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Dow North America Louisiana Division Consolidated Audit Ethanolamines / Glycol Ethers Plant Chemical Exposure Index Dow Confidential A 01961 .1 TDF'NTTAI,, Ethanolamlnes / Glyc I Ethers CE1 Audit 1993 Summary The Ethanolamlnes / Glycol Ethers plant has three products with a measured CEI number of 100 or greater. These three are Chlorine, Ethylene Oxide (EO), and Propylene Oxide (PO). Chlorine is used in the cooling tower to control biological growth. A total of 4,000 bs of chlorine is stored in the plant in two 2,000 bs cyfinders. Chlorine is added to the cooling tower at an average rate of 20 to 30 pounds per day. The chlorine is stored in an area at the northwest comer of the cooing lower away from any plant traffic. Emergency procedures exist to handte an emergency involving these cyfnders. EO is used in both the EthanotaiTiines and Glycol Ethers plants as a raw material. EO is stored in D-101, a 500 gaL surge drum, and is pumped to R-201 (Ethanoiamines reactor), and R-101 (Glycol Ethers reactor). EO can be used by both plants r by only one dependtog on production needs. The EO drum is located to the southwest comer of the block, xl EO is piped in from Glycol 2 via an underground pipeine. This drum is covered by both a monitor gun and a sprinkler system. Combustible gas detectors are also stationed around D-101. PO is used only in the Glycol Ethers plant as a raw material PO is stored in D-101 A, a 500 gal. surge drum, and is pumped to R-101. The PO drum is located in the southwest comer at toe plant just north of D-101. PO is piped from Glycol 1 via an above ground pipeline. This drum is covered by both a monitor gun and a sprinkler system. Combustible gas detectors are also stationed around D-101 A. r DO DoNr O ? 9^ -j ^ TFNT rAl' GLYCOL ETHERS/ETHANOLAMINES RAW MATERIALS PRODUCT HOW RECEIVED ETHANOLAM1NES ETHYLENE OXIDE ANHYDROUS AMMONIA SODIUM BOROHYDRIDE E-SERIES DOWANOL ETHYLENE OXIDE N-BUTANOL POTASSIUM HYDROXIDE OLEIC ACID P-SERIES DOWANOI^i PROPYLENE OXIDE METHANOL POTASSIUM HYDROXIDE OLEIC ACID PIPELINE RAILCAR 4# BAGS PIPELINE BARGE 400# DRUMS TANK TRUCK PIPELINE BARGE 400# DRUMS TANK TRUCK VENDOR GLYCOLH 1ST MISSISSIPPI/ OCCIDENTAL MORTON THIOCOL GLYCOLH SHELL/BASF/ CELANESE VAN WATERS & ROGERS EMERY/UNICHEMP GLYCOLI BORDENS VAN WATERS & ROGERS EMERY/UNICHEMP mate ym ASrAH TOPPPK ETHANOLAMINES / GLYCOL ETHERS The Ethanolamines Process Process Flow Sheet CTW __________________ _____ E-101 ----------------- -------------------------------- . D-101 P-201 A/B (EQ fad Pumpal Sundyne Vertical Centrifugal 316LSS 19,200 tbs/hr <3> 2100 ft Head 75 hp 3500 rpm motor Gearbox 14,700 rpm EO FROM GLYCOL 2 - D-101 (EO Suroe Drum) 3 ttl.D. x8.5ftT-T cs 7 Design P&T: 200 psig & 250 F ) Operating P&T: 100 psig & 30 C Capacity: 500 gals (3,600 lbs) PSV set pressure: 200 psig ( P-201 A/B TO REACTOR Dow Confidential wmmmm--m JAS 5/7/93 uu A 019614 O 'O N F ID F N T T A I !,AL'AH Kint'tn ETHANOLAMINES / GLYCOL ETHERS The Glycol Ethers Process Process Flow Sheet - PM Series P-101 A/B (PO F--d Pumpst Sundyne Vertical Centrifugal 316L SS 38,000 lbs/hr @ 1900 ft Head 100 hp 3500 rpm motor Gearbox 14,700 rpm GLYCOL 1 O f o r* & P-101A (PO Surge Drum! 3 ft I.D. x 8.5 ft T-T cs Design P&T: 200 psig & 250 F Operating P&T: 100 psig & 50 C Capacity: 500 gals (3,300 lbs) PSV set pressure: 200 psig s P-101 A/B TO REACTOR Dow Confidential JAS 5/7/93 CLEAd tUKPt-H ETHANOLAMINES / GLYCOL ETHERS The Ethanolamines Process Process Flow Sheet P3-20ff (Ammonla.Stofagt.Sphtre) 35 ft ID CS Design P: 300 psig Operating P&T: NH3 vapor pressure & Ambient temperature Capacity: 750,000 lbs Maximum inventory limited to 500,000 lbs by plant management PSV set pressure: 300 psig To Ammonia Recovery Sytem Ammonia from n oo nrilcara 5 o V.H vO P-205 A/B Dow Confidential JAS 5/7/93 ivrt-rtri ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index CEI Summary Chemical Ammonia Chlorine Ethylene Oxide Propylene Oxide CEI -EEPG (public) " .............. Radius @ 8 mph Neutral wind Cone. = EEPG 48 2.394 miles 288 1.762 miles 108 0.244 miles 96 0.049 miles I iWiNJaxjno:J L96 to y oa Dow Confidential JAS 5/7/93 CLUAa TOPPER ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Worst Case Scenarios - Descriptions \ WORST CASE SCENARIO DESCRIPTIONS CHLORINE Ruptured Chlorine cylinder 3/4" inch hole ETHYLENE OXIDE EO feed pumps (P-201 A/B) seal failure (2 sq. inch hole) and empties EO surge drum (D-101) PROPYLENE OXIDE PO feed pumps (P-101 A/B) seal failure (2 sq. inch hole) and empties PO surge drum (D-101 A) AMMONIA Ammonia sphere (DS-205) develops 2 sq. inch hole in bottom oa Dow Confidential JAS 5/7/93 019618 ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Worst Casa Scenarios - Prevention WORST CASE SCENARIO PREVENTIVE MEASURES CHLORINE Ruptured Chlorine cylinder 3/4" inch hole PREVENTIVE MEASURES All Chlorine cylinder checked for 5 year hydrostatic test record prior to offloading Cylinders located in traffic-free area Dow Confidential JAS 5/7/93 ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Worst Case Scenarios - Prevention WORST CASE SCENARIO PREVENTIVE MEASURES ETHYLENE OXIDE EO feed pumps (P-201 A/B) seal failure (2 sq. inch hole) and empties EO surge drum (D-101) PREVENTIVE MEASURES EO feed pumps part of plant's PPM program EO feed pumps are swapped regularly (twice a month) EO surge drum part of LAD Pressure Vessel program (NDT testing) Combustible gas detectors Sprinkler system Dow Confidential JAS 5/7/93 ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Worst Case Scenarios - Prevention WORST CASE SCENARIO PREVENTIVE MEASURES AMMONIA Ammonia sphere (DS-205) develops 2 sq. inch hole in bottom PREVENTIVE MEASURES DS-205 part of LAD Pressure Vessel program (NDT testing) Ammonia gas detectors Sprinkler system o ?> H S' tV Dow Confidential JAS 5/7/93 ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Worst Cass Scenarios - Pravantlon WORST CASE SCENARIO PREVENTIVE MEASURES PROPYLENE OXIDE PO fMd pumps (P-101 A/B) seal failure (2 sq. Inch hole) and empties PO surge drum (D-101A) PREVENTIVE MEASURE3 PO feed pumps part of plant's PPM program PO feed pumps are swapped regularly (twice a month) PO surge drum part of LAD Pressure Vessel program (NOT testing) Combustible gas detectors Sprinkler system o o Dow Confidential JAS 5/7/93 1 9ft? DRV RUN 06 07 93 13:57 1 6 3 GE CHLORINE SP. RELEASE L PIPEBIC 3 0.310 06^07'93 63 13i5S 7.6 0 B 63 2.6E+00 9.2E+02 16.4 14.1 CHI ORINE 13:54 MET AND RELEASE REPORT 14:54 2, o o tv *. o. -nt min ^ irsr' SUPERI^URE fO B E N BfcT 5 A 4nb 80bEbenbe obeh s e c /y y /v / X/ X A. A /\ /x y-y yx ,'i' /X /V X X \ / , 1/ / /X / /V /v / / X/ 1v ..... / ^x 7 X /A\, A X X/ X/ / ;:7 1 / /V' A Ax A-,/ 7 \X DO A 019625 CONFIDFNTTAI. DRV RUN 06 07 93 13:44 1 6 4 GE AMMONIA SP . REl EASE U JETREL _________ 200______ ______ 5 06/07/93 63 13:40 6 .3 0 B 63 3.0E+01 1.fE+04 16.4 16.4 numohim 13*33 MET AND RELEASE REPORT 14:39 00 A 0J96?6 ONFTDFNTT At.. DRV RUN m 07 93 13(50 3 i| >EF`*j<v HI / 0.4a 5 0 GE AMMONIA SP. RELEASE U JETPEt 200 5 06'07 93 13(50 6 .3 0 B 63 63 3.0E+81 2.9E+04 16.4 16.4 UI1MONIA 13(39 MET AND RELEASE REPORT 14(39 r\ i AAi Pi hP/m IP* r\PiP*i 4 &sr> P ETHANOLAMINES / GLYCOL ETHERS 1\1 r1 Chemical Exposure Index Past CEI Incident Ammonia Spills ( May 14 & 15,1992) May 14,1992 E-218 (D-218 Reboiler) gasket failure on tubeside (1/4" hole in head gasket) E-218 operating at 85 psig on tubeside Spill last approximately 3.5 hours Spilled 843 lbs Ammonia (696 lbs to air /147 lbs to water) Mitigation response - applied deluge guns to spill area o o 3> O D w Confidential JAS 5/7/93 C O N F ID F N T T ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Past CEI Incident Ammonia Spills ( May 14 & 15,1992) May 15,1992 D-218 overpressure (vapor outlet valve closed) All flange gaskets blown out Entire system inventory lost to atmosphere in minutes Spilled 2,434 lbs Ammonia (2,085 lbs to air / 349 lbs to water) No mitigation response oo So 2^ -o Dow Confidential JAS 5/7/93 nw- ? ^i>r^ gXxxxxVS -3 E ^------------ ~I--*--- [0 04 FT 04-- I DO A 019A?9 OONFTDFNTIAI ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Systems Evaluation* OPERATING PROCEDURES STRENGTHS Written shutdown/startup procedures and checklist Procedures follow guidelines of ISO-9000 (creating, revising, and communicating changes) L Dow Confidential JAS 5/17/93 00 A 019630 00N F T DFNTT Al,, ETHANOLAMINESI GLYCOL ETHERS ---- Chemical Exposure Index Systems Evaluation PLANT COMMUNICATIONS STRENGTHS Up to date emergency call list Written procedure for notification in a emergency Documentation or procedures for worst case emergencies Dow Confidential JAS 5/17/93 ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Systems Evaluation* AREA MONITORING SYSTEM STRENGTHS Use combustible gas detectors and ammonia detectors OPPORTUNITIES Evaulate/investigate how to make gas detectors more reliable Dow Confidential JAS 5/17/93 U.SAH ETHANOLAMINES / GLYCOL ETHERS arnicaI Exposure Inoc* Systems Evaluation PLANT PIPING SYSTEM STRENGTHS Outside-the-block material distribution system monitored for leaks OPPORTUNITIES Evaluate PPM system for piping systems D w Confidential JAS 5/17/93 00 A 019633 conftdfnttal I l t.-i lOMT-H ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Systems Evaluation PLANT MECHANICAL EQUIPMENT STRENGTHS PPM program in place Pumps for oxide/alcohol/ammonia tandem seals 1n^ qi n oO o Ui Dow Confidential JAS 5/17/93 l l 'jr* t.r ETHANOLAMINES / GLYCOL ETHERS Chemical Exposure Index Systems Evaluation TRAINING FOR EMERGENCY RESPONSE STRENGTHS Appropriate personnel trained in the use of emergency equipment Periodic inpsection/testing of emergency equipment Shift personnel involved in quarterly "what if" emergency scenario Emergency procedure written for "what if scenarios OPPORTUNITIES Utilize Env. Superintendent to review results of "what ff" scenario with all personnel that could be affected A 01 3*9(S S CONFTDFNTTAL. Dow Confidential JAS 5/17/93 6