used(2) I. 0*^1 i l1 Credit Factor Used{2) 1 Credit Factor Used(2) l f _- Loss Control Credit Factor = C-i X C2 X C3(3) = |Q.(f 1 (Enteron line 7 below) PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire & Explosion Index (F&EI)......................... (See Front) 2. Radius of Exposure.............................................(Figure 7) ftorm 3. Area of Exposure................................................................. ft2orm2 4. Value of Area of Exposure........................................................................................................ $MM 5. Damage Factor................................... ............... (Figure 8) 6. Base Maximum Probable Property Damage - (Base MPPD) [4 x 5J.................................... SMM 7. Loss Control Credit Factor..............................(See Above) Q , lc Cj 8. Actual Maximum Probable Property Damage - (Actual MPPD) (6x7)................................ $MM 9. Maximum Probable Days Outage - (MPDO)..... (Figure 9) days 10. Business Interruption - (Bl).................................................................................. .................. $MM (2) For no credit factor enter 1.00. (3) Product of all factors used. Refer to Fire & Explosion Index Hazard Classification Guide (Form #471 -00001) for details. 6 DO A 044700 3ACX OF FORM C-2S3B0 Rwl01-M (471-00036) c0nftoent^l FIRE & EXPLOSION INDEX AREA/COUNTRY STTE PREPARED BY; r%CC. DIVISION LOCATION DATE i-AQ MANUFACTURMQ UNIT PROCESS UNIT 4- /ti <Z> 1 q CO l | pod- -p- (COO APPROVED BY: (Superintendent) BUILDING KpruAca-- t 4 L<l>v- REVIEWED BY: (Management) - REVIEWED BY: (Technology Center) REVIEWED BY: (Sefety A Loss Prevention) MATERIALS IN PROCESS UNIT PP<D - eP"X STATEJJF OPERATION DCiPE BASIC MATERIAL^) FOR MATERIAL FACTOR JCdESWN ___STARTUP ___NORMAL OPERATION ___SHUTDOWN P DC MATERIAL FACTOR (See Table 1 or Appendices A or B) Note requirements when unit temperature over 140 F (60 C) 1. General Process Hazards Penalty Factor Range V (0 Penalty Factor Used(i) Base Factor............... A. Exothermic Chemical Reactions B. Endothermic Processes C. Material Handling and Transfer D. Enclosed or Indoor Process Units E. Access F. Drainage and Spill Control t-t rv v- Pv e aal or cu.m. 1.00 0.30 to 1.25 0.20 to 0.40 0.25 to 1.05 0.25 to 0.90 0.20 to 0.35 0.25 to 0.50 General Process Hazards Factor (FO..................................................................................... 2. Special Process Hazards Base Factor............... A. Toxic Material(s) NW* 2 B. Sub-Atmospheric Pressure (< 500 mm Hg) C. Operation In or Near Flammable Range Inerted ___ Not Inerted 1. Tank Farms Storage Flammable Liquids 2. Process Upset or Purge Failure 3. Always in Flammable Range D. Dust Explosion (See Table 3) E. Pressure (See Figure 2) Operatina Pressure -- 7 psia or kPa aauae Relief Settina 5 O psia or kPa aauae F. Low Temperature G. Quantity of Flammabie/Unstable Material: Quantity'1 T*alborkg 1. Liquids or Gases in Process (See Figure 3) Hr. = L ,7> BTU/lb or kcal/ka p-VCi 2. Liquids or Gases in Storage (See Figure 4) 3. Combustible Solids in Storage, Dust in Process (See Figure 5) H. Corrosion and Erosion 1. Leakage - Joints and Packing J. Use of Fired Equipment (See Figure 6) K. Hot Oil Heat Exchange System (See Table 5) L. Rotating Equipment 1.00 0.20 to 0.80 0.50 0.50 0.30 0.80 0.25 to 2.00 .& 0.20 to 0.30 0.10 to 0.75 0.10 to 1.50 0.15 to 1.15 0.50 1.00 .-- * -- --- 0 -so i . ?sc 1,00 C.M 0.50 -- --.-- -- -- ----- -------- --------- , -- Special Process Hazards Factor (F2)........................................................................................ ................ "2 . Process Unit Hazards Factor (Fi x F2) = F3......... Fire and Explosi n Index (F3 x MF s F&EI).......... 62. FORM C-22360 Rev/01-*i (471-0X08) (1) For no penalty use 0.00. 5 [30 A 044701 CONFIDENTIAL LOSS CONTROL CREDIT FACTORS 1. Process Contr I Credit Factor (C^ Feature a. Emergency Power b. Cooling c. Explosion Control d. Emergency Shutdown e. Computer Control Credit Fact r Range 0.98 0.97 to 0.99 0.84 to 0.98 0.96 to 0.99 0.93 to 0.99 Credit Fact r Used(2) 1 1 1 0.il Feature f. Inert Gas Credit Factor Range 0.94 to 0.96 g. Operating Instructions/Procedures 0.91 to 0.99 h. Reactive Chemical Review 0.91 to 0.98 i. Other Process Hazard Analysis . 0.91 to 0.98 Credit Factor Used(2j i | ' ! 0,ei\ o .on 2. Material Isolation Credit Factor (C2) Feature a. Remote Control Valves Credit Factor Range 0.96 to 0.98 b. Dump/Blowdown 0.96 to 0.98 Ci Value<3) On<z-i Credit Factor Used(2) 0.lb i \ Feature c. Drainage d. Interlock Credit Factor Range 0.91 to 0.97 0.98 Credit Factor Used(2) l _J______ 3. Fire Protection Credit Factor (C3) Feature a. Leak Detection Credit Factor Range 0.94 to 0.98 b. Structural Steel 0.95 to 0.98 c. Fire Water Supply 0.94 to 0.97 d. Special Systems 0.91 e. Sprinkler Systems 0.74 to 0.97 C3 Value(3) 0 Credit Factor U$ed(2) oM \ O 1 0,^7 Feature f. Water Curtains g. Foam h. Hand Extinguishers/Monitors i. Cable Protection Credit Factor Range 0.97 to 0.98 0.92 to 0.97 0.93 to 0.98 0.94 to 0.98 Credit Factor Used(2) 1 1 1 C3 Valued) (Q , <g,Q) Loss Control Credit Factor = Ci X C2 X C3(3) = Q . (c 7 (Enter on line 7 below) PROCESS UNIT RISK ANALYSIS SUMMARY 1. Fire & Explosion Index (F&EI)......................... (See Front) 2. Radius of Exposure................. ...........................(Figure 7) ft orm 3. Area of Exposure................................................................ ft2 or m2 4. Value of Area of Exposure........................................................................................................ $MM 5. Damage Factor.................................................. (Figure 8) 6. Base Maximum Probable Property Damage - (Base MPPD) [4x5]................................... . $MM 7. Loss Control Credit Factor............................. (See Above) O (4>"7 8. Actual Maximum Probable Property Damage - (Actual MPPD) [6x7]................................ $MM 9. Maximum Probable Days Outage - (MPDO)..... (Figure 9) days 10. Business Interruption - (Bl)...................................................................................................... $MM (2) For no credit factor enter 1.00. (3) Product of all factors used. Refer to Fob & Explosion Index Hazard Classification Guide (Form #471 -00001) tor details. 6 SACK OF FORM C-223B0 FWOI-M (A71-OOC30 DO A 044702 confidential \Jo^uncse. .'Ocjhr "7m~c m- t 17/9^ \ -UDO prcno bro.\j^ r-cch^ /vJ^> p K^^cu-rvv.. Qo*v\ \je. ^AoK. ^ S 14 p^v. -K-q, u7 C"I O"^ TM l ^1 5 1 FTj l k levi&l v' n Wc-^ 4-o m -= S ' "7c>4<jjl \ ^ ufi, l ~ l ^ 1 V-TTCz-S/^2- V^.(> ' = ^ (0 l <* *1 \fe l-C-t-3 =^lOOlbs iAsAsA4IV)Vs) S_j^SlUi*H&b<Ligua^.&-*e^*s acS^pa ga^ssa s*i^gg 5,55,5,51 T-IOOO o. Th |=h`c.cJL vo lu^e. 1'0 'PaC.^ i'n^ 'J0^0/Yl- 0 r"e^ j - - - ----------- o \s-v-*. I -- TT (/ 5-"-,*^. -^ t -a - _ - lj^ "T __-- ^ o . o"3T o-1? -Vo-V-^U OO -- -- ^ C - ^ S > " La 4 ^ O' ' - DO A 044703 CONFIDENTIAL AREA: U.S. / N. Am. PLANT: Glycol I PLANT RISK ANALYSIS SUMMARY DIV./LOCATION: Louisiana Division DATE: 3/10/92 REPLACEMENT VALUE: PO $54.5 / <|PG $20.2 PREPARED BY: Dean / Tyler Process Units PO Storage Area tl PO Storage Area #2 PG Hydrogenator Area #3 Reactors Area 14 Reactors Area #5 Distillation (T-102C) Area 16 Distillation (T-102B) Area 17 Distillation (T-300) Area #8 Thr x - Area #9 Material Factor MF 24 24 21 F&EI (F3XMF) Value Area of Exposure $HH 70.8 4.0 70.8 4.0 71.6 10.2 Base HPPD $MM Actual MMPD $HH Days Outage KPD0 2.6 1.30 2.6 1.30 5.7 3.70 23 23 50 B.I. Loss $HM 2.0 2.0 2.0 21 65.1 4.5 2.5 1.20 21 65.1 4.5 2.5 1.20 24 96.0 3.4 2.5 1.40 22 1.9 22 1.9 26 2.2 24 117.0 6.8 5.3 2.90 70 3.5 24 140iO 1 16 99.2 4.0 . 5.0 2.5 1.60 3.0 1.15 28 2.4 22 1.9 C?-3o-?z) t?v"- *hP0- A-rfrt- & to (3/te) \L lo s 3 -o \.?3 l .37 2.3 tl. DO A 0 4 4 7 0 4 c o n f id e n t ia l DO A 044705 CONFIDFNTIAL FIRE AND EXPLOSION INDEX *1 ' LOCATION DATE pu lant MATERIALS IN PROCESS UNIT Pl 11 O A i STATE OF OPEHATION START-UP . SHUT-DOWN : : NORMAL OPERATION PROCESS UNIT 7 S4 evaluated BY MATERIALS AND PROCESS REVIEWED BY basic materialiS) for material factor MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unit temperature over 14(TF) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR 1.00 PENALTY USED 1.00 A EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.2SI Q ENDOTHERMIC PROCESSES (FACTOR .20 to .40) C MATERIAL HANOUNG & TRANSFER (FACTOR .25 to 1.05) D. ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .90) E. ACCESS f drainage and spill control (factor 25 to srn Gals. GENERAL PROCESS HAZARDS FACTOR (F.) 2. SPECIAL PROCESS HAZARDS .35 I> O CASE FACTOR-------- 1.00 1.00 t A TOXIC MATERIAL(S) (FACTOR 0 20 10 0 SOI B SUB-ATMOSPHERIC PRESSURE ( 500 mm Hgi o -H- .50 C OPERATION IN OR NEAR FLAMMABLE RANGE INERTED . : NOT INERTED 1 TANK FARMS STORAGE FLAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D DUST EXPLOSION (FACTOR .25 to 2.00) (SEE TABLE II) E PRESSURE (SEE FIGURE 2) OPERATING PRESSURE . sopsig RELIEF SETTING pstg .50 .30 SO C> . F LOW TEMPERATURE (FACTOR .20 to .30) G QUANTITY OF FLAMMABLDUNSTABLE MATERIAL: QUANTITY 1^3SS lbs., / 3.T.*' BTU/lb 1. LIQUIDS, GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3. COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) H CORROSION AND EROSION (FACTOR .10 to .75) I. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.SO) J. USE OF FIRED HEATERS (SEE FIG. 61 O i (f O O.I o 0.1 O y2" - K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L. ROTATING EQUIPMENT .50 SI'LUAI PROCESS HAZARDS FACTOR (F,) m UNIT HAZARD FACTOR (F, x Fj F,). FIRE AND EXPLOSION INDEX (F, t MF F 4 Ell - *2. f5 7 0,? FORM C 223U0 H-4-87 (471-036) 6 AO A 044706 CONFIDENTTAI -r\o PO.AtEAi EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (Ci) .98 .97 to .99 .84 to <3S> .96 tO<32> .93 to .99 f) Inert Gas - ^ t. g) Operating Instructions/ Procedures h) Reactive Chemical Review t -'*'"7 'tm 1 Cl Total O (S)tO .96 to .99 .91 t0<98) 2. Material Isolation {C2) a) Remote Control ValvesC''"6Dto .98 b) Dump/Blowdown fT95)to .98 c) Drainage d) Interlock C2 Total C.^ez-i * .91 to .97 .98 1. ^ ^ v. wl*to*+** 3. Fire Protection (C3) ^ ^ a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems ' 'Jc .94 to .95 tocas) .84 to .91 .94 to <32> .91 f) Sprinkler Systems ~ g) Water Curtains h) Foam i) Hand Extinguishers^onitor|5 j) Cable Protection GZ3>to .97 .97 to .98 .92 to .97 .95 to .98 a .94 to .98 C3 Value O'buZ * Credit Factor = Ci X C2 X C3 - S> (p Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) no toO C> . tr to O' u Rb ft. $MM $MM $MM $MM I.^I 1. 11 O *F" (0 '/ & /V - days. Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) DO A 044707 CONFIDENTIAL FIRE AND EXPLOSION INDEX LOCATION #L1' PLANT ^ C& \ MATERIALS IN process UNIT PROCESS UNIT evaluated by 1 1 PO "T- T"ni.Ta. MATERIALS AMD PROCESS REVIEWED BY DATE ! A 3 Po________________________ STATE OF OPERATION START UP . , SHUT-OOWN Af'tfORMAl OPERATION BASIC MATERIAL(S) FOR MATERIAL FACTOR p o____________________ MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Npie requirements whan unit temperature over 14QF) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR A, EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 10 1.25) B ENDOTHERMIC PROCESSES (FACTOR .20 ro .40) C. material HANDLING 8 TRANSFER (FACTOR .25 to 1.0S) 0 ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .90) E ACCESS F DRAINAGE AND SPILL CONTROL (FACTOR 25 10 50) Gals. GENERAL PROCESS HAZARDS FACTOR <F.) 1.00 .35 2. SPECIAL PROCESS HAZARDS ua:,l i acium 1.00 PENALTY USED 1.00 \ >O 1.00 Jzl. % A TOXIC MATERIAL(S) (FACTOR 0.20 to 0 801 6. SUB-ATMOSPHERIC PRESSURE ( 500 mm Hg) O,H .50 C OPERATION IN OR NEAR FLAMMABLE RANGE U INERTED 1 TANK FARMS STORAGE FLAMMABLE LIQUIDS 2. PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D. OUST EXPLOSION (FACTOR .25 to 2.00) (SEE TABLE II) Q NOT INERTED .50 tO . S' .30 .80 E. PRESSURE (SEE FIGURE 2) OPERATING PRESSURE. F LOW TEMPERATURE (FACTOR .20 to .30) psig RELIEF SFTTINgS o pslg 0,Z_3 G QUANTITY OF FLAMMARI F/l INSTABLE MATERIAL QUANTITY Zfel.QOO Iht.. H^= -3-y 'Crti l/lh 1 LIQUIDS. GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) I* CORROSION AND EROSION (FACTOR .10 to 75) I. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L. ROTATING EQUIPMENT O 'GO . I O C. lO .50 SPECIAL PROCESS HAZARDS FACTOR (F,) UNIT HAZARO FACTOR (F, Fj Fj). ' I IRf AND EXPI OSION INDEX (F, * MF F 4 l|. *7O - S FORM C-22380 R-4-B7 (471-036) DO A 044708 I 'f+^ j i EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (Ci) .98 .97 to .99 .84 to .96 to<^5 .93 to .99 f) Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Xyl'-f Ci Total 0 . * to .96 Spto .99 .91 to$tp 2. Material Isolation (C2) a) Remote Control Valves .98 b) Dump/Blowdown CPto .98 c) Drainage d) Interlock C2 Total 0.471 t*B a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems r> o-J 3. Fire Protection (C3) ^^ .94 to<J) .95 to(2P .84 to .91 .94 to .91 f) Sprinkler Systems g) Water Curtains h) Foam , i) Hand Extinguishers^lpnitors]) j) Cable Protection C3 Value O <0 teT. * .91 to .97 .98 <zto .97 .97 to .98 .92 to .97 .95 to .98 0 .** <0 .94 to .98 Credit Factor = Ci X Cz X C3 = & Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) 10 .-s 1oO O . its b ft. $MM SMM O. c $MM SMM * Product of all factors used. BACK OF FORM C-22300 R-4-87 (471-036) 7 1.1 _L_L*k o. a IL days. CO A 044709 CONFIDENTIAL txhimiA FIRE AND EXPLOSION INDEX LOCATION DATE Ncv. plant <- 4 \ ' maiumais in imiOCESS ONII \ PROCESS UNIT evaluated by l47Jru . "T* \ c.'ou MATERIALS AND PROCESS reviewed by l X P-- 1 MAH. nh OPERATION MAIU UP `''SHUTDOWN \ NORMAL ONE NATION SASIC MATENIAL(S) FOR MATERIAL FACTOR H V ^ t~(Q Q MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unit temperature over 140 F) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR 1.00 A EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 io 1.2S) B ENDOTHERMIC PROCESSES (FACTOR .20 to .40) C MATERIAL HANDLING 1 TRANSFER (FACTOR .25 lo 1.05) O ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .90) E. ACCESS F DRAINAGE AND SPILL CONTROL (FACTOR 25 lo 50) Gals. GENERAL PROCESS HAZARDS FACTOR (F,) . .35 PENALTY USED 1.00 ."iO oir 2. SPECIAL PROCESS HAZARDS BASE factor 1.00 1.00 # A TOXIC MATERIAL(S) (FACTOR 0.20 lo 0,80) B SUB-ATMOSPHERIC PRESSURE ( 500 mm Hg) .50 C OPERATION IN OR NEAR FLAMMABLE RANGE . INERTED !.j NOT INERTED 1 TANK FARMS STORAGE FLAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE FAILURE 3. ALWAYS IN FLAMMABLE RANGE D DUST EXPLOSION (FACTOR 25 lo 2.00) (SEE TABLE II) E PRESSURE (SEE FIGURE 2) OPERATING PRESSURE psig RELIEF SETTING i.iT PS'O F LOW TEMPERATURE (FACTOR .20 to .30) .50 .30 .80 o.*i G QUANTITY OF FLAMMABLEiUNSTABLE MATERIAL. QUANTITY S^-U lbs,. H * BTU/lb 1 LIQUIDS, GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE, DUST IN PROCESS (SEE FIG. 51 H CORROSION AND EROSION (FACTOR .10 to 75) I. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L. ROTATING EQUIPMENT D..r /., o.lo O. .50 SPECIAL PROCESS HAZARDS FACTOR <F;) -- #" UNIT HAZARD FACTOR (F, x Fi F,|. FIRE and EXPLOSION INDEX (Fj x MF F i El) - ~l I FORM C-22380 R-4-87 (471-036) 6 DO A 044710 CONFIDENTIAL EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (Ci) .98 .97 to .99 .84 to@) .96 to .99 .93 to .99 f) Inert Gas f* -u g) Operating Instructions/ Procedures h) Reactive Chemical Review Try f Ci Total * .94 \<(S6) to 39 .91 to () S-i 2. Material Isolation (C2) a) Remote Control Valves (6)10 .98 c) Drainage b) Dump/Blowdown .96 to d) Interlock Cz Total O - t-'Bla * to .97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .94 to .98 .95 to .98 .84 to .91 .94 to .91 f) Sprinkler Systems g) Water Curtains h) Foam i) Hand Extinguishers/Klonitorg^ j) Cable Protection C3 Value n . \ 1 2. * .74 to .97 O .97 to .98 -92 to .97 .95 to <B> .94 to .98 Credit Factor = Ci X C2 X C3 = o to 6>S Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) 1 . <0 O.SL ft. $MM $MM $MM $MM /Z. t7. O H. n r3 M . Co - days. * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) DO A 044711 CONFIDENTIAL CAniDI I rt FIRE AND EXPLOSION INDEX * LOCATION DATE PLANT G> l vc. o \ MATERIALS in process UNIT 1 PROCESS UNIT EVALUATED BY 0*7 /2t_ tJemrS "T". MATERIALS AND PROCESS REVIEWED BY ________ pule ;>|A|| Ul </l*l HAIMlH ' ........, 1 START-UP , : SHUT-DOWN ^/normal operation V4I i- u po^ PCM BASIC MATERIAL!*) FOR MATERIAL FAC I OH Pf ` a v. 11*. c,__________ MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unit temperature over 140" F) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR 1.00 a. EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.25) B ENDOTHERMIC PROCESSES (FACTOR .20 to .401 C MATERIAL HANDLING & TRANSFER (FACTOR ,25 to 1.05) 0 ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .90) E ACCESS F DRAINAGE AND SPILL CONTROL (FACTOR 25 to .50) Gals GLNtHAL PROCESS HAZARDS FACTOR (F,| .35 PENALTY USED 1.00 O O . 1*^ 2. SPECIAL PROCESS HAZARDS BASE FACTOR 1.00 1.00 # A TOXIC MATERIALS! (FACTOR 0 20 10 0 80) B SUB-ATMOSPHERIC PRESSURE I 500 mm Hg) O ~l~ .50 C OPERATION IN OR NEAR FLAMMABLE RANGE .; INERTED !J NOT INERTEO 1, TANK FARMS STORAGE FLAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D DUST EXPLOSION (FACTOR 25 lo 2 00) (SEE TABLE M) E PRESSURE (SEE FIGURE 2) OPERATING PRESSURE. psig RELIEF SETTING. S' psig F LOW TEMPERATURE (FACTOR .20 to .301 .50 .30 80 0.3 o. r-r _^ G. QUANTITY OF FLAMMABLE/UNSTABLE MATERIAL: QUANTITY U lbs.. H = 1. LIQUIDS. GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2 LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) II CORROSION AND EROSION (FACTOR 10 to 75) I. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE L ROTATING EQUIPMENT BTU/lb .50 ir o. i o 0.10 SI'I CIAI PHCXJLSS I IAZAHUS I ACIOR (I i) # UNIT HAZARD FACTOR (F. x F, Fj). -2. o 3. \ f IRC AND EXPLOSION INDEX (F, x MF F i El) - (q l FORM C-22380 R-4-B7 (471-036) 6 DO A 044712 CONFIDENTIAL & c. +o as EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control Tou 1. Process Control (Ci) .98 .97 to .99 .84 torffit) .99 .93 to^ f) Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Ci Total O . *7 1 2. Material Isolation (C2) a) Remote Control Valves >>to .98 b) Dump/Blowdown .96* to^^p c) Drainage d) Interlock C2 TotaF 4? S s' b r\< .96 to .99 .98 to .97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .94 to .98 .98 C4 to .91 <^4~tb .97 .91 f) Sprinkler Systems g) Water Curtains h) Foam i) Hand Extinguishers/ftlonitors'} j) Cable Protection C3 Value uO '"t S * .74 to .97 .97 to .98 .92 to .97 to .98 .94 to .98 Credit Factor = Ci X C2 X C3 = O H Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) 45. I -------5Jg. o. s <s <S - HT4 ft. $MM vT.r $MM 2. o $MM $MM 1. 3 /r ____L3 days. * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) DO A 044713 CONFIDENTIAL cAmoi i n FIRE AND EXPLOSION INDEX m1 pa lant 1 PROCESS UNIT LOCATION EVALUATED BY ~r, Tu, 'ef*- materials in process unit MATERIALS AND PROCESS REVIEWED BY DATE 1 t/i^/S* . ^7P C.W PPC ^lAlfc Oh OPERATION J *1 START-UP . . SHUT-OOWN TJ^JORMAL OPERATION Pc V4 basic material(S) for material factor MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unit temperature over 14(TF) 1. GENERAL PROCESS HAZARDS BASE FACTOR--------------------------------------------------------------------------------------------------------------------------------- A. EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.251 B ENDOTHERMIC PROCESSES (FACTOR .20 to .40) C MATERIAL HANDLING A TRANSFER (FACTOR .25 lo 1,05) D ENCLOSED OH INDOOH PROCESS UNITS (FACTOR .25 <0 .90) E ACCESS F DRAINAGE AND SPILL CONTROL (FACTOR 25 10 .501 Gals. ftrKirftAi PonrPQQ uiAZAonc CArma ic.% ........ ..... 2. SPECIAL PROCESS HAZARDS PENALTY 1.00 PENALTY USED 1.00 tO 'S.O .35 Q '2-*5 _t. 5-5 BASE FACTOR -------------------------------------------------------------------------------------------------------------------------------- 1.00 1.00 A TOXIC MATERIAL(S) (FACTOR 0.20 to 0 80) B SUB-ATMOSPHERIC PRESSURE ( 500 mm Hg) O . -Z. .50 C OPERATION IN OR NEAR FLAMMABLE RANGE J INERTED 1 TANK FARMS STORAGE FLAMMABLE LIOUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE 0. DUST EXPLOSION (FACTOR .25 to 2 00) (SEE TABLE II) NOT INERTED .50 .30 O . 3 .80 e prfssurf isff figurf ?i operating preskmrf F LOW TEMPERATURE (FACTOR .20 to .30) psig rfmff sftting "2 pdg O . 1 -3 G QUANTITY OF FI AMMAR1F/IINSTARIFMATFRIAI QUANTITY ft Ihe H - V 4 ,"l YI^RTI l/lh 1. LIOUIDS. GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIOUIDS OR GASES IN STORAGE (SEE FIG 4) 3 COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) H CORROSION AND EROSION (FACTOR .10 lo ,75) 1. LEAKAGE - JOINTS AND PACKING (FACTOR .10 lo 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) . V5 a * O O , i <3 K HOI Ull IILAt EXCHANGE SYSTEM (FACTOH lb It) 1.10) ISEE TABLE III) L. ROTATING EQUIPMENT .50 SPECIAL PROCESS HAZARDS FACTOR (Fj) -- - UNIT HAZARD FACTOR (Fi x F, Fj)------------------------------------------------------------------------------------------------------------ ------------- - -2., O 3.1 f . f IRC AND EXPLOSION INDEX (F, x MF F A El) - I FORM C-22380 R-4-87 (471-036) 6 DO A 044714 CONFIDENTIAL EXHIBIT B LOSS CONTROL CREDIT FACTORS I*-' " Emergency Power Cooling Explosion Control Emergency Shutdown Computer Control to e. 1. Process Control (Ci) .98 .97 to .99 .84 to jS> <SDto *99 .93 to ($> f) Inert Gas ^ v g) Operating Instructions/ Procedures h) Reactive Chemical Review <2>to .96 (<9T)to .99 to .98 wVi, WH Ci Total : ,~T 1___* A*'*> 2. Material Isolation (C2) Remote Control Valves ^to .98 c) Drainage Dump/Blowdown .96 tO(3P d) Interlock C2 Total O <&&& * .1 . ^91^0 .97 .98 Leak Detection Structural Steel Buried Tanks Water Supply Special Systems 3. Fire Protection (C3) .94 to .98 po .98 .84 to .91 <J3)tO .97 .91 f) Sprinkler Systems g) Water Curtains h) Foam i) Hand Extinguishers?[Monitors> j) Cable Protection C3 Value O ."7 * .74 to .97 o ^ "2. .97 to .98 .92 to .97 <3S>t0 .98 .94 to .98 Credit Factor = Ci X C2 X C3 = 0 h Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days.Outage (MPDO) G. Business Interruption Loss (B1) Sn - O'SS ft. $MM - $MM 3. 0 $MM , /. V 3 /r $MM_ 7.3 days. * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) DO A 044715 confidential 7 FIRE AND EXPLOSION INDEX t LOCATION DATE \ / (3/&=l PLANT GWcoi nr MATERIALS IN PROCESS UNIT PROCESS UNIT T*~ 102. Ls) evaluated by T. T-r MATERIALS AND PROCESS REVIEWSO 8Y ?Q- PO c - pcipg STATE of OPERATION START-UP . SHUT-DOWN i/nORMAL OPERATION basic material(S) por material factor TO____________________ MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unit temperature over IRQ F) 1. GENERAL PROCESS HAZARDS BASE FACTOR A EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.25) B ENDOTHERMIC PROCESSES (FACTOR .20 to .401 C MATERIAL HANDLING & TRANSFER (FACTOR .25 lo 1.05) 0 ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .901 E, ACCESS i miAiNAo: and l control it actor ?s to soi Gsn. OLNI.HAL PROCESS HAZARDS FACTOR (F,| PENALTY 1.00 .35 2. SPECIAL PROCESS HAZARDS IJASL I ACIOM 1.00 PENALTY USED 1.00 Z 5 \ - ^a 1.00 A TOXIC MATERIAL(S) (FACTOR 0.20 10 0 80) B SUB-ATMOSPHERIC PRESSURE ( 500 mm Hg) C OPERATION IN OR NEAR FLAMMABLE RANGE . . INERTED 1 TANK FARMS STORAGE FLAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D DUST EXPLOSION (FACTOR 25 lo 2.00) (SEE TABLE II) D NOT INERTED o 4 .50 o . 5 .50 .30 .80 E PRESSURE (SEE FIGURE 2) OPERATING PRESSUREpsig RELIEF SETTINGpsig F LOW TEMPERATURE (FACTOR .20 to .301 G QUANTITY OF FLAMMABLE/UNSTABLE MATERIAL; OUANTITy3l_2^IDS.. Hc* U-Zv i^TU/lta 19 1. LIQUIDS. GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) H CORROSION AND EROSION (FACTOR .10 lo .75) I. LEAKAGE JOINTS AND PACKING (FACTOR .10 to 1.501 J. USE OF FIRED HEATERS (SEE FIG. 6) K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L. ROTATING EQUIPMENT O .Q. Q , \O .50 mm i:iai montcc i ia/ahds facioii (r,) # UNIT HAZARD FACTOR (F. * Fi Fjl_____ 3 2H.O I IRC AND EXPLOSION INDEX (F, MF F & El) - FORM C-22380 R-4-87 (471-036) 6 DO A 044716 CONFIDENTIAL T"-1 o z. c_ EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (Ci) .98 .97 to .99 .84 to<1|D .96 to .99 93to<^) f) Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Ci Total o z.1 * .94 to .96 .91 to .99 * rs smo .98 p1 " (.V 2. Material Isolation (C2) t - a) Remote Control Valves <^po .98 b) Dump/Blowdown .96 to .98 c) Drainage d) Interlock C2 Total G *2 " H- * O'-- ^ Oa '-* a) Leak Detection 3. Fire Protection (C3) .94 f) Sprinkler Systems 6** b) Structural Steel <495^0 .98 g) Water Curtains c) Buried Tanks .84 to .91 h) Foam d) Water Supply C^Qo .97 i) Hand ExtinguishersZ^onitors^ e) Special Systems .91 j) Cable Protection C3 Value o ~i~73 ^91>o .97 .98 -w; .74 to .97 o .efZ .97 tor^FD .92 to .97 .95 to .94 to .98 Credit Factor = Ci X C2 X C3 = O- 5 Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) t 0.-74 0 ft. $MM $MM $MM $MM /r. 0 /m .&.1 C.1- JT - V days, * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) 7 DO A 044717 CONFIDENTIAL FIRE AND EXPLOSION INDEX Ll PLANT PROCESS UNIT LOCATION evaluated by Cs> ly Co\ -Li MATERIALS IN PROCESS UNIT T-loZS (A) T- "Tv MATERIALS AND PROCESS ^ j ^>C \`PE' REVIEWED BY 0AT Won/. \ state of operation .. START-UP I i SHUT-DOWN 'jt nNoORMAL operation BASIC MATERIALS) FOR MATERIAL FACTOR v> o MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unn lemperalure over 14(7 F) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR ,,................................................................................................................................... 1.00 PENALTY USED 1 00 2.4- A EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 <0 1.251 B ENDOTHERMIC PROCESSES (FACTOR .20 to .40) C, MATERIAL HANDLING & TRANSFER (FACTOR .25 10 1.05) D. ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .90) . ACCESS F DRAINAGE AND SPILL CONTROL (FACTOR 25 10 50) .... Gals. .35 e>< ZS 2. SPECIAL PROCESS HAZARDS BASE FACTOR ------------------------------------------------------------------------------------------------------------------------- W- t A TOXIC MATERIAL(S) (FACTOR 0.20 lo 0 80) B. SUB-ATMOSPHERIC PRESSURE ( 500 mm Hg) C. OPERATION IN OR NEAR FLAMMABLE RANGE INERTED C NOT INERTED 1. TANK FARMS STORAGE FLAMMABLE LlOUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D. DUST EXPLOSION (FACTOR .25 to 2.00) (SEE TABLE II) E PRESSURE (SEE FIGURE 2) OPERATING PRESSURE psig RELIEF SETTING *0 psjg F. LOW TEMPERATURE (FACTOR .20 to .301 r, ntUNTiTvnc FI AMM4BI P/IINSTAfll FMATPRIAI -nilANTITY.SC^C^lh* hc-73,2, BTII/lh t. LIQUIDS. GASES ANO REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LlOUIDS OR GASES IN STORAGE (SEE FIG. 4) 3. COMBUSTIBLE SOLIDS IN STORAGE. OUST IN PROCESS (SEE FIG. 5) H CORROSION AND EROSION (FACTOR 10 lo .75) 1. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE 111) L. ROTATING EQUIPMENT SPECIAL PROCESS HAZARDS FACTOR (F,) 1.00 .50 .50 .30 .80 .50 1.00 0.40 3 23 /. 2 O.lO 0.10 * UNIT HAZARD FACTOR (F, x F Fi). FIRE AND EXPLOSION INDEX (Fj *MF F & El) FORM C-22380 R-4-87 (471-036) 6 DO A 044718 CONFIDENTIAL I \ ~7 'T-' o >- e. EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control Tfi C 1. Process Control (Ci) .98 .97 to .99 .84 to @> .96 to .99 .93 to <22> f) Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Ci Total o. ^2 { .94 to .96 .91 to .99 &, <9 5 QTfrto .98 2. Material Isolation (C2) v a) Remote Control Valves .98 c) Drainage b) Dump/Blowdown .96 to .98 d) Interlock <T^D to .97 .98 C2 Total o.sm- * L* a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems ~ 3. Fire Protection (C3) a rA- .94 to^fjP f) Sprinkler Systems fpO .98 g) Water Curtains M to .91 h) Foam <T93Cto .97 i) Hand Extinguishersi^onitors]) .91 j) Cable Protection c,- .74 to .970 .97 to (HD .92 to .97 .95 to^9H? .94 to .98 C3 Value * Credit Factor = Ci X C2 X C3 = & *s*^> *5 Enter on Line D Below < UNIT ANALYSIS SUMMARY A-1.F&EI A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) \\ "7 t oo______ n. $MM O "T-S o. ...s.s g $MM $MM $MM * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) ~1 o . i i.r sr 1.1 days. DO A 044719 CONFIDENTIAL < FIRE AND EXPLOSION INDEX * *> ............-........ PLANT Q1VC 1 1 PROCESS UNIT T-3 o o LOCATION evaluated by ~T.T^Ur- MATERIALS IN PROCESS UNIT MATERIALS AND PROCESS REVIEWED BY date v. blAIL 01 OPERATION START-UP I I SHUT-DOWN Ppc -X Pg (/NORMAL OPERATION BASIC MATERIAL(S) for material factor po MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements when unit temperature over 140'F) 1. GENERAL PROCESS HAZARDS BASE FACTOR. PENALTY 1.00 A. EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.25) B ENDOTHERMIC PROCESSES (FACTOR .20 to .401 C. MATERIAL HANDLING & TRANSFER (FACTOR .25 to 1 05) D. ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to ,90) E. ACCESS F ORAINAGE AND SPILL CONTROL (FACTOR .25 to 50) Gals. GENERAL PROCESS HAZARDS FACTOR (F.) .35 2. SPECIAL PROCESS HAZARDS BASE FACTOR 1.00 PENALTY USED 1 00 O. 1.00 A TOXIC MATERIALS) (FACTOR 0.20 to 0 B0) B SUB-ATMOSPHERIC PRESSURE I 500 mm Hg) C. OPERATION IN OR NEAR FLAMMABLE RANGE INERTED NOT INERTED 1 TANK FARMS STORAGE FLAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D DUST EXPLOSION (FACTOR .25 to 2 00) (SEE TABLE II) L 1`IIESSUHE (SEE FIGURE 2) OPERATING PRESSURE _ . psig RELIEF SETTING SO psig F LOW TEMPERATURE (FACTOR .20 to .30) G. QUANTITY OF FLAMMABLE/UNSTABLE MATERIAL; OUANTITYi at BTU/lb .50 .50 .30 SO O .q<Q .O.fo O 3 o. 2.^ l. LIQUIDS, GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE, DUST IN PROCESS (SEE FIG 5) H. CORROSION AN0 EROSION (FACTOR .10 to .75) I. LEAKAGE - JOINTS ANO PACKING (FACTOR .10 to 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) o./ O 0.10 K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L. ROTATING EQUIPMENT .50 Off01At PROCESS HA7ARDS FACTOR (F,| m UNIT HAZARD FACTOR (F, x F, F,|. (a. FIRE AND EXPLOSION INDEX (Fj * MF F & El) - ^ L- ' ' -- -5 FORM C-22360 R-4-87 (471-036) 00 A 0447->,, CONFroFNTr^0 EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control Toe 1. Process Control (Ci) .98 .97 to .99 .84 to .98 .96 to .99 .93 to f) Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Ci Total .94 to .96 .91 to .99 o . .91 2. Material Isolation (C2) a) Remote Control Valves (Tfjpto .98 b) Dump/Blowdown .96 to .98 c) Drainage d) Interlock C2 Total O.*' (TTrjto .97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) A- .94 to .95 to .98 .84 to .91 >o .97 .91 f) Sprinkler Systems g) Water Curtains h) Foam _____ _ i) Hand Extinquishers/Monitors- j) Cable Protection C3 Value o <z\ 4- .74 to .97 <0, i z. .97 .92 to .97 ,95to@) g 1 .94 to .98 Credit Factor = Ci X C2 X Ca = -rv te'&S Enntteer on Line D Below UNIT ANALYSIS SUMMARY F & El Radius of Exposure Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) t 1 IS ft. O. UT $MM jo . (0 5S $MM $MM $MM 1 3 .7 ?.8 JJL days. * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) DO A 0447?1 CONFIDENTIAL I |-3oO I______________________________ a-*? \'<g|U>gt "77*7 t 1 */ o -f-- ic/<ii'n4 tp " c --i Sci^ <at Tvr-v-j cs U-t-O Ca_ '^rrO'iN-c & 111 -{"Sc In re,p rrlLkrs>2' * 5 C. =>) ^ (. s "") = l ^2.~1 V'^S ipj^ am<so>iRf-s* s s*s!>-S*>r- ^-7~s-I ! 1 ,-fOO f'^'"3, esc?;:*. n/*\ o '*-^<5l - ^C' a,'-- '*=>o~ .'7*, J(Z-sseL ,OT~ - C oV - "t =*. " V-T-3 Lc^e.' s "7.5 {. rrVjr;z - -iiiW* ^ =L fT 4 Cal') 5 -r' ` H "3 T O H- M- 1 '* UtfJVK'- -- tf5ii _ _ *s;;p . "To -r\s_ - - ^ - <bs t*ftio.^<\ ry j I I * D0 ft 044722 CONFIDENTIAL :XIUKI I A FIRE AND EXPLOSION INDEX 1 LOCATION # PLANT PROCESS UNIT evaluated BY Ca 1 ^ CO l "X materials in PROCESS unit T. -TLaI. MATERIALS AND PROCESS REVIEWED BY DATE i / ra>/%^ Vc. i P E- ^ STATE OF OPERATION blAMT-UP . SHUT-00WN KTSORMAL OPERATION BASIC MATgRlAUS) FOR MATERIAL FACTOR Voc MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR B) Note requirements whan uml temperature over 140 F) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR-----------------------------------------------------1-------------------------------------------- --------------------------- > 1.00 A, EXOTHERMIC CHEMICAL REACTIONS (FACTOR ,30 to 1.2S) B ENDOTHERMIC PROCESSES (FACTOR .20 to ,40) C. MATERIAL HANDLING & TRANSFER (FACTOR .25 10 1 05) 0. ENCLOSED OR INOOOR PROCESS UNITS (FACTOR .25 to .90) E, ACCESS F DRAINAGE AND SPILL CONTROL (FACTOR 25 10 501 Gals. .35 2. SPECIAL PROCESS HAZARDS IIASE FACTOR .. . -- ---------------------------------------------------------------------- - 1 00 PENALTY USED 1.00 cp.J-o ---- -- -- -- O.SO ~L- . 1,00 I (=> A TOXIC MATERIALISl (FACTOR 0,20 lo 0 801 B SUB-ATMOSPHERIC PRESSURE ( 500 mm Hg) C OPERATION IN OR NEAR FLAMMABLE RANGE LtTInEHTED NOT INERTED t TANK FARMS STORAGE FLAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS IN FLAMMABLE RANGE D DUST EXPLOSION (FACTOR 25 to 2 00) (SEE TABLE II) E. PRESSURE (SEE FIGURE 2) OPERATING PRESSURE psig RELIEF SETTING F LOW TEMPERATURE (FACTOR .20 to .30) G. OUANTITY OF FLAMMABLE/UNSTABLE MATERIAL: QUANTITY- >1 lbs.. He= psig BTU/IO .50 .50 .30 80 O .H o.r -- | O.Jo -- -- -- -- 1. LIQUIDS, GASES AND REACTIVE MATERIALS IN PROCESS (SEE F|Q. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) II r.OHHOSION AND FIIOSION (FACTOR 10 In 75) 1. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1,50) J. USE OF FIRED HEATERS (SEE FIG. 6) K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L. ROTATING EQUIPMENT .50 SPECIAL PROCESS HAZARDS FACTOR (F,) ------------------------------------------------------------------------ ----------;---------------- ----- # UNIT HAZARD FACTOR (F, * F, F,) ------------------------------------------ ----------------------------------------------------- >- -- O. 1 -- t 0. | o. I -- o.r 3. / > , T- PIPE and EXPLOSION INDEX |F) * MF F a El) FORM C-22380 R-4-87 (471-036) DO A 044723 CONFIDENTIAL 11.X ('v-1 < O EXHIBIT B LOSS CONTROL CREDIT FACTORS 1. Process Control (Ci) a) Emergency Power .98 b) Cooling .97 to .99 c) Explosion Control g&o .98 Jr d) Emergency Shutdown <3>to .99 e) Computer Control <g>o .99 f) Inert Gas - ** x~ g) Operating Instructions/ Procedures h) Reactive Chemical Review Ci Total tn . S * <g> .96 C91>o .99 C91>o .98 2. Material Isolation (C2) N`--r - a) Remote Control Valves (Js)o .98 c) Drainage - b) Dump/Blowdown C9\o .98 d) Interlock .91 to .97 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems C2 Total 0 .qos * 3. Fire Protection (Ci) i. A. - .94 to .98 4 b f) Sprinkler Systems .95 to .98 g) Water Curtains .84 to .91 h) Foam .94 to .97 i) Hand Extinguisher^ZMonitors^) .91 j) Cable Protection .74 to .97 o.*o .97 to .98 .92 to .97 CT) .98 .94 to .98 C3 Value >.-730 * Credit Factor = Ci X C2 X C3 =? Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) ^ \, -z. ___ ___ 0 `1*0 ft. $MM $MM $MM $MM il. o (g . C T.r -3 C- "3 . days. * Product of all factors used. BACK OF FORM C-22380 R-4-87 (471-036) 7 DO A 0447^4 c ONF rOFNTlAL CCF*.' C-Z2380 R-i-9? -''-0361 6 f~ o 'J O -t ^ u ' W\ W1 A /-_ *- i Z-//&/ <? \j > 0 /^, -U C.i^- - 3,**0'a ^ / / va%(, "2. S"~7 o J"^r *. j ^ << "(o.^)(s^^)_z <*o ^ lzisWxI ooo A li \S"o *Tn~S -P*^ ;~lJ"+. ryjl "1"o+ -1 - /. "S *? <*' ^ k LL ^S 00 -P *- jj \*y t % ^ A-*- **- _3 I, ~1 s*n fS y,<vvo . c.,,`"t" + ----- /.*7 1 j"**?^ J/^"; .'j A..' - l4 ^ i ) l , C /"V? ,rvi C . ^ />7/^ *K/ r. (Z. r /v A' 1*4 y^)* ./<*/a, J"V / ^ ?-T0 /z. a^ V. "3 /'*/*'> 4* 2f^ - Q.^fTC V.c/, - O. S' v Arc- * r + O, 7 <+*-1 * <^/V^ X V ~\ C. A^u*" ^ *f A 0447PS "NFIDFNTrfll6 U _________ *>-//*/ lx. A r * -- *C. o ^ H7 , A/1<* fc-'K" a ( * t *" 2 * "2. _/ o o *7- C * -A- lit A^' aT' A*.^ - 1. o ^ ` 3 o'7- / A / "j * . O 9O<3O<9O / -6o*7. C_ S> +; j t-i-' J a 3. i <AV w(MIuWvII /S> O SIX A < <.*- ^ *7* t <^0 *7 a ' k if / 00 *7* j* + ^ k G c *^/- /Oo'7. zr n- C* * it*./* ^ *7 / J' * *^1 /* /0 a ^ JW,,.- " f 7 / *7 0 ~7~'"S>1<-'* *K/ S'0 7' / 15 *7. / O O *"7* /A ' ^* * J (T AArf >' ~h Cs fc / / Ji Z C*A L Ua / * AJ _~7 1 f/.AA.t 0 __ C c, .1 / ^<9 <_ '"O'" /c. s* Z. o Z. o O.-T v5"~, S' smm 2C . ^ ^ /3 ."7 Z. o' Z. o /."7 3- o / A /~o T* -- A rtg. ? /^-o* <-ri /^io0 '/ li r-y* DO A 044777 confidential 21.V *V A O ^. o z. - O // o EXHIBIT A FIRE AND EXPLOSION INDEX 0 LOCATION LAP, . _______________________________ date L/rf/9- PLANT QUco 1 i MATERIALS IN PROCESS UNIT PDC STATE OF OPERATION I START-UP Z SHUT-DOWN NORMAL OPERATION PROCESS UNIT b\J- 9oo EVALUATED by 60 U MATERIALS AND PROCESS REVIEWED BY BASIC M< 'ERIAL(S) for material factor MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR 8) Note requirements when unit temperature ovttf 140 F) 1. GENERAL PROCESS HAZARDS PENALTY BASE FACTOR----------------------------------------------------------------------------------------------------------------------------- to- 1.00 I PENALTY USED l 00 A, EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.25) B. ENDOTHERMIC PROCESSES (FACTOR .20 to .40) C. MATERIAL HANDLING & TRANSFER (FACTOR 25 to 1.05) D. ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .901 E. ACCESS F. 0RAINAGE AND SPILL CONTROL (FACTOR .25 to .50) K'&'SOO Gals. ftFNFRAI PftfViFftfi HA7Afll*)Q FArTriQ /e.i 2. SPECIAL PROCESS HAZARDS -------- -------- .35 0- 35 0,5- i.rs BASE FACTOR ---------------------------------------------------------------------------------------------------------------------------- to 1.00 1.00 J A. TOXIC MATERIAL(S) (FACTOR 0.20 to 0.80) ( B. SUB-ATMOSPHERIC PRESSURE ( <500 mm Hg) 50 C. OPERATION IN OR NEAR FLAMMABLE RANGE INERTED 1. TANK FARMS STORAGE FLAMMABLE LIQUIDS 2. PROCESS UPSET OR PURGE FAILURE 3. ALWAYS IN FLAMMABLE RANGE D. DUST EXPLOSION (FACTOR 25 to 2.00) (SEE TABLE II) Z NOT INERTED .50 .30 80 . PRESSURE (SEE FIGURE 2) OPERATING PRESSURE O psig RELIEF SETTING psig F LOW TEMPERATURE (FACTOR .20 to .30) 04 -- -- ------- -- a. m O' xl -- G. QUANTITY OF FLAMMARLE/UNKTARLF MATERIAL: QUANTITY / - H - <J JCfc? RTtl/lh C <.* 1. LIQUIDS. GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIOUIDS OR GASES IN STORAGE (SEE FIG. 4) 3. COMBUSTIBLE SOLIDS IN STORAGE. OUST IN PROCESS (SEE FIG. 5) H. CORROSION AND EROSION (FACTOR .10 to .75) 1. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.50) J. USE <JF FIRED HEATERS (SEE FIG. 6) ---------- -- QA 0,3 K. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) L ROTATING EQUIPMENT --- .50 --. SPECIAL PROCESS HAZARDS FACTOR <F*> --------------------------------------------------------------------------------------------------------------- to. 3 .5> V UNIT HAZARD FACTOR (Fi x F? - Fj)_________________________ to- 4.59 FIRE AND EXPLOSION INDEX (Fj x MF * F 4 El)---------------------------------------------------------------------- FORM C-22380 R-4-S7 (471-036) 6 ^ ---------- to- A 044728 CONFIDENTIAL * \03 EXHIBIT B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control 1. Process Control (Ci) .98 .97 to .99 .84 to .98 .96 to .99 .93 to .99 f) Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Ci Total o.% .94 to .96 .91 to .99 .91 to .98 2. Material Isolation (C2) a) Remote Control Valves .96 to .98 b) Dump/Blowdown .96 to .98 c) Drainage d) Interlock C2 Total 0. 97 .91 to 97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .94 to .98 .95 to .98 .84 to .91 .94 to .97 .91 f) Sprinkler Systems g) Water Curtains h) Foam i) Hand Extinguishers/Monitors j) Cable Protection C3 Value 6X\ .74 t5T97 .97 to .98 .92 to .97 .95 to .98 .94 to .98 Credit Factor = Ci X C2 X C3 = Enter on Line D Below UNIT ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. `Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) 105 ft. 0-fol $MM 0.~74fe $MM $MM $MM 3_ _ _ _ _ lY3 I. 37 je5. 1L_Z. days. * Product of all factors used. BACK OF FORM C-22380 R-M7 (471-036) 00 COtyp- A tal vpra-- wot /ma EXHIBIT A FIRE AND EXPLOSION INDEX m> SPtLANT G^ycl J- i CVLOCATION A <-< PROCESS unit Kti - Uoi A evaluated by V* *- C). t- REVIEWED BY materials in process unit MATERIALS AND PROCESS DATE i, ft Pro/^s/ltAu- Q%. Li STATE OF OPERATION START-UP a SHUT-OOWN I'CoRMAL OPERATION BASIC MATERIAUS) FOR MATERIAL FACTOR ^ 1 <* aC MATERIAL FACTOR (SEE TABLE I OR APPENDICES A OR 81 Note requirements when unit temperature over 14(TF) 1. GENERAL PROCESS HAZARDS BASE FACTOR PENALTY 1.00 PENALTY USED 1.00 "LH A. EXOTHERMIC CHEMICAL REACTIONS (FACTOR .30 to 1.25) B. ENDOTHERMIC PROCESSES (FACTOR .20 to .40) C. MATERIAL HANDUNO & TRANSFER (FACTOR .25 to 1.05) D. ENCLOSED OR INDOOR PROCESS UNITS (FACTOR .25 to .90) E. ACCESS F, DRAINAGE AND SPILL CONTROL (FACTOR .25 to .50) Gals. GENERAL PROCESS HAZARDS FACTOR (Fi) 3= .35 O.XS- . ~L S' 2. SPECIAL PROCESS HAZARDS BASE FACTOR '--r.yT--.- 1.00 1.00 A. TOXIC MATERIAL(S) (FACTOR 0.20 to 0.80) B. SUB-ATMOSPHERIC PRESSURE ( <500 mm Hg) o .V .50 C. OPERATION IN OR NEAR FLAMMABLE RANGE B'iNERTED 1. TANK FARMS STORAGE FLAMMABLE LIQUIDS 2. PROCESS UPSET OR PURGE FAILURE 3. ALWAYS IN FLAMMABLE RANGE D. DUST EXPLOSION (FACTOR .25 to 2.00) (SEE TABLE II) NOT INERTED E. PRESSURE (SEE FIGURE 2) OPERATING PRESSURE psig RELIEF SETTINGpsig F. LOW TEMPERATURE (FACTOR .20 to .30) $ G. QUANTITY OF FLAMMABLE/UNSTABLE MATERIAL: QUANTITY IOQ loalbs., Hc 1 VL,'>BTU/lb .90 .30 .80 o. 1. jSr* ft: 1. LIQUIDS. GASES AND REACTIVE MATERIALS IN PROCESS (SEE FIG. 3) 2. LIQUIDS OR GASES IN STORAGE (SEE FIG. 4) 3. COMBUSTIBLE SOLIDS IN STORAGE. DUST IN PROCESS (SEE FIG. 5) H. CORROSION AND EROSION (FACTOR .10 to .75) I. LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1.50) J. USE OF FIRED HEATERS (SEE FIG. 6) K, HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15) (SEE TABLE III) l_ ROTATING EQUIPMENT .50 SPECIAL PROCESS HAZAROS FACTOR (F^ UNIT HAZARD FACTOR (Ft x Fj - Fj). 3-^H FIRE AND EXPLOSION INOEX (Ft x MF - F & El) FORM C-22380 R-4-87 (471-036) DO A 044731 6 CONFIDENTIAL L EXHIBIT B LOSS CONTROL CREDIT FACTORS fA<=>0\/ 1. Pr cess C ntrol (Ci) a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown e) Computer Control .98 .97 to .99 .84 to .98 96^0 .99 .93 ta_99 0 Inert Gas g) Operating Instructions/ Procedures h) Reactive Chemical Review Ct Total O.P'- .94 to .96 .91 to .99 5*. * 1 2. Material Isolation (Ca) a) Remote Control Valves .96 toCgip c) Drainage b) Dump/Blowdown .96 to .98 d) Interlock C2 Total O. 7~ * (^9pto .97 .98 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .94 tq<98^) .95 to38 .84 to .91 .94 to(|J) f) Sprinkler Systems (0 % g) Water Curtains h) Foam iWdand ExtinquishersSJApnitorsJ) .91 j) Cable Protection C3 Value Q.~l *i 1 * .74 to .97 .97 to .98 ,92 to .97 ____ .95 to .98< .94 to .98 Credit Factor = Ci X C2 X C3 = Q *1 Enter on Line D Below UNIT ANALYSIS SUMMARY A-1.F&EI A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MMPD (A-3 X B) D. Credit Factor E. Actual MMPD (C X D) F. Days Outage (MPDO) G. Business Interruption Loss (Bl) 0 or1^ 0 .StH ft. $MM 3.0 $MM 1.11 $MM |.3o $MM o.re_________ days. * Product of all factors used. BACK OF FORM C-22380 R-4J7 (471-036) 7 DO A 04473? CONFIDENTIAL CHEMICAL EXPOSURE INDEX SUMMARY Complete the following Table (See Note 1) by filling in and multiplying the appropriate Risk Factor Scale numbers for each of the major Risk areas as identified in the following formula (See "Definitions of Scale Numbers'' CEI. page 6): 1. X II. X III. X IV. X V. * VI. ACUTE HEALTH HAZARD SCALE NO. VAPOR QUANTITY SCALE NO DISTANCE (RECIPROCAL) SCALE NO. MOLECULAR WEIGHT SCALE NO. PROCESS PENALTIES SCALE NQ CHEMICAL EXPOSURE INDEX Identification of Containment Vessels being evaluated: Name or Number (See Notes 2 & 3) Source#1 K To (1) Public (2) Other in-company Facility (3) Non-company Plant or Business Source #2 (if needed) ______________ To (1) Public (2) Other in-company Facility (3) Non-company Plant or Business 1. II. Z zH z. H III. IV. 3H H 3 i V. VI. (CEO 1 <1 L l 1 9 C. 1 j1 NOTE 1 -- The distance scale number in column III is the only factor normally expected to change, so column III and the corresponding CEI (column VI) are all that would normally be expected to differ from the first calculation for each source. NOTE 2 -- Only different sources of the same chemical should be evaluated on this sheet. Use a separate Chemical Exposure Index for every different chemical. NOTE 3 -- Use additional sheets if additional sources with differing potential impact are present. NOTE 4 -- It is important to document the worst case scenarios for future reference. See "Review Procedure and Check List," page 7. Back at Form C41720 TOW DO A 044733 CONFIDENTIAL 5 CHEMICAL EXPOSURE INDEX PLANT _ G\ 'f C.'O I A. CHEMICAL (One per Index) rr LARGEST SINGLE CONTAINMENT PRESSURE OF CONTAINMENT FLASH POINT, C ~ 1^ C LOCATION L N" O * o * j *v ^ Qi1-1^ TOTAL QUANTITY IN PLANT > TEMPERATURE OF CONTAINMENT___ 7r. PJ i G BOIUNG POINT12 ^____________________ MOLECULAR WEIGHT EMERGENCY EXPOSURE PLANNING GUIDELINE (EEPG) CONCENTRATION, (Refer to CEI Pg. 6 & Tables I & II, Pgs. 10-11)________________________ I. Complete the Chemical Exposure Index Summary (on page 5) and show highest CEI to the Public-------------------------------- This CEI number determines the level of review needed: 0 to 1(0,nternal review -- Superintendent and Major Manager review and sign every two years. 100 to 300 Site Review Committee, Superintendent and Major Manager review every two years, 300 to 400 Area Representative and the preceding group review every two years. Above 400 Corporate Representative and the preceding group review every two years. II. Complete Chemical Exposure Review Checklist (see page 7, CEI) prepare Review Package, and indicate date ready for further reviews. (Will be scheduled with Loss Prevention Contact) ____________ III. List any Sights, Odors, or Sounds which might come from your facility and cause public concern or in quiries (e.g., smoke, large relief valves, odors below hazardous levels such as mercaptans or amines, etc.) Reviewed by: Date Plant Superintendent or Manager: ____________________________________________ Major or General Manager __________________________________________________ Site Review Representative: _____________________________________ _______ ____ (If Public CEI is above 100) Area Review Representative: _________________________________________________ (If Public CEI is above 300) Corporate Review Representative: ____________________________________________ (If Public CEI is above 400) Form C-91720 ^aA73A 4 i -=. ~X. H > 3 a ^ u r r Ll - HH P "7" - -7.-T7 O2- = rz, G i4* ' -P+-1 ~a_ J *= (J.O k U.O0 = *ro ? = q r />j;o- Lir -L'-t.Hz (n,0(i.O 1^ -- Z , ^ <d -- L C=> p-O V O *" --------------------- C-T2. c.) _ CI.O-1 /O pf t 48=! /a h= =,8 ; h -T*.C> 8~irsf y-- $ u p -. ni. < izr't-) /VI w - d''('2--c'7-`'' SO 1 ^ 1 ^ v/ - ^ * /o v = C o Q G L /* DO A 044735 CONFIDENTIAL ---w h 04A73& CONFIDENTIAL PLANT: DIVISION: RE-CAP WORK SHEET C'L'/tOC 4 t_________ La. `PtV/S/O'V________ PREPARED BY: DATE: - ^Aia. Z/zhl ProceiJ Units Unit Hazard Factor F3 Material Factor MF F&EI (f3xmf> (A) Value Area of Exposure $MM (B) Damage Factor from Figure 7 10 P .5TOA6 o 7/ .5TDA46f RO 4.o 4,o ^PftOpVCEOS. '\S 70 fleAcn>/L Aau4 / 3.35- 3 ,65 11 ReJtcrcrt. AkA JS / Atea & - T`/ozc 3.4S y.7j 5,(0Ate* 9~ T-&i(b / Ate* to - T-3do 2/ Zt 21 Zt 2/ 2/ li 2./ 24 84 7038 76.6ST 74.6S* <?9.27 !07.( s3.S M 9.02/7 4.0 M 3,o aT <4>.0m S,5M . 00 -6>t> 62 >43 63 ,72 . 74 .79 1C) Base MPPD SMM (AXB) (D| Credit Factor CixC2xC3 from Figure 9 2,3 m ,3/8 2-3 M ,3'C * bC* 2SZM ZStM .44 46 2>/4 M ,48 w /^r ,4? 4-35FT ,42 (E) Actual MPPD $MM (CXD) 727 M 727 H $,>? >7 4/S1* M / iS9 M* t .04 M 2,13 FT Z.&7M (FI Days Outage MPDO from Figure 10 Zo 20 50 22 22 23 33 33 oo % o m 0o 3> _ , '-si ' FORM ps~rn-*f> LEGEND: PO - PROPYLENE OXIDE COLUMN OR STORAGE PDC - PROPYLENE Dl- CHLORIDE STORAGE DCiPE - ETHER STORAGE EPICK - EPlCriORCHYDRIN STORAGE *' 4 f * * ri 4 rJ*j~--u!> PROCESS WATER SPRINKLER SYSTEM SPRINKLER SYSTEM TRIP YALVE DELUGE GUN LJ DO A 044738 CONFIDENTIAL 1 Otoe i/ Ewnpnu ^cgrnMTftm. CREDM FMnug? h ) E niff(jtncy Power b) Cooling c) E yplosion Control d) Emergency Shutdown 1. Process Control (C1) .97 .95 to ^8 .75 to .94 to e) Computer Control P9 to .98 to .94 f) Inert Gas g) Operating Procedures (fpo .99 b) Reactive Chemical Review .85 to C? Total All_\ 2. Material Isolation (C2) a) Remote Control Valves $4) l>) Dump/Blowdown (j^to .96 C7 Total c) Drainage dl Interlock jjffif.-* .85 to .95 d t l'c - /. t .96 a) Leak Detection b) Structural Steel c) Buned Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to< .92 to .75 to J35 .90tof .85 C3 Total f) Sprinkler Systems g) Water Curtains h) Foam j| Hand Extinguishers k) Cable Protection o.sl to .96 95 to .97 87 to .98 &) 92 to .97 90 to .96 0.3/S See Figure 9 for conversion to C, XC2XC3Parmr* /Tn Lins D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius ol Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) * Product of all factors used. ~7Z ft. SMM Or (p C* CiutM 0,'itS /-- v3.5 m *2. 30 * m7,000 20 davii. 81- x 3?qoot> X,7z 3oA / 000 1 DO A 044742 CONFIDENTIAL 0 FIRE AND EXPLOSION DEX Exhibit'A' CtL" coI # I 7/ fro> MATERIALS AND PROCESS' P.D, a4Z>> AJ iOC V|NT| Z/d/uC, MATERIAL FACTOR (SEE TABLE I APPENDIX A) 1. GENERAL PROCESS HAZARDSISEE TABLE U ASt F AC TOP A l *0 I HC AMIC HI ACTIONS i ( iCTO 30 to 1 ?5> U 1 NOOtHfHMIt (Uf.CTlONSIf4CTO 70,0 401 c MATERIAL HANOL'NG (L TRAINSER (FACTOR 70 to 85) D E NCLOSE D PROCESS UNITS if ACTOR 30 to 001 ACCESS f OR aiNAOE IF ACTOR 75 to SOI 0 2. SPECIAL PROCESS HAZARDS BASE E ACTOR A PROCESS TEMPERATURE luE OMLy ONEI I A8QVt ELAShpoint 7 ABOvfc boiling point 3 above auto ignition 8 lOwpRESSuRC i$uB atomQShE RiC> C OPERATION in On NEAR ElammablE Range I TANK FARM STORAGE ELAMMA0LE LlOUIOS 7 PROCESS UPSET OR RuRGE FAILURE 3 always in f lammablE Range O Oust explosion if actor 70 to 7 OOKSE E T able nil E PRESSURE tSEE flGUC 71 E LOW TEMPERATURE IE ACTOR 70 to SOI G Ou ANT IT Y OE E LAMM ABLE mate RIAL I LlOUIOS OR CASES IN PROCESS ISEE E IG 31 7 LIQUIDS or CASES in storage tSEE EIG. oi 3 COMBUSTIBLE SOliOS IN STORAGE ,SEE FIG 51 H CORROSION ANO EROSION IF ACTOR .10 to 751 J LEAKAGE - JOINTS ANO packing IE ACTOR .10 io 1.501 K. use OF FIREO HEATERS (SEE Fig fil L. HOT OIL heat exchange SYSTEM ifaCTQR .15 to 1.15HSEE TABLE ivi M. rotating EQUIPMENT. PUMPS COMPRESSORS SPECIAL PROCESS HAZARD FACTOR (F?) UNIT HAZARD FACTOR IF,.F? F^i fiRt ANOExPLOSiON index if3.mFi f nii|. FO"M C lllll rimrco PE NALTy i 00 PENALTY USED 1.00 .35 ).o 1 00 1 00 .30 `30 .00 ?5 50 50 .30 30 .eo 2S 731. . 10 . 10 .50 3.6 A-,0 DO A 044743 CONFIDENTIAL 84 Exhibit B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C,) .97 .95 to .98 .75to@> .94 to@ e) Computer Control 0 .98 f) Inert Gas g) Operating Procedures h) Reactive Chemical Review o .94 o .99 .85 to^p) Cf Total LM-- a) Remote Control Valves b) Dump/Blowdown 2. Material Isolation (C2) )to .96 c) Drainage d) Interlock C} Total 0' .85 to .95 <d ih ~ / ( .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to( ,92to@ .75 to .85 .90 to<|? .85 f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection MlC3 Total ^6P to .96 .95 to .97 .87 to .98^-^ .92 to .90 to .96 C, X C2 X c3 * 0-3/6 See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure Value of Area of Exposure Damage Factor Base MPPD (A-3 X B) Credit Factor, Actual Actual MPPD (C x D) Days Outage (MPDO) 7Z ft. SMM Of (p SMM o-iis ML 42. 2M ^7 Z7j_00 20 dav^_ 81- 822- X 310.000 X, 7= 'Product of all factors used. #/^y, oo o ack or FOAM C-ltllt A DO A 044744 CONFIDENTIAL FIRE AND EXPLOSION ..<DEX Exhibit 'A' rCTuf G)r\j X. b^Q^ylgK)^. OVw<jgL MATRIA`l5 AND PROCESS 1 -- * P/LDPoIe-m^ OUyo^l, M-lO " Hz^ (HuivpAc^oi,'o CAUtMTI 1 * IOIVINTI *TM J matcoiai cArmo icpp tari p i APPPwniv ai 1. GENERAL PROCESS HAZARDS (SEE TABLE III A f\ r ttASf fACTOfl ------------------------------------------------------------------------------------------------------------------------------------------------ fr- A t xOThERmiC reactions (FACTOR .10 to i 25 i a PNOOTHC RMIC nc ACTIONS FACTO ?0 to .*0) C material handling & transfer if ACTOR .25 IO .H5I o enclosed process units (factor so io 901 E. ACCESS f orainage (Factor 3510 soi r.f nf rai, ARnt-Ejs hajaRD factor if i , ,,, U t/Ae^/lCAJA+iofO 1u PFNALTV ) 00 , 30 PENALTY USED 1 00 .3 0 1 35 | 125 . z5 -1. 5-5 2 SPECIAL PROCESS HAZARDS ucro ....................... ........................ - A PROCESS TEMPERATURE iUSE ONlv ONEi 1 above Flashpoint 3 ABOVE soiling point 3 a90ve auTOiCniTiOn 5 SRC n Sue A rOMOSPtHE RtCi C operation inor near flammable Range 1 tank farmSTORace Flammable LiOulDS 2 process upset or purge failure 3 ALWAYS IN KAMMABlE RANGE O OUST EXPLOSION (FACTOR 25 IO 2.00KSEE TABLE III) ............ - ... 1 00 .30 GO 75 .50 50 ,30 .80 1 00 Jo Q _ E PRESSURE (SEE FIGURE 21 F lOw TEMPERATURE FACTOR 30'0 501 ; QUA\r, t v o* * LAWAgwE vate ftiA. i LIQUIDS CR CASES IN PROCESS 'SEE =iG. 31 3 LIQUIDS OR GASES IN STORAGE 'SEE F iG 41 3 COMBUSTIBLE SOLlOS in storage SEE Fig 51 m CORROSION AND EROSION IF actor 10 m T5' 1 } 'i 1j |q j ! j jQ . LEAKAGE- joints AMO PACK INC IE actor IQ to I 501 ________________ :| Q I | <0*11 K St OF F'REO HE ate RS 'SEE F iG. u) |j l hot oil heat exchange system (Factor .15 to i.ismsee table >\ i M ROTATING EQUIPMENT PuM*S. COMPRESSORS .50 >tCiAL PROCESS HA3ARD FACTOR IF.1 , MO u\ ` HAJAROMCIOH *P} m f ? P 3J------------------------------------------------------------------------------------------------------------------------------------ fr. ` HE A\L> 1 (PLCSiON INOE X IF^.MFl F *, Fl 1---------------------------------------------------------------- --------------------- 3,35. 10.35 i- . r. . x 111 .a ; i , -.. t DO A 044745 CONFIDENTIAL Exhibit B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C1) .97 .95 to .75 to(3) .94 to .98 e) Computer Control f) Inert Gas g) Operating Procedures .89 to .98 .50 to .94 (86)io .99 h) Reactive Chemical Review ^5tcQ96) Cn Total IMSA 2. Material Isolation (C,) a) Remote Control Valves <g> b) Dump/Blowdown S4 to^y c) Drainage d) Interlock C2 Total 0-. 747____ ' Jg^to .95 .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protect-i-o--n- (C43) .90 to .97 .92 to .97 .75 to .85 .90tof95) .85 f) Sprinkler Systems 9> Water Curtains h) Foam i) Hand Extinguishers k) Cable Protection C, Total 0.857 .60 to .96 .95 to .97 .87 to .98 ,92to .97 .90 to .96 <&> <3D c, xCj xc3. 0,5.31- _ See Figure 9 for conversion to Actual Credit Factor. (To Line D below). A-1. F & El A-2. Radius of Exposure RISK ANALYSIS SUMMARY _70l3 j-*) ft. A-3. Value of Area of Exposure SMM B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) (e ol ,(/rf,o SMM $MM *5. gq m *3. Mm so davs. (ff0^7)* Br 'Product of all factors used. EX =*2-10,000 sack or Fomm c-ime cn^r 44746 confidential Exhibit B .OSSCONTROL CREDIT FACTORS 1. Process Control (C1) a) E rncrycncy Power X97} e) Computer Control .89 to .98 ( y j/ b) Cooling .93 fj Inert Gas Jj) to .94 N~ c) Efcxxpplioossiioonn Ccoonnttrrootl .75 to .96 Ofcj g) Operating Procedures 786lo.99 Emergency Shutdown ^4Xo .98 hj Reactive Chemical Review (|}o .96 C( Total 0. son 2. Material Isolation (C2) a) Remote Control Valves b) Dump/Blowdown K94 to .96 Cj Total c) Drainage d) Interlock 0.7f r .85 to .95 (5^ .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems Fire Protection (C3) .90 to .971 .92 to .971 .75 to .85 <9p>to .95 .85 Sprinkler Systems Water Curtains Foam Hand Extinguishers Cable Protection C3 Total (?'77 2- _ * .60 to .96 .95 to .97 .92 to .97 .90 to .96 C, X C2 X C3 = - Q7 See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El 76,45 A-2. Radius o( Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) ft. SMM 0'!r3 SMM CP, */(> SMM 9., Q.M. & 2'Szm /. IS ? Sri zz. 'Product of all factors used. x a$,soo x lo c 30 ^S^,0 3S >ck or ro*M QO a 044748 CONFIDENTIAL MATERIAL FACTOR (SEE TABLE I APPENDIX A) 1. GENERAL PROCESS HAZARDS (SEE TABLE II) 8ASC FACTOR A E XQT Mt RmiC RE ACTIONS '* acTgr 30 to I ?'jt 8 ENOOTHF RMlC FU ACTIONS IF ACTOR ,70 10 4QI____________ c. MATERIAL hanOlinG A transfer IFACTOR .75 io .851 O EnClOSEO PROCESS UNITS (FACTOR 30 io ,'JOi E ACCESS F DRAINAGE if ACTOR ,75 io .SO)____________________________________ general process hazaro factor if,i____________________________ 2. SPECIAL PROCESS HAZARDS BASE FACTOR A PROCESS TEMPERATURE iuSE ONlv ONEi I ABOVE Flashpoint 7. above soiling POinT 3 ABOVE AuTOiGnition B LOW PRESSURE ISUB ATOmOSPhE RiCI C operation in OR near Flammable range i tank farm storage Flammable liOuiOS 7 PROCESS UPSET OR PURGE FAILURE 3, always in Flammable range D OUST EXPLOSION IFACTOR .75 io 7 OOMSEE TABLE Mil E PRESSURE (SEE FIGURE 71 F. LOW TEMPERATURE IFACTOR .70 to .501 G QUANTITY OF F LAMMAflLE MA TE RIAL ) LIQUIDS OR GASES IN PROCESS ISEE FIG 31 7 LIQUIDS or GASES IN storage IS6E F K3. Ft 3 COMBUSTIBLE SOLIDS IN STORAGE ISEE FIG 51 H CORROSION ANO EROSION (FACTOR .10 to .>51 J LEAKAGE - joints and Packing (FACTOR .10 in 1501 K USE OF fireo HEATERS ISEE FIG. G) L. HOT Oil heat EXCHANGE SYSTEM (FACTOR ,15 io t.ISlISEE TABLE IVI M ROTATING EQUIPMENT. PUMPS. COMPRESSORS SPECIAL PROCESS HAZARD FACTOR IF.1 PENALTY I 00 MALT V USE Q 1 00 2/ 3r> A it> \ oo 1 00 .30 "oo TT Oik. .50 50 "3F .80 0.2 US I .3 Z.3S -------- -------------------- UNIT HAZARD FACTOR (F(F? Fj( ----------------------------fire ano explosion index if ,mfi fneii-------------------------------------------------------------------------------------------------------------- ------------------ -- 7U5 rMa C-IIH* MINrcD -!- 00 A 04A7A9 CONFIDENTIAL Exhibit B LOSS CONTROL CREDIT FACTOR. 1. Process Control (C?) a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown .75 to .96 @>o,98 e) Computer Control .89 to .98 {) Inert Gas g) Operating Procedures JZQ to .94 C86^o .99 h) Reactive Chemical Review (>>.96 C, Total 0> 560____* a) Remote Control Valves b) Dump/Blowdown 2. Material Isolation (C2) c) Drainage d) Interlock C2 Total 0,7l a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to -9/) f) Sprinkler Systems .92 to .97 gg g) Water Curtains .75 to .85' h) Foam ($0ho .95 .85 ' j) Hand Extinguishers k) Cable Protection C3 Total 0*172- * .60 to .96 .95 to .97 8710 `98 .92 to .97 QjJ .90 t,o .96 c xc xc- 0-307 See Figure 9 for conversion to Actual Credit Factor. (To Line D below). A-1. F & El A-2. Radius of Exposure RISK ANALYSIS SUMMARY 7l?,(*5 ..kjjl- A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) SMM 0.1*3 $MM 2.5ZW D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) #IS ^ Hi SMM ZZ. day? `Product of all factors used. 4^-x iis.noox-io20 1 #51,0 33 ACK OF FORM C-1I1IS -I ( <7t-*><) DO fit CO/yp- 044^sr. IdntjaL fire and explosion jdex Exhibit'A' Pla <fuenii/Jj L<l . J.iTT Ghee! I hra< R T-IOZC MATERIALS AND PROCESS C A T Al t fl /Yfi/yQ Pride - PDC - DC/PE tOLVCNTl ft/o/ZC. MATERIAL FACTOR (SEE TABLE I APPENDIX Al 1. GENERAL PROCESS HAZARDS (SEE TABLE BASEfACTOR A F XOTMt HMIC HE ACTIONS IE ACTO 30 10 1 251 IMOOlHfRMIC REACTIONS If ACTOH 20 te 401 c material HANOEimC A TRANSFER if actor .20 to B5I O ENCLOSED PROCESS UNITS (F ACTO 30 to .J0 E ACCESS DRAINAGE If ACTOR 25 to .SOI general process hazard factor if t> 2. SPECIAL PROCESS HAZARDS base factor a PROCESS TEMPERATURE (USE Only ONEi l. ABOVE F LASH POINT 2 ABOVE BOILING POINT 3 ABOVE AUTOIGNlTlON B LOW PRESSURE (SUB aTOmOSPmERiCI C operation in OR near Flammable Range i tank farm storage flammable liOlmos 2. PROCESS UPSET OR PURGE FAILURE 3. always in F LAMMABLE range D OUST EXPLOSION IFACTOR .25 10 2.00IISEE TABLE nil E PRESSURE (SEE FIGURE 21 F. LOW TFMPERATURE (FACTOR .20 (0 .501 pf nalt v I 00 0>3 Pt NALT Y USE D I 00 0> 3 2/ .35 <zs 1.S5 l 00 1.00 .30 Too" TT .50 50 3&,30 .HO ZS g ouantity of flammable material 1 LIOUIOS OR GASES in PROCESS (SEE FlC. 31 2 LiOUIDS OR GASES IN STORAGE ISEE FIG. 41 3. COMBUSTIBLE SOLIOS IN STORAGE 'SEE F IG SI N CORROSION ANO EROSION IFACTOR .10 10 .>51 J LEAKAGE - JOINTS ANO PACKING IF ACTOR .10 io 1.501 K. USE OF FlREO HEATERS ISEE FIG. 61 L. MOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 10 1.15IISEE TABLE IV) M. ROTATING EQUIPMENT. PUMPS. COMPRESSORS SPECIAL PROCESS HAZARD FACTOR IF^I unit hazard factor if,*f f i________--_______________ _________________________________________ FIRE ANO FXPLOSION INDEX (F3MFI Ffl, CD bU * so 10 4 10 .50 3.05 4.73 ------------------------ ta. n?7 POPH C-ltlM PPIMTCD DO 4 Cnfi0 447$i Exhibit B LOSS CONTROL CREDIT FACTOR 1, Process Controt (C, 1 a) Emergency Power b) Cooling c) Explosion Control (^9?) .95 to .98 .75to(f) d) Emergency Shutdown (94)to .98 e) Computer Control .89 to .98 f) Inert Gas g) Operating Procedures .90 to .94 (gf)to .99 h) Reactive Chemical Review uSoio ,96 C. Total . 54-7 2. Material Isolation (C2) a) Remote Control Valves^94j b) Dump/Blowdown 794to .96 c) Drainage d) Interlock C2 Total . 767 0.95 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C?) .90 to .92 to(97) .75 to .85 .90 to .85 f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection C, Total ,, . 807 j/J?--"X .60 to .96 (-^S J .95 to .97 -- .92 to .97 .90 to .96 C, X Cj X c3 . iQ. 33? . See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El v4< A-2. Radius of Exposure SG it- 4 A-3. Value of Area of Exposure SMM *.OM B. Damage Factor C. Base MPPD (A-3 X B) 0.7Z SMM i Z.tUM D. Credit Factor, Actual 0-48 jt ___ * 1 .Dim E. Actual MPPD (C x D) SMM F. Days Outage (MPDO) 23 dayL- Ji 'Product of all factors used. orBACK FORM C*J Oo eTT4? PropulejM Qy/de - PPC - DC/fh lOLVUMTt /fa MATERIAL FACTOR (SEE TABLE 1 APP6N0IX A) 1. GENERAL PROCESS HAZARDS (SEE TABLE III BASf TACTOfl ----------------------------------------------------------------------------------------------------------------------------------------------- -- A t xOTmEMMiC REACTIONS If ACTOR 30 10 t 7b' U ENDOTHERMIC RE actions iFACTQR 30 1C JOI c. MATtSiAL manOlinG a TRANSFER IFACTOR ,7b to ,851 0 ENCLOSED PROCESS UMTS (FACTOR .30 to 001 E ACCES5 F DRAINAGE ifACfOA 25 in .501 n M E R A l PROCFSS NAZARO f ACTfifl f E 1 Z. SPECIAL PROCESS HAZARDS BASE F ACTOR ------------------------------------------------------------------------------------------------------------------- ------------------------------- A PROCESS TMPeRATu6 (USE OMV ONi t, ABOVE F LASH POINT 2 above BOILINC point 3 ABOVE AUTOiCN! riON B. LOW PRESSURE tSUB ATOMOSPHE RIC) C Operation in OR near Flammable Range 1 tank Farm STORAGE Flammable liOUIOS 2. PROCESS UPSET OR purge failure 3. always in Flammable range 0 OUST EXPLOSION (FACTOR 75 10 2 OOJISEE table mi E PRESSURE ISEE FIGURE 2) F, LOW TEMPERATURE (FACTOR ,20 to ,501 P NALTV 1 00 o-3 PE nalT y USED 00 6-3 ,35 1 00 .30 .GO .75 .50 50 .30 MO D. 2f hS 1 00 CaO ' 30 71 G Quantity of f lammablE mate rial i LtOuiOS OR OASES IN process ISEE FiG. 3) 2 LIOUIOS 0 CASES IN STORAGE (SEE FiG. A) 3 COMBUSTIBLE SOLIDS IN STORAGE iSEE Fig 5i H CORROSION AND EROSION IF ACTOR .10 to .75) J LEAKAGE* JOINTS AND packing'FACTOR .10 m t.SOI K. USE OF FlREO HEATERS ISEE FIG. G) L. HOT OIL HEAT EXCHANGE SYSTEM IFACTOR .15 IO 1.15115b F TABLE IV) m. rotating equipment, pumps, compressors i./a jo ,/i 7 10 ,50 SPECIAL PROCESS HAZARD FACTOR IF^I , UNIT HAZARD FACTOR IF, , F? Fj( -------------------------------------------------------------------------------------------------------------------------------------- -- 3,S5_ 5. to ------------- _ fire ANO explosion INOEK iFj.MFl FilchPOM C*XI> MINTED *** (*-!*) DO A 044753 CONFIDENTIAL >07- / 7 Exhibit B LOSS CONTROL CREDIT FACTOR a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C,) C, Total e) Computer Control .89 to .98 f) Inert Gas o .94 0.597 . f9) Operating Procedures h) Reactive Chemical Review 0.99 o .96 2. Material Isolation {C2J a) Remote Control Valves b) Dump/Blowdown .94 to .96 c) Drainage d) Interlock C3 Total 0. 747 ^>o .95 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection <C3) f) Sprinkler Systems g) Water Curtains h) Foam .90 j) Hand Extinguishers .85 k) Cable Protection o,m C Total .60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 C, X C2 X C3 --... See Figure 9 for conversion to A---------- 1 Cartnr fTn I inp O hpinwl RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) It 7,1 . `tO ft. SMM 6.74- $MM 0,43 $MM 6* O tPt 4-.MM 2 33 'Product of all factors used. A C K Of FORM DO A 044754 CONFIDENTIAL FIRE AND EXPLOSION f DEX Exhibit *A" LOClTtOH dTTZ" ?/?//* Qlu/ol 2~ 'prepv/e.rte Oxif/c CiTLf|^ ^ /Pofje. flfC& /O , T~- 3QC materials and process "fPC- PC/ lOkVlHTt A^Ajt 1. GENERAL PROCESS HAZARDS (SEE TABLE III BASE. t AC TOP --------_____...... ...... ................. ............... A E xoThF RmiC reactions if ACTOR ,30 to 1 75> u endothermic re actions (Factor jo to .401 c MATERIAL HANOLING & TRANSFER 1 F ACTOR .15 to BSI 0 ENCLOSED PROCESS UNITS (FACTOR .30 to .001 C. ACCESS F. DRAINAGE (FACTOR .J5 10 .501 GENERAL PROCESS HAZARD FACTOR (*( 1 ............ k- 2. SPECIAL PROCESS HAZARDS base factor ------------------------------------------------------------------------------------------------------------------------------------------------- -- A PROCESS TEMPERATURE (USE ONLT 0N| 1. ABOVE F LASH POINT ? ABOVE BOILING POINT 3 ABOVE AUTOIGNITION a LOW PRESSURE (SUB aTOmOSPhE RiCI c operation in or near flammable range i tank farm storage flammable liouioS 7 PROCESS UPSET OR PURGE FAILURE 3 almavj in HammablE range 0 OUST EXPLOSION (FACTOR .JS to 7 00IISEE TABLE nil PRESSURE ISEE FIGURE 71 F. LOW TEMPERATURE (FACTOR .70 to .501 P MALTY 1 00 _ PC NAUT Y US D 1.00 0'3 .35 _ p2s - t.ss 1 00 1.00 .30 .00 u .75 SO 50 .30 30 .RO 125 c. quantity of flammable material 1 LiQutOS OR GASES IN PROCESS (SEE FIG. 31 7 LIOUIOS OR GASES IN STORACE ISEE FiC 41 3 COMBUSTIBLE SOLIOS IN STORAGE (SEE FIG. 51 H CORROSION ANO EROSION 1F ACTOR .10 to .75) j. leakage - joints ano packing (factor .10 to i.soi K. USE OF FIRED HEATERS (SEE FIG. 61 L. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to 1.15IISEE TABLE IV) M. rotating Equipment, pumps, compressors SPECIAL PROCESS HAZARD Factor ic^i .50 , unit HAZARD FACTOR IF, iF?iF , ----------------------------------------------------------------------------------------------------------- ------------ r- ).LH JO .10 JO US s.(,o yi Fire ANO EXPLOSION INDEX IFj.MFl F r. LI) .................... ...................................... ......- --. 00 A 044755 CONFIDENTIAL ML Exhibit B LOSS control credit factors 1. Process Control (C,) a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown r.^jJ J5 to .98 .75 to ^9^ to .98 e) Computer Control f) Inert Gas g) Operating Procedures h) Reactive Chemical Review .89 to .98 .90 to .94 (|> .99 (^8f>Vto .96 C, Total 2. Material Isolation (C2) a) Remote Control Valves^^) c) Drainage b) Dump/Blowdown .94 to .96 d) Interlock C,, Total . O. 7U 0.95 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection C3 Total O.tQ 7 .60 to -96^' 4s) .95 to .97 .87 to .98 .92 to .97 .90 to .96 c, X c2 X c3 = >r33<? See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) 97 ft. 4.7? $MM S MM 04$ $MM tfs, 4.3S7U 1,09 S3 -^25 Vy/jo * Product of all factors used. 0 71 0BACK OF FOAM C-Ill** R-I*-> (< - ><) o 0 A 0447SA C0NFrD5NTrAL HIGH HAZARD PACKAGE - GLYCOL ill PHASE II 4. a. Propylene raw material available by pipeline from LHC If2, and salt dome storage. and Chlorine raw material available by pipeline from division chlorine plants. Caustic raw material available by pipeline from division Caustic Plant. b. Propylene oxide by customers by tank car. Propylene glycol to customers by tank car, barge. PDC to division Solvents Plant for internal use. c. ,d. Division emergency fire water supplied by seven diesel driven deep wells and one diesel driven pump in Water Treating Plant Deep wells and water treating rated at 5000 G.P.M. @ 125 psi each. e. Spare parts are available in Louisiana Division and other Dow locations. DO A 044757 donftdenttai. PLANT: DIVISION: RE-CAP WORK SHEET GLiCOL =4 /__________ L.A. XW/S/Qa/_________ PREPARED BY: DATE: Z/sjil Process Units Unit Hazard Factor F3 Material Factor MF F&EI (f3xmfJ (A) Value Area of Exposure $MM IB) Damage Factor from Figure 7 10 $TOAC> Po. If ^TDH&f' Ro. 4.o 4.o 2/ Zl 84 84 3.S m 3. /"i . UL> .A PfcOf^LFfJC. Ciyco*- 3-3 5* 7! 70.2S 9.02/7 42 70 ReActs si Ae.tu4 3 i5 Z! "1 (o. (ai> -9.0 AT ,A3 2/71 R^Acn/t Aoea -5 3.GS 1GMS 4.0 H 43 Ac.ca $ - 7-lozc 4-1i 2/ 99.27 3.0 aT .72 Adf-A 9 ' T-krtfb 5.to Zl }07,t ls> . 0 .7* AtLB* /O- T-3DO 5.Go 2./ 117, G S,5 m -79 (C) Base MPPD SMM (AXB) (D) Credit Factor C1xC2xC3 from Figure 9 8.3 m .3lS 2.3 M . 3/r < 44 2SZM .94 2.Si. M 94 2 ,IG M ll.tj.tf iaJ" .42 .49 4-35 FT .42 (E) Actual MPPD SMM (CXD) 727 M 7S7M 3.4? M f./S9 H l 1*57 m" t >0<m 7.13 M Z. C><7 Pf (F) Days Outage MPDO from Figure 10 20 20 SO 22 Zz 23 33 33 . . nzHMQaoz"nn oo J> oi** 3> (/t f~ oo FORM C-SOOIG R-IO-IO {471 -037) L.tfe id j. PROPYLENE C H r7~`i:uiucrjr'p Cip_ crtioAiW -H2-0 ' CHLOROHYORIN REACTOR . . -- ,t OXIDE REACTOR CO NFIDENTIAL | CRUDE i 1 OXiDE STORAGE-2 o o o yi vO STORAGE 3 GLYCOL REACTOR Hz 0 t|\ ! 1 i1 GLYCOL-/? CRUDE OXiDE STORAGE 2 --1> COMPRESSOR CRUDE OXIDE STORAGE-1 L STORAGE-3 ---------------o. --------------> 'A EVAPORATOR USP H2 0 STRIPPER ri - Lr * ---------- ( SALEA31 OXIDE s *.0. . PURIFICATION PGI DPG A / ?&, - 't stit ' 00 & **/'/} Sra, / f I LEGEND: P0 - PROPYLENE OXIDE COLUMN OR STORAGE rDC - PROPYL ENE Dl- CHLORIDE STORAGE DCiPE - ETHER STORAGE RICH - t PICriOF.'CH YD RIN STORAGE rff/T, f. V --o> I' l > PROCESS VATER SPRINKLER SYSTEM SPRINKLER SYST EM TRIP YALVE DELUGE GUM D0 A 0A4760 confidential FIRE AND EXPLOSION IN^EX Exhibit 'A' Cr\:r,.l H 1 -------------- /-------- > M )*( h ,, p.o. <. * T 4 1 v t f t /Vv/'/f 70 ho - - ; V f0 0 c ~ / MATERIALS AND PROCESS tOLVi NM 4 I* --Received ! ------------------ L-V-P ' 7 |P A- Safety dept. MATfHJAl FACTORIAL! T AIR E I APPCNDlX A| 1 Gf NT RAL PROCESS HAZAHDS l.r>f E TABLE II) it AM > A I Hill A | . 1 ) I i t t It M II Ml /.C' I'.L. I AC I 'IH JO in I Ji' II ( t.t II) I a! II' III. HI AC I II) (I i i I AC TO I* ?0 it 40' C M A I I II l A L 11 AN (l L H-C C, I R ANSf R l f 4 C TOFF JO lo (J t MCI OSI O CIIDCI OS uUlTS If ACTOn 30 io 'JOI f ACU SS__________________________________ r OHAiN Mil IfACfOH 7'jio SOI Ci rjt n al pnoci r.ii i// ajiej ( ac t0' if , >____________ 2 SPECIAL PROCESS HAZARDS II A II i ac TO n A pnori i.3 7 l Ml'l H A T UE lUf.C ON L v ON [ I I AIIOMl I l A 'ill MO>N 7 J A HU V I HOI! INC, POlM I 3 Alio . I ah ii)ii.m J iOn a i o^v pmi ".?iufi( iiu(j aiomoji'hi ic> C Ol'l n A 7 lON IN on Nt 4H I L tV.t.'lOll ANGE I Tank i irj ;nmf, F lamvaglC liOuiOS 7 phoci :.S ui'SI 7 on fu`'i.l f *iiu 3 AL7>4V; IN I lAMMAHU HANOI o oust iruiiioi if aC7o ?i u : qomsf e iaih! mi ( Pm VjUHI tSi l f ir.unr ji f l OW T l MCI f A 7 1 III I l f AC 7 on 70 III i Ol Pi NAl 1 V t no rt NAl Tv uSf o J oo ID 1 00 30 3 0 CO : 00 SO .30 no Jjo. 2S l. Oil AN 1 ll V Ol I iM.tMAIIll 1,1 AT | HI A l. i l lOiHijj fin r.A.i in ciinri ss mi f ir, 31 ? 1 lOlUDS OIH liASI S IN SIOIIAO.I IM I 1 It 4 1 3 COmHuMiuU SOuDS IN jIOHf.r,[ <5(1 (I(, 'll 11 CORnnsifiN ano fiOSiom if ACion . 10 >n ;S) j leakage- joints and pack inG if actor iOm i.ioi * USE Of FiFU O h a TE ns ISF f iC ft I SIS , 10 . 10 L. mot Oil MEAT EXCHANGE SvstimiIjcTOH ,15m 7.7SHNE t TaolI ivi M ROT A T INC E OUlPME N I PUMPS COMPAl SSOHS .so SPF Cl AE PRO CE SS HrtfAliO F ACTOR II ^ i u UNIT HA2ARO Facto FI |F(.I fj, __ _ FIREANQfxCiOMONlNOlX IF . MF I If. Ill f,0 Oo C0^Nrr^ - 64 t o C lt\*C 1`HiSltll N`l'lO (.#, 0*4) Exhibit B )sS_C0NTROL_CREPIT FACTORS a) tft-ff(j(:ficy f'ov/tr b) Cooling c) yplosion Conlrol fi) Emergency Shutdown 1. Process Control (C,) 97 .95 to .98 ,75to@ .94 to/Si) e) Computer Control f) Inert Gas g) Operaiing Procedures h) Reactive Chemical Review P9 to .90 (9()h)to .94 .99 .85 io^9$ T fi. Remote Control Valves I)) Dump/Blowdown 2. Material Isolation (C2) >10.96 c) Drainage d) Interlock C7 Total O' .85 to .95 di }'( - /, L .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to0? .92 toffi .75 to .85 .90io<fP .85 f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection QtS I C3 Total 6p to .96 95io .97 87 to .98 92 to .97 .90 to .96 c, x C2 X C3 O'316 See Figure 9 for conversion to Actual Credit Factor. (To Line 0 below). A-1. F & El A .0 Radius ot Exposure A-3. Value o 1 Area ol Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor. Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) "Product of all factors used. n-- 7Z ft. SMM 0,(r(r ^ SMM . O.ilf ,sni 4 2. DO A 044764 CONFIDENTIAL 7Z7, OOP 20 days. T - 2J2- v 3 o.oo x, 7z 3oa / #/^y. ooo n {* - ? x *r x * 0M C-iJiBO ^MlfSJTCC DO A 044765 CONFIDENTIAL Exhibit 6 bPSsCONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C,) .97 .95 to .B8 .75 to .94 to^9^) e) Computer Control f) Inert Gas g) Operating Procedures M. to .98 ftto -94 (|jpo .99 h) Reactive Chemical Review .85 Cf Total LM-' a) Remote Control Valves h) Dump/Blowdown 2, Material Isolation (C2) to .96 c) Drainage d) Interlock C2 Total 0> .85 to .95 d, - (.0 .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) 90 \o(9J^ 92 to 75 to J85 90 tol(Cf? 85 C, Total f) Sprinkler Systems 9) Water Curtains h) Foam i) Hand Extinguishers k) Cable Protection o.sl .60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 0.316C, c3xc3 = See Figure 9 for conversion to P art nr ITo Line D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A*3 Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) 7Z ft. SMM 0. o.ns SMM /s. 5 01 4 2. 3W -727, 000 ZP -days,,.. 31 c / 722^ X, 7: ?0A ' Product of all factors used. #ASV 00 O fiiCk Of fOM C-tlMQ *< ) DO A 044766 ( FIRE AND EXPLOSION ..<DEX Exhibit'A' <$> G t-y JT_ ____EiLO.p4lH.MEl Toe . i c* ** Ij * Vi fiz._(JtlyJjj tiAa tp gt a 1 PArrno Kf t tari t i aPppmoix At m P\ __________________________ _____________________ r '*1______ V GENERAL PROCESS HAZARDS (SEE TABLE II) tlAUf fACTQR ---------------------------------------------------------------------------------------------------------- - pf nalT y 1 00 PENALTY l/5 0 i 00 t a (*oiHtflMicl Acriuivs if ACTOfl 30 to \ 25i a E NDOT Mt HMiC OC actions if ACTOB 70 10 .401 C matEhiac handling ft TRANSFER iFacTOR 25 10 .HSi 0 ENCLOSED PROCESS UNITS |FACTOR 20 10 001 t ACCESS F DRAINAGE IEACTOR 75 10 501 r.ENFRAl PROCESS HAZARD F ACTOR IF ,! _ ,, _ U jAe r\ nCKJA^i n fd |O . 30 .30 35 .Is - . 2.5 1,.5-s 2 SPECIAL PROCESS HAZARDS MA$f factor --.........*--..........-.......................................... ... -- 1 00 l 00 a process temperature iuse onl* onei 1 A0OvE F E ASH POINT ? ABOVE aO'SINE. POlN T J :gOvf auJO'CMDON J e 'nr ..i.'Bt sue a tcmosphe rici 30 00 .(oO 75 50 c operation in or NEAR FlAmmablE RANGE 1 TANK FARM STORAGE f LAMMABLE LIQUIDS 2 PROCESS UPSET OR PURGE failure 3 ALWAYS IN FLAMMABLE RANGE D OUST Explosion (FACTOR 25 io 2 OOl(SEE TABLE nil 50 30 .80 E PRESSURE (SEE FIGURE 21 F LOW TP MPLR ATURE FACTOR 20 'Q 50) COuantiTt of FlammaBlE materia. i u'QuiD'iOfl L.A5E.5 IM PROCLSj, -i,fE fig. 31 7 UOUiDS O" GJSfS im iTC^JGt '5c ^iC 41 3 COMBUSTIBLE SOLIDS IN STORAGE SE E FIG 51 i CORROSION anO E ROSION IF ACTOR io io >5 . leakage joints and pack inG iF actor io to 1 50> ' SEOFFiREOhEATERS'SEEFiGuI 1 .j ! .io : .10 ! .10 1 1j ............. L HOT oil HEAT EXCHANGE SVSTE.M (FACTOR .15 IO I.ISIlSEE TABLE ivi M rotating Equipment Pumps COMPRESSORS .50 'iCtAL PROCESS Hi/ARD FACTOR i F ~ > HA/;HDuLit;H i | ^ f , F y -------------------------------- ----------------------^ HE ANO XPli'S.ON 'NOE X iF . a MF 1 I 1 HI----------------------- r l.w ------------------ - 3.35 10.25_ ---------------- ,____ _ rnGA 044?67 C0NFIDNTIal LOSS CONTROL CREDIT FACTORS (IslO ~ *7 a) E mergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1* Process Control (C1) .97 .95 to .98. ,75to(9p .94 to .98 e) Computer Control .89 to .98 f) Inert Gas ;9D to .94 9) Operating Procedures Qjfmo .99 h) Reactive Chemical Review ,$5tcQ)6) , C1 Total JDuVA ' 2. Material Is-o- la<tio n~ (C2) a) Remote Control Valves s^\ b) Dump/Blowdown TJ4 to^36) c) Drainage d) Interlock C2 Total Dt%l____ ' @10 .95 .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply el Special Systems 3, Fire Protect-i-o-n-- (` C43) .90 to .97 .92 to .97 .75 to .85 .90tof95) .85 f) Sprinkler Systems g) Water Curtains h) Foam J) Hand Extinguishers k) Cable Protection .60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 <&> Q/rr5p)\ C3 Total 0.857 ,c, X C, X C, = 0 5.31 -_ See Figure 9 for conversion to Actual Credit Factor. (To Line D below). A-1. F & El RISK ANALYSIS SUMMARY -70i 35 A-2. Radius of Exposure ft. A-3. Value of Area of Exposure SMM B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) k^ - W/ f,o SMM SMM %..?q m #3, m m. SSL davs. 'Product of all factors used. SACK OK FORM C-22 MD R tO-tO (* 7 I >0) ) BT A^oooo. Exhibits /% J s/f/t'L. "`"GUv'i * I ------------------------- 7----------- ----------- -------- 7& rickfluf ftrre 4- MATERIALS AND PROCESS tbCJ Peg Cell EHIu^jT 9 tOlvtNTt ____________________ ___________________ MATERIAL FACTOR (Sf f 7 AfcLf I APPENDIX A) 1 GENFRAL PROCESS HAZAKOS (CfcE TARLE III 11-ai.r f AC. Kill A I XO T HI HMlC Ml AC I MIN'. I AC 1 OR '0 'O I ?OI U l nUU 1 mi hmt (n r.c I in'..1. . i /-t I OR ?0 if "0i c m A 1 11< IA L m an 1)1 im, r. liUNii f n it ACTOR 25 lu flit O I NCLOr.l O I'ROCES: UNITS it ACTOR 30 to yOl ACCL SS f ORainaOI IFACIOR 25 io SOI GENERAL PROCLOU HA/ARO (actor If J_____________________________ PFIJALTY I 00 2. special process hazards HASf f AC tom 100 A PROCCr.i T l Ml'f R A T uRE I USE OfJLVOMtl I Alio V L f L A s H COIN T 3 AEIOVE DOuiNr, COIN? 3 AOOvt auiOiGniTiOm a LOW PRE SSuRE <SU6 ATOMOSPmE me I .30 To ~ so C Ol'f RAllON IM 0 M MfAR FLAMMABLE RANCE I TANK r ARM STORAGE fLAMMABlE LIQUIDS 3 PROCESS UPSET OR AuRCt (AiluRE 3 always im Flammable RamCE O Dust xPLOSiOM IF ACTOR 25 to 2 QOIISE E T ABLE ml so .30 BO E PRESSURE ISE E fir.uRE 21 P LOW I f mi-E r a i u(U ifactqR 20 to .50) ______________________ PE malT v uui o I 00 Zf I.5D J 00 0 ! (p 0,2 G OllAMlllV Of FlAMMAHlE MATERIAL 1 lkjumjs or t.Asrs im process isee fic 31 2 LIQUIOS OR I.ASESIM STORAGE IS EE FiG a I 3 COMBUST KILE Si) L ids im ST or age ISEE Flit SI H CORROSION AMO f ROSlON IF ACTOR .10 ia (SI J LEAaAI',1 JOlM I s AMO p ACK ino IF actor 10 IA 1 SO) * USE Of FiRED HEATERS (SEE FiG Fii L MOT Oil meat Exchange SYSTEM iFaCTOR .15 10 1.1SHSEE TaeIlE ivi M rotating EQUIPMENT Pumps COMPRESSORS ilS. li .3 special process hazard factor if^i UNIT HAZARD F ACTOR IFj.Fj F3I Fire and Explosion in 01 x iF^.mm i aeii ^0**4 I0-O 00 A 044769 CONFIDENTIAL z-?s 3> (rS ----- -- 7U5 Exhibit B ,OSS CONI HOLCREDIT FACTORr 1. Process Control (C, ) a) L mergency Power b) Cooling c) E xplosion Conirol (97) e) Computer Conirol ?o.93 _ f) Inert Gas .75 to .96 Og) g) Operating Procedures Cl.89 to .98 M) to .94 <86to .99 d) E mergency Shutdown $4 to .98 h) Reactive Chemical Review to .96 C, Total O' SCO * 2. Material Isolation (C2) a) Remoic Control Valves & b) Dump/Blowdown (94 to .96 c) Drainage d) Interlock C3 Total 0* .85 to .95 .96 a) Leak Dejection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to ,97 0^5) 0 Sprinkler Systems .92 to .97 .75 to .85 ^9^io .95 .85 g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection .60 to .96 .95 to .97 .87 to .98 ^ .92 to .97 Qj) .90 to .96 C, Total 7C, X C,, X C3 = O' 30 See Figure 9 for conversion to Actual Credit Factor. (To Line D below). A-1. F & El RISK ANALYSIS SUMMARY 76,45 A-2. Radius oI Exposure A-3. Value ot Area ol Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credit Factor, Actual ft. SMM 0*lr 3 SMM CO, om *2'52#--7---- - E. Actual MPPD (C x D) F. Days Outage (MPDO) SMM Z'i. jjayi `Product of all factors used. iZ-x \iS,i0o%.10 - 3D ! #5 ?/ o 33 ? '1n fire and explosion Exhibit'A' rTrfr" --------- - *------ - r,{ ^jt I ftatfuerrt \/J( WHi 1 If Rentier f\rrfr ~ c ** f\rc& S___ MATERIALS AND PHOCESS TVopuli/uz i C A ? * L Y 41' f/tAJP hh 0, f Cl 1.1 ' fbCj tCfl , Ctl( f IIOOLLVVCINNTI */r/?z MATERIAL FACTOR (SEE TABLE 1 APPENDIX A| 1. GENERAL PROCESS HAZARDS IStE TABLE II) BASI FACTOR --------------------- ----------------------------------------------------------------------------------------------------------------------------- A X 0 T HE RMIC ML ACT IONS 1 ACTOR 30 10 1 251 B [NOOIHF HMlC l ACIIOM II ACTOH ?(l is JQl c M A T Rial hanOuNC a transfer IFaCTOR .25 io b5i o enclosed process units ifactom 10 to yoi E ACCESS F DRAINAGE (F ACTOR .25 io .SOI GENE RAL PROCESS HAZARD FACTOR IF ^ 1 2. SPECIAL PROCESS HAZARDS BASE FACTOR ------------------------------------------------------------------------------------------------------------- ---------------------------------------p- A PROCESSTEMPERATURE (USE ONLY ONEI 1 ABOVE F Lash POINT 2 ABOVE BOILING POINT 3 ABOVE AUTOIGNITION B LOW PRESSURE ISOB ATOMOSPHE Rici C OPE RA TlON IN OR NE AB F LAMMABLE RANGE i tank farm storage Flammable liquids 2 PROCESS UPSET OR PURGE FAILURE 3 ALWAYS in FLAMMABLE RANGE D Oust E KPLOSiON IF ACTOR 3S io 2 OOHSEE table mi PE N A L T Y 1 DO - PE NAl T Y USL 0 1 00 7/ U/ 31 1 00 .30 GO 7$ .50 50 .30 .80 1. 3Z> 1 00 E PRESSURE l$EE FIGURE 2) f low tempehature (Factor .20 10 ,soi C'2 <r\ C OUANTiTY of flammable material 1 LIQUIDS OR GASES IN PHOCESS (SEE FiG 31 2 LIQUIDS OR GASES IN storage (SEE FiG At 3 combustible SOLIDS IN STORAGE (SEE Fig SI H CORROSION ANO EROSION IF ACTOR ,10 io .751 J LEAKAGE . JOINTS ANO PACK ING If ACTOR 10 in ISO! It USE OF Fired HEATERS ISEE FiG Gl L. HOT Oil Ht AT EXCHANGE SYSTEM IFACTOR IS io T.lSHSEE TABLE IVI M ROTATING EQUIPMENT, PUMPS. COMPRESSORS 1 .3 SO SPECIAL PROCESS HAZARD FACTOR IF..I UNIT HAZARD FACTOR IF F F1 , ________________ z.?s_ 3, iS . ----------------- F IRE ANO Exp lQSiOn ind x if3 * mF i f * < i; - ______ p. lb.(r5 C IMi MIN1LO D0 A 044771 CONFIDENT! At. Exhibit 5 I OSS CONTROL CREDIT FACTOR. 1. Process Control (CT) a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown .75 to .96 (^4>o .98 e) Computer Control .89io.98 f) Inert Gas SQ to .94 g) Operating Procedures .99 h) Reactive Chemical Review (po .96 C, Total 0<5CD _ * 2. Material Isolation (C-,) a) Remote Control Valves b) Dump/Blowdown $94}o .96 C3 Total c) Drainage d) Interlock 0.71-S .85 to .95 MO) .96 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) ,90to f) .92 to .97 (gj) 9) .75 to .85 <9>to .95 h) j) .85 k) Sprinkler Systems Water Curtains Foam Hand Extinguishers Cable Protection .60 to .96 .95 to .97 '87,0`98/<?) .92to .97 (JiSJ .90 to .96 C3 Total Q.3o 7C, X C2 X C3 * See Figure 9 for conversion to Actual Credit Factor. (To Line D below). A`1. F & El RISK ANALYSIS SUMMARY 7 A-2, Radius of Exposure A*3. Value of Area of Exposure B. Damage Factor C. Base MPPD {A-3 X B) D. Credit Factor, Actual ft. SMM 0.1*3 SMM o.M y.iom &2-SZW E. Actual MPPD (C x D) F. Days Outage (MPDO) SMM Zt. iJavi, 'Product of all factors used. T-X Uf/W X 10 20 ' #51,0 33 BACK OK KOM C 1J 0 B * 1 O-iO (i 7 1-0 5 ) 00 A 04477? CONFIDENTIAL Exhibit B kOSS CQNTROL CREDIT FACTOf 1. Process Control (Ct) a) Emergency Power b) Cooling cl Explosion Control C'$T) ".95 to .98 ,75to@ d) Emergency Shutdown (94)to .98 e) Computer Control .89 to .98 f) Inert Gas g) Operating Procedures .90 to .94 (Tqz) ($6ho .99----- ^ (I^)to .96 h} Reactive Chemical Review C, Total .nJLtl___ * 2. Material Isolation (C2) a) Remote Control Valves'C94) b) Dump/Blowdown 794 to .96 C2 Total c) Drainage d) Interlock * y k 7--- a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to .92 to .75 to .85 ,90td@ .85 ' f) Sprinkler Systems 9) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection C3 Total .60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 c, X c2 X C3 *___. See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) D. Credil Factor, Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) W'Z 7 8(3 ft. $MM _ >7Z 0a -4A Cd\ SMM SMM 4 -- J ____ * Z.lLM " 1 1 . Ur\LTIFHVi 23 ------------ ' ---------- -- 81-Art, off `Product of all factors used. DO A 044774 CONFIDENTIAL BACK Of rOKU C-IIJAO B-l*-oj*TI-o>) Exhibit 6 i nsS CONTROL CREDIT FACTOR a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1, Process Control (C,) e) Computer Control 1) Inert Gas g) Operating Procedures h) Reactive Chemical Review C Total 0 1 2. Material Isolation (C2) a) Remote Control Valves Vi9 b) Dump/Blowdown .94 to .96 c) Drainage d) Interlock C3 Total o. 7f,7 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems Fire Protection (C3) f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection C3 Total f),W .60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 c,xc;xc3-^2/-23t_, See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El ..1(7-1 A-2. Radius of Exposure A-3. Value of Area of Exposure B. Damage Factor 90 tt. SMM 6. 74- 6.o m C. Base MPPD (A-3 X B) D. Credit Factor. Actual E. Actual MPPD (C x D) F. Days Outage (MPDO) OA8 $MM $MM ZJ3W 33 .jiayii too `Product of all factors used. DO A 044770 CONFIDENTIAL **CK OK rOHM C`22**0 AT4AIAL* Propy/fAJd: CATAL**/* ^ /)/bfJ Oxtflc ~ /UC- pC/pS lOLtffMTI MATERIAL FACTOR ISEE TABLE 1 APPENDIX A! 1. GENERAL PROCESS HAZARDS ISEE TABLE II) UASl f ACTOR ....-- - ' --- -- .... - -- i-- a t xotmi mmic at actions'Factor jo t i !i' 0 InoOThI hmjC RE ACTIONS IF ACTOR 70 io 40> c material hanounc a. transfer ifactor .75 io ssi 0 ENCLOSED PROCESS UNITS IFACTOR .30 to 501 C. ACCESS F ORAINAGE (FACTOR .25 to SOI CENE HAL PROCESS HA2ARD f AT.TOR |F , 1 -- -------- 2. SPECIAL PROCESS HAZARDS BASE FACTOR ------ --------------------------------------------------------------------------------------------------------------------------------------------- A PROCESS TEMPERATURE IUSE Only ONEi i, above Flashpoint 2 ABOVE BOILING POINT 3 ABOVE AUTOlGNlTlON 8 LOW PRESSURE ISUB ATOMOSPHE Rici C ope Ration in OR near Flammable range t tank farm storage Flammable liOuiOS 2 PROCESS UPSET OR PURGE Failure 3 always in Flammable range 0 OUST EXPLOSION ifactor .2S IO 200IISEE TABLE nil PRESSURE ISEE FIGURE 21 F. lOw TEMPERATURE IFACTOR .20 to .SOI Kl h* A LTV 1 00 Pfc nalTv ustu 1 00 0 ? z/ .35 '2S_ 1- - I.-& l oo 1 00 .30 .00 . (, * .75 ,50 50 3D.30 .80 125 G Ouamitv of Flammable material 1 LIOUIOS OR CASES IN PROCESS ISEE FIG 31 2 LIOUIOS OR GASES IN STORAGE ISEE FIG 4> 3 COMBUSTIBLE SOLIDS IN STORAGE ISEE F iG 51 h CORROSION AND EROSION (FACTOR .10 to .751 J LEAKAGE - JOINTS ANO PACKING IF ACTOR .TO io 1 SOI K. use OF FiREO HEATERS (SEE FIG. 01 L. HOT OIL HEAT EXCHANGE SYSTEM (FACTOR .15 to I.ISlISEE TABLE )V1 M. ROTATING EQUIPMENT. PUMPS COMPRESSORS Special process hazaro factor if^i .50 UNIT HAZARD FACTOR (F., i <x 3 Fire AND EXPLOSION INOEX |f , mh ff.ll) I'OBM C-IItat Mini CO H*|0-tO (|M-014| ~ DO A 044777 CONFIDFNTIAL ).LD JO .10 *10 10$ s.Oo - im ivY K Exhibit B , OSS CONTROL CREDIT FACTOR! a) Emcrgency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C1) C.91) .95 to .98 .IS to g) to .98 C. Total e) Computer Control .89 to .98 f) Inert Gas .90 to .94 g) Operating Procedures o .99 Sh) Reactive Chemical Review 0iSj7- o .96 2. Material Isolation (C2) a) Remote Control Valves/,{9^ c) Drainage b) Dump/Blowdown .94 to .96 d) interlock C? Total 0 > %7_,, o .95 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 to^9^ .92 to ,75to^5 .90 to() .85 ' f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection o.fo'l C3 Total ,60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 c, X Cj X c, = 0,3 39 See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure -U7`k 97 (.. sm A-3. Value of Area of Exposure B. Damage Factor C. Base MPPD (A-3 X B) f). 77 $MM 04$ /.4,35 Hi D. Credit Factor. Actual /; z,oy E. Actual MPPD (C x D) SMM F. Days Outage (MPDO) 33 dayii `Product of all factors used. BACH OF F OHM C-J I J R-l *(*<->> I DO A 044778 CONFIDENT! At. ~T rv\e.x r^r rAaVervaV FaeV&rs: T~; PO P A Cc.oT-') Ace f Mole Frac. EP PT .Mf= .GOT tJi?;% <Ot-( 1 .o is 43.2. 1113 HOH.t, 1 (p -O 1^ \ Co H,0 .CM M 0 PDC SOS 1 Cd om3<o9<tto*<3t EPr sen ,OZT Nif '--z ,G\1 i ZS.ta 01 EA 0 10 ItX (tanr*t , MP TCP DcxPE ,o\s .GO(d *1 -a OCoZ. I70> ZH \A DM UOO i , I4T I3.40& ,n ; s ,v*5 ! 1 5.H ' L_--1 T TiA; PA ACE R^O PDC epic ?CH 2HP TCf bCZPE. HdVc. Ft-ssc .006 .Q M ,C>.0 , OIT 1 O O O O o 1.00 KF "ET l(* l Co . \Cj>8 is,an "3,8 CK --=> 8(p^V TZ >(scV5CK--^(slP+ T102A D0 A 044779 CONFIDENTIAL. FIRE AND EXPLOSION INDEX Exhibit *A" wt 1 X location LAD I 2. MATERIALS AND PROCESS DATE V's/a? "Tn/PA/Ace/Hp/Pnc/FPTI/PCH/IMP / TCP.V_D.cXPE- CATAALLYvSSTTSS 1 ' ** ^ ' SOUVCNTS 1. GENERAL PROCESS HAZARDS (SEE TABLE II) BASE FACTOR ------------------------------------------------------------------------------------------------------------------------------------------ft- A. EXOTHERMIC REACTIONS FACTOR 30 ro t 25> 8 ENDOThE R\iiC RE ACTIONS > F ACTOR 20 tc 40* c - -0MATERIAL AMBLING Si TRANSFER FACTOR 25 S51 0 ENCLOSED PROCESS UNITS (FACTOR 30 to 90i E ACCESS F ORAINAGE FACTOR ,25 to 50) (F `GENERAL PROCESS HAZARD FACTOR 2. SPECIAL PROCESS HAZARDS 3ASE FACTOR ------------------------------------------------------------------------------------------------------------------------------------------- ft- A PROCESS "EMPERATURE -USE ONLY CNEl $I ABOVE F _ A H POINT '2 ABOVE 30 i L NG POINT 3 ABOVE AuTQlGNlTlON 3 lOW PRESSURE SL8 ATOMOSPhERiC) C OPERATION IN OR NEAR FLAMMABLE RANGE =1 TANK i3M STORAGE FlammaSlE liQuiCS : PROCESS uPSE1" OR PURGE failure 3 alwavs,nflammable Range 0 OUST EXPLOSION tFACTOR 25 to 2.00MSEE TABLE III) E PRESSURE (SEE FIGURE 2] F LOW TEMPERATURE 'FACTOR ,20 to 50) oo \p E A L T V PENALTY USED 1,00 \s,M 0,3 1 | ! ;s i j j . 25" __________ \.S5~ __________ !__________ 1__________ ` 30 O O | 1i GO . so a (o ! '5 =0 ! 1 50 30 30 1 j' i !i j ,ZS ! O quantity of Flammable material 1 LIQUIDS OR GASES IN PROCESS (SEE FIG 2) 2 LIQUIDS OR GASES IN STORAGE (SEE FiG. 4) 3 COMBUSTIBLE SOLIDS IN STORAGE (SEE FiG. 5) H CORROSION ANO EROSION (FACTOR .10 to .75) J LEAKAGE - JOINTS AND PACKING (FACTOR .10 to 1 50) useX. OF Fired HEATERS (SEE F'G. 5* L, mOTOILhEAT EXCHANGE SYSTEM (FACTOR . 15 to 1.15H SEE TAB LE lVt M ROTATING EQUIPMENT PUMPS. COMPRESSORS * i | .1 j ,\ j ./ ! 50 SPECIAL PROCESS HAZARD FACTOR (F^ UNIT HAZARD FACTOR | F ^ x F - F^J ............ . ............... .................. - f -------------------- --- 3,05 M,"T3 FIRE AND EXPLOSION INDEX iF^ . MF; F 4 |,----------------------------------------------------------------------------------------------------------------------------------------- 1Z,8 FOAM C-UHO FRINTED ft-10*to (l71-0J*) DO A 044780 CONFIDENTIAL Exhibit B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C1) C. Total e) Computer Control .89 to .98 f) Inert Gas o .94 fg) Operating Procedures h) Reactive Chemical Review o .99 o .96 .A2 l952t.oM.9a8terial Isolation (C2) a) Remote Control Valves ,..7954~t)o) c) Drainage b) Dump/Blowdown d,9>44t\oo.9.968 d) Interlock C, Total 2Ms3_' a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) .90 toC9?) .92 to) .75 to .85 .90 tof9B> .85 f) Sprinkler Systems g> Water Curtains h) Foam i) Hand Extinguishers k) Cable Protection C3 Total ' SOT * ,60 to .96 .95 to .97 .87 to .98 .92 to .97 .90 to .96 ,1"S' , S' C, X c2 X c3 - / ^ ^ See Figure 9 for conversion to Actual Credit Factor ITn L ine D belowl. RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure Lo 1 ft. A-3. Value of Area of Exposure SMM B. Damage Factor C. Base MPPD (A-3 X B) $MM D. Credit Factor, Actual E. Actual MPPD (C x D) SMM F. Days Outage (MPDO) `Product of all factors used. 30 10 47 03EkACK or FORM C-II - -o( !- ) 8 D0 ft 044781 CONFIDENTIAL Exhibit C PLANT:_____ Z. DIVISION;_____ , RE-CAP WORK SHEET PREPARED:. DATE: Process Units (T) Reactor Q Furnace (?} Compressor Unit Hazard Factor *3 6.44 i I 5.99 | | 5,94 Material Factor MF F&El <f3xmf) (A) Value Area of Exposure SMM (B) Damage Factor From Figure 7 1 147' 27 174 j ISO'. 3 i 87 \| ! i 80* 16 I 96 ! iz.our S3 1 120' 24 ' 143 15.0 ! j ' 83 (C) Base MPPD SMM (AXB) 13.0 (D) Credit Factor CixC2xC3 From Figure 9 | .49 7.0 12.5 57 1 i 46 te> Aciml MPPD SMM ICXO) 1 if) ' Oayl Out.,, : MPDO | From | Figure 10 S.4 ] 40/110 4.0 28/90 5 7 35/110 Three Process Units in a hypothetical plant "2" have been evaluated with results shown above. Assume a total Replacement Value of plant "2" at S50.0MM. Then from the above re:cap the highest Base MPPD is S13.0MM and the highest Actual MPPD is $6.4MM with an MPDO range of 40 to 110 days for the Reactor (Process Unit 1). DO A 04478? CONFIDENTIAL 9 Exhibit B LOSS CONTROL CREDIT FACTORS a) Emergency Power b) Cooling c) Explosion Control d) Emergency Shutdown 1. Process Control (C,) c> .95 to .98 TSto^jT] e) Computer Control f) Inert Gas g) Operating Procedures .89 to .98 .90 to .94 fMXo .99 h) Reactive Chemical Review <<85jfr .96 Total 54T- 2. Material Isolation (C,) a) Remote Control Valves C-94 b) Oump/Blowdown .94 to .96 c) Drainage d) Interlock C2 Total i"~1 Lc^ o .95 a) Leak Detection b) Structural Steel c) Buried Tanks d) Water Supply e) Special Systems 3. Fire Protection (C3) f) Sprinkler Systems g) Water Curtains h) Foam j) Hand Extinguishers k) Cable Protection C3 Total ' 8Q~?~ * .60 to .96 .95 to .97 .87 to .98 _ .92 to .974 ^ ^ .90 to .96^--------- cxcxc See Figure 9 for conversion to Actual Credit Factor. (To Line D below). RISK ANALYSIS SUMMARY A-1. F & El A-2. Radius of Exposure ft- A-3. Value of Area of Exposure SMM B. Damage Factor C. Base MPPD (A-3 X B) SMM D. Credit Factor, Actual E. Actual MPPD (C x D) SMM F. Days Outage (MPDO) days. Product of all factors used. orBACK FORM C'tZltO ft-<9-o(471*03) 6 Op 04 Exhibit C PLANT;______ DIVISION:_____ _ RE-CAP WORK SHEET PREPARED:. DATE; Process Units Reactor \2s Furnace (5^ Compressor Unit Hazard Factor pj Material Factor MF F&EI (f3XMF) (A) Value Area of Exposure 5MM (B) Damage Factor From Figure 7 i | 1 6,44 27 1 5.99 | j 5.94 16 r 24 1 147* 174 1 15.0'. 3 ! ! 96 QQt 12.01K , ;| ; 120143 15 0 87 | j I 58 ! j i 1 S3 (G) Base MPPD $MM IAXBI 13.0 7.0 (0) Credit Factor |C,xCjxC3 Prom i Pisure 9 | .49 i 1 i 57 i1 12.5 .46 il Actual MPPO SMM ICXQ> 6.4 4.0 5.7 tF) Oayt Outage MPDO From Figure 10 ! I 40/110 i 1 I. j 28/90 ! i : 35/110 Three Process Units in a hypothetical plant "Z" have been evaluated with results shown above. Assume a total Replacement Value of plant "Z" at S50.0MM, Then from the above re:cap the highest Base MPPD is S13.0MM and the highest Actual MPPD is S6.4MM with an MPDO range of 40 to 110 days for the Reactor (Process Unit 1). 0AA78A 00 ^ conf t dehtt^l 3 FIRE AND EXPLOSION INDEX Exhibit "A" LANf LrlucM X' TlOZPi MATERIALS AND PROCESS LAD TT2 oTTt------- J----- CATALYST SOLVENTS MATERIAL FACTOR ISEE TABLE I APPENDIX A) 1. GENERAL PROCESS HAZARDS (SEE TABLE III SASE FACTOR A, EXOTHERMIC REACTIONS-FACTOR 30 to i 2S) 9 SNQQThermiC RE actions FACTOR 20 to 40) C, Material HANDLING & TRANSFER -FACTOR 25 ro 35) O ENCLOSED PROCESS UNITS (FACTOR 30 ro 30) E ACCESS F DRAINAGE 'FACTOR 25 ro 50J GENERAL PROCESS hazard factor iP,i 2. SPECIAL PROCESS HAZARDS 3ASE FACTOR A PROCESS TEMPERATURE use Onlv ONE) i above flash point 2 ABOVE BOILING POINT 3 ABOVE AUTQIGNITION 8 low PRESSURE SUB ATOMOSP^ER'CJ C. OPERATION IN 03 NEAR FLAMMABLE RANGE 1 TANK FARM STORAGE FLAMMASuE LlQO'OS 2, PROCESS UPSET OR PURGE FAILURE 3 always in flammable range O OUST EXPLOSION (FACTOR 25 to 2.00II5EE TABLE III) E. PRESSURE (SEE FIGURE 21 F, LOW TEMPERATURE FACTOR ,20 :o .50) G quantity of Flammable material 1 LIQUIDS or GASES IN PROCESS iSEE FIG. 31 2 LIQUIDS OR GASES IN STORAGE 'SEE FiG ai 3, COMBUSTIBLE SOLIDS IN STORAGE !SEE FIG 51 h CORROSION ANO EROSION iFACTOR ,10 to ,75) 9e mAt"v t 00 O. o PENALTY USED t 00 Q. 3 k.cW Q.L5 l.SS 1 00 .30 75 ,50 50 30 .30 | ; ! , CD i | ! 1 T I j ! J J j 1 ............ " ,2J !i 1i 1 . ICL jj 11 j |1 J LEAKAGE - JOINTS ANO PACKING FACTOR 10 to 150) K. USE OF FIREO HEATERS (SEE F*G 6) L. ho TOlLHEATEx CHANGE SYSTEM (FACTOR . 15 to 1.1 5) 1SE E T AS LE l V l M ROTATING EQUIPMENT PUMPS, COMPRESSORS __J 1j t j 50 SPECIAL process hazard factor ifti m UNIT HAZARD FACTOR (F, Fj ' F.,1 ------------------------------------------ --------------------------------------------------------------------------------- -- 6,(0 - RE AND EXPLOSION INDEX (Fj < MF) . F S Ell--------------------------------------------------------------------------------------------------------------------------------------- -- 81.8 3M C-ZZJ10 PKIMTED -19-0 (4>1-0J) 7 DO A 044785 CONFIDENTIAL