Document Oz0QJJrQd090M6j4qVLnoEmEL

PRESENTATION TO VCSA OCTOBER 1993 CTL015081 DEVELOPMENT OF MAJOR HAZARDS LEGISLATION FLIXBOROUGH (28) SEVESO SAN CARLOS (215) MEXICO CITY (500?) BHOPAL (3000?) CHERNOBYL (?) BULGARIA PVC (17) SANDOZ BASEL HERBORN (5) PIPER A (167) JONAVA (80?) EXXON VALDEZ PHILLIPS TX (23) ARCO TX (17) BANGKOK LPG (63) 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 loon UK EC 1 2 - ACMH 82/501 COUNCIL DIRECTIVES 3 87/216 88/610 CTilS082 Official Journal of the European Communities COUNCIL DIRECTIVE of 24 June 1982 on the major-accident hazards of certain industrial activities (82/501/EEC) --------------------------------/------------------------------- STATUTORY INSTRUMENTS 1984 No. 1902 HEALTH AND SAFETY The Control of Industrial Major Accident Hazards Regulations 1984 -------------------------------------------------------------------------- /------------------------------------------------------------------- STATUTE BOOK OF THE SWEDISH NATIONAL BOARD OF OCCUPATIONAL SAFETY AND HEALTH Ordinance (AFS 1989:6) concerning LARGE-SCALE HANDUNG OF CHEMICALS CTL015083 PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LIMITED SEVESO DIRECTIVE Article 3 ... the manufacturer is obliged to take all the measures necessary to prevent major accidents and to limit their consequences for man and the environment. CTL01&084 HYDRO PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LIMITED SEVESO DIRECTIVE Article 4 ... all manufacturers are required to prove to the competent authority at any time... that they have identified existing major accident hazards, adopted the appropriate safety measures, and provided the persons working on the site with information, training and equipment in order to ensure their safety. CTL015085 & HYDRO I PRESENTATION TO VCSA - OCTOBER 1993 TTirmTimTniTiH'i Article 5 HYDRO POLYMERS LIMITED SEVESO DIRECTIVE TOP-TIER SITES SAFETY CASE containing (a) information on dangerous substances (c) information on (b) information on - installations and processes - meteorological conditions - people on site and exposed - management systems - hazard sources - potential accident causes - control systems and preventive measures - onsite emergency equipment, response and plans - the name of the person responsible for safety CTL015086 HYDRO DOCUMEN HYDRO POLYMERS SAFETY CASE as required by the CONTROL OF INDUSTRIAL MAJOR ACCIDENT HAZARDS REGULATIONS 1984 REVIEW ISSUE : JULY 1992 Page 2 of 74 HPl-SHE-4100 Issue 3 CTL015087 DOCUMEN HYDRO POLYMERS LIMITED - SAFETY CASE SECTION CONTENTS 1. DEFINITIONS AND ABBREVIATIONS 2. INTRODUCTION 2.t Preamble 2.2 Review Notes 3. MATERIAL HAZARDS 3.1 Vinyl Chloride 3.2 Analytical Methods for VCM 3.2.1 In-Process Analysis 3.2.2 Safety and Environmental Monitoring 3.3 Hazards of Vinyl Chloride 3.3.1 3.3.2 3.3.3 3.3.4 Acute Toxicity Chronic Toxicity Flammability Other Personnel Hazards 3.4 Purity of VCM 3.5 Other Materials 3.5.1 Dangerous Substances 3.5.2 Hazardous Materials 4. THE INSTALLATIONS 4.1 The Environs of Hydro Polymers Limited 4.2 Aycliffe Site Plan 4.3 The Vinyl Chloride Polymerisation Process 4.4 Personnel at Aycliffe Site 4.5 Land Use Local to Hydro Polymers Page 3 of 74 CTL015088 HPL-SHE-4100 Issue 3 5. MANAGEMENT SYSTEMS 5.1 Management Structure and Arrangements 5.2 Management Procedures far Safety 5.3 Engineering and Operational Safety Standards 5.3.T; 5.3.2 5.3.3 5.3.4 Design & Construction Inspection & Testing Operation & Maintenance Plant Audits 5.4 Training DOCUMENT 6. POTENTIAL FOR MAJOR ACCIDENTS 6.1 Hazard and Risk Assessment Methodology 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 Hazard Ranking Evaporation and Gas Dispersion Atmospheric Effects Fires Vapour Cloud Explosion Failure Rates and Fault Trees Ignition Modelling 6.2 Sources of Major Accidents and Hazard Ranges 6.2.1 Potential Accident Sources 6.2.2 Potential Accident Causes and Assessment 6.2.3 Accident Consequence Scenarios 6.2-5: Maximum Hazard Ranges 6.3 Prevention and Limitation of Accidents 6.3.1 Measures for Accident Prevention 6.3.2 Limitation of Accidental Damage and Consequences 6.4 Probabilities and Consequences of Major Accidents 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 Runaway Reaction Failure of C Plant VCM Sphere, TK-2B Overview of Major VCM Release Potential Uncertainty in Hazard Assessment Conclusions on Risk 6.5 Emergency Procedures and Planning 6.6 Meteorological Conditions 6.7 Personnel Particularly Exposed to Hazards 7E^PROGRESS^ND' eoture plans 8. "references PROCESS DRAWINGS Page 4 of 74 CTL015089 HPL-SHE-4100 Issue 3 PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LIMITED SEVESO DIRECTIVE Article 7 Offsite Emergency Plan Article 8 Information to the Public CTL015090 HYDRO OTTitiifTiiiii--i-nnr m PRESENTATION TO VCSA - OCTOBER 1993 NORSK HYDRO CORPORATE PROCEDURES TITLE : PROCESS SAFETY OBJECTIVE : AH hazards which may give rise to process related accidents shall be identified, understood and controlled. APPLICATION : All operations which involve the manufacture, processing, storing or internal transportation of materials representing a risk to life, environment and property. CTL015091 HYDRO PRESENTATION TO VCSA OCTOBER 1993 HYDRO POLYMERS LIMITED PROCESS SAFETY MANAGEMENT SYSTEM Process safety information Process safety studies [HRA] hazard ranking and assessment risk acceptance criteria Operating Procedures [CTS-11] Safe work practices [CTS-04] Modifications to process variables and equipment [CTS-01] Quality control and maintenance of equipment [CTS-03] Competence and training [CTS-12] Investigation & reporting of incidents & accidents [CTS-02] Emergency planning and response [CTS-10] Pre-startup safety reviews M Inspections and auditing CTL015092 ((( PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LIMITED PROCESS SAFETY AUDITS 1. Systems Audit 2. Compliance Audit Detailed check lists for carrying out the Audit. CTL015093 & HYDRO PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LTD AUDIT CHECK LIST Modifications to Process Variables & Equipment Is responsible person for decision clearly stated? Are normal/acceptable operating bands defined for plant & process conditions? CTL015094 ( HYDRO *** - .xr, ,, PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LTD AUDIT CHECK LIST Modifications to Process Variables & Equipment Are upper and lower safe limits defined for plant & process conditions? Who authorises deviation/experimentation outside normal process condition range? CTL015095 ((( HYDRO PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LTD AUDIT CHECK LIST Modifications to Process Variables & Equipment Are there safety reviews prior to changes, e.g. covering - new materials? - corrosion effects? - equipment design limitations? CTL015096 HYDRO PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LTD AUDIT CHECK LIST Modifications to Process Variables & Equipment Are special startup & operating instructions provided?________ Are there required Hazop-analyses or similar? Are all changes traceable and documented? CTL015097 ( nWiJtTil PRESENTATION TO VCSA - OCTOBER 1993 HYDRO POLYMERS LTD AUDIT CHECK LIST 10 Modifications to Process Variables & Equipment Does change of trip setting require use of modification procedure? Do changes require change of P&ID and other documentation?__________________ CTL015098 PROCESS SAFETY PROFILE Key; # Audit Team Scores j.----- Q.--j SPC Score Range & Mean TOPIC Process-related incident performance Annual improvement goals Annual plans of action Management commitment and enthusiasm SCORE [excellence --] 0 1 23496 H p H t H }" |* * - H Level of technical safety provision Housekeeping Process safety information Process safety studies Operating procedures Safe work practices Modifications to process variables and equipment Quality control and maintenance of equipment Competence and training Investigation and reporting of incidents and accidents Emergency planning and response Pre-startup safety reviews Inspections and auditing < H C1 HR- 1A \ - ....... H f" ---- 1 0... H ....... i- 1 ....... I" -1 ....... flL.. 1 f- H ivj fj... H 1.. 3... \ Overall average score D Mean Scores; 3.76 423 CTL015099