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PPG Industries, Inc. Industrial Chemical Division Lake Charles, Louisiana
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PPG INDUSTRffiSect to Protec
EXHIBIT HP$
JuNd^oc. ia91l -1D1i
-R-2284
August 10, 1982
HANSON, D. B.
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The Reliability Study of the Lake Charles Plant "B-ll" - EDC Plants 1 & 2 CONFIDENTIAL
Distribution G, C. Strickler (Abstract only) 1. R. P. Lynch/J. E. Fike 2. R. P. Byars/E. J. Tullier 3. E. F. Parsons 4. J. H. Morgan/R. E. Baker (w/o Appendix) 5. B. M. White (w/o Appendix) 6. R. E. Sanders 7. Author 8. C. R. West - G. O. Technical Files (Title Page Only)
Key Words Reliability Study EDC Proof-Testing Vapor Cloud Explosive Mixture Loss Prevention Review Toxic Release Flammable Release Vaporizer LP/EDC Reactor
SL 012406
TABLE OF CONTENTS
AbstractIntroduction Discussion Recommendations Table I Table II Appendix
1 2 2 4 6 7 9
SL 012407
RELIABILITY STUDY OF EDC PLANTS 1 & 2
LR-2284/1
ABSTRACT
CONFIDENTIAL:
Subject to Protective Order of 14th Judicial District
No. 91-1145
A detailed Reliability Study (Level III) and a Loss Prevention Review were made on EDC Plants 1 & 2. Fault trees were drawn and quantified to determine the frequency of occurrence of potential hazards encountered during the operation of the vaporizers and the reactors. The potential hazards, identified and studied, were the possibility of liquid chlorine entering the reactor, reactor overpressurization and the formation of an
xplosive mixture of chlorine and ethylene in the vent or the vapor space of the reactor. Flammable liquid spill fires were not in the scope of this study, since system integrity is assumed. Implementation of the proposed recommendations significantly reduces the frequency of occurrence of these potential hazards and enhances the reliability of EDC Plants 1 & 2.
SL 012408
INTRODUCTION
CONFXDF.KTlAb: protective order
Subject to
lour t a 1 District o
o 14th JuNdoic- ia91-11X5
LR-2284/2
A Level III Reliability Study was made of the EDC Plants 1 & 2 as part of the continuing effort to study all of the units in Plants "B-l" and "B-ll". This report will complete the study of Plant "B-ll" .
DISCUSSION
To become familiar with the EDC Plants 1 & 2, the operating manual and the P & I drawings were studied. Discussions with operations personnel along with plant tours provided operating knowledge of the plants. Cause-Consequence sheets were then developed with the aid of an operations representative for each piece of equipment in th plant. This indicated the areas of potential hazard which were the chlorine vaporizers and the EDC Reactors 1, 2 & 3. Fault trees were developed for these areas assuming system integrity (no pipe leaks, pump leaks, sample point leaks or failure due to corrosion). The remainder of the plant was assumed to be covered sufficiently by the Cause-Conseqnece she ts.
The fault trees were quantified using data from the ICI manual of failure rates by D. W. Heckle along with information gathered from previous studies, operations experience, and other published sources. Some of the failure rate data obtained was modified to fit th conditions applicable to the EDC Plants 1 & 2.
The hazards or top events covered by the fault trees are:
1. The possibility of liquid chlorine entering the reactor, and a run away reaction.
2. The formation of an explosive mixture of chlorine and ethylene in the vent.
3. Reactor overpressurization from feed or pressure control valve failures.
4. The formation of an explosive mixture of chlorine and ethylene in the vapor space of the reactor.
Th frequency of occurrence for each hazard, associated with the plant in Its current condition, was calculated assuming a six-month proof-test interval. This assumption was based on the fact that the proof-test program is well established and accepted. If the hazard frequency was too high,recommendations were incorporated into the fault trees. The fault trees were then re-calculated to see how effective the recommendations were at reducing the hazard frequency. If the hazards involve possible releases of either flammable or toxic materials the amount and the frequency of these releases were evaluated to defermin if the calculation of the severity of these releases was required. The ICI computer program TOXIDISP was used to calculate the severity where necessary.
The potential release of CI2 from the vaporiz rs was not evaluat d du to the pending project to modify vaporiz r shutdown systems. The possibility of CI2 r I ases from the r actor, due to th failure of th Cl2 flow control valve, was remote and did
SL 012409
COMF1DEHTIAI
OfSli?ha\
Prtecti;e Order
Of 14th Judicial District Court
No. 91-1145
LR-2284/3
not warrant further evaluation. Th pot ntial problems associated with excessive oxygen entering with the chlorine were not addressed because they are included in the DSA Gas to EDC Reliability Study.
Flammable releases were handled according to C. R. West's paper "Fire/Explosion Methodology". Under the guidelines in this paper most of the potential releases did not meet the criteria to form a vapor cloud. Those releases, caused by still overpressurization, that did meet this criteria were comparable to releases that were evaluated by TOXIDISP in the OHC II study and found to present minimal cloud hazard according to this methodology. EDC release from the reactor due to overpressurization was studied using the TOXIDISP com puter program to determine the probability that a vapor cloud of sufficient concentration (1/2 the lower explosive limit) to pose a hazard would encounter a known ignition source. The computer program revealed that the cloud was well below the concentration to be con sidered hazardous (1/2 LEL) by the time it reached the ground. Therefore there is no hazard from the release of EDC from the reactors, strippers or stills other than a local fire hazard at the point of release.
A Loss Prevention Review was conducted to expand the scope of the Reliability Study. The additional examination of the process with respect to codes of practice, fire protection and other items not normally embraced by a Reliability Study should strengthen the overall process safety posture.
The Loss Prevention Review for EDC Plants 1 & 2 was conducted using the General Office Loss Prevention Manual. With the aid of an operations representative and other informed personnel it was determined that EDC complied with most of the requirements. Several points of contention are currently on the Loss Prevention Job (LPJ) List and there are several control valve failure position changes that are under consideration.
The LPJ list was studied to determine the status of jobs that the ORC or previous safety studies had requested but had not yet been completed. This review found that the jobs on the LPJ list are receiving very little emphasis although many of the jobs are on hold waiting for either C2H4 analyzers to be installed, the vaporizer shutdown system project to be completed or modernization of the diaphragm cell chlorine plant. The remaining jobs warrant discussion by the ORC.
The Reliability Study of the EDC tank vent lines requested by LPJ-929 was incor porated into this study. This covered the equipment to process the EDC vents to the incin erator from the converted Butadiene Tank and the EDC Day Tank. This system was similar to the system covered by a reliability study in P-71 on the million gallon tank among others. Therefore the LPJ-929 system was studied qualitatively and appeared to be reliable which was substantiated by the fault trees and calculations done on P-71.
RESULTS
SL 012410
The results presented in Table I show the frequency of occurrence of hazards associated with the operation of the vaporiz rs and r actors. Each hazard frequ ncy was calculat d to show what could b expected by the plant in its present condition and if modifications w re recommended.
CONFIDENTIAL: ofS1u4bjecjtutdNooic. Pia9r1ol teDi cs i/ts>i'JvtreicOt rCdeo-r"
LR-2284/4
The vaporizers, in their current condition, appear vulnerable to allowing liquid
chlorine to enter the reactor. Several layers of modifications were recommended with
each layer increasing the reliability of safe chlorine vaporizer operations. The vaporizers,
as presently equipped, could be expected to allow liquid chlorine into the reactor about
once every 10 years. With the addition of a Low Temperature Alarm on the CI2 Surge
Tank this frequency can be reduced by over a factor of 10 to once every 105 years. This
modification plus Low Steam Pressure and Flow Alarms further reduces the frequency to
once every 476 years. The installation of dual steam traps coupled with the above recom-
m ndations virtually eliminates the hazard down to once every 14,000 years.
The possibility of an explosive mixture of C2H4 and CI2 occurring in the vent header is about once every 1,000 years. This calculation was made assuming the C2H4 analyzers were incorporated Into the shutdown system.
The frequency of occurrence of reactor overpressure releasing flcmmable or toxic gases to the atmosphere is about once every 28 years with the reactor system as is. The addition of a redundant pressure transmitter reduces this frequency by almost a factor of 10 to once every 257 years. This possible release when evaluated by the TOXIDISP com puter program proved to be non-hazardous as far as a vapor cloud explosion is concerned because the amount of material released would be dispersed before it reached an ignition source.
I The chance of a vapor phase reaction/explosion in the reactor is almost once every 1,000 years.
RECOMMENDATIONS
In order to reduce the hazard of frequencies to acceptable levels several additions should be made as well as maintaining high maintenance and operations standards. These include:
1. Improve chlorine vaporizer system by engineering:
A. Dual steam traps on each vaporizer with access for observation of conden sate flow.
B. Low steam pressure and flow alarms on streams to vaporizers.
C. Low CI2 temperature alarm on the bottom of the surge tank.
2. Study chlorine vaporizers plant wide to develop a uniform standard for materials of construction, instrumentation, and operating practices.
3. Incorporate a standard vaporizer shutdown system.
0U4"
SL
LR-2284/5
4. Improve EDC Reactor reliability by installing:
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A. C2H4 analyzers on the vents.
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B. Redundant pressure transmitter on each reactor (1, 2 & 3).
5. Restrict to a minimum the amount of time the reactor shutdown system is on by-pass.
.6 Provide proper proof-testing at the intervals specified in Table II.
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7. Revise and update EDC operating manual (LPJ-980).
.8 Revise and update P & I drawings to accurately show what exists in the field.
9. Review the LPJ list to determine status of fobs requested and remove those of marginal impact. This will be done by the Operations Review Committee.
Approved App roved CLaJj^ jl . juJT
Date
'L'
Date *? / 2 3/ 83
Date Q/)t
___________
SL 012412
Fault Tree
TABLE I
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LR-2284/6
HAZARD FREQUENCIES (6 Month Proof Test Interval is Assumed)
Hazard (Top Event)
Occasions/Year
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Years Between^9> Occurrences
1 Liquid Cl2 entering the reactor and leading to a runaway reaction.
A. Cl2 vaporizer system as is
.1035
9.66
B. With low CI2 surge tank temperature alarm
.0095
105
C. With "B" and low steam pressure and flow alarms
.0021
476
D. With "C" and dual steam traps w/observation
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14,318
4 Formation of an explosive mixture of chlorine and ethylene in vent (C2H4 analyzers assumed in operation)
.00099
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7 Reactor over pressurization
A. Reactor system as is
.0361
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B. With redundant pressure transmitter .0039
257
8 Formation of an explosive mixture of chlorine and ethylene in the vapor space of the reactor
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SL 012413
TABLE II
PROOF TEST SCHEDULE
Vaporizers
Low Instrument Air Pressure Alarm Steam Header Low Pressure Alarm Vaporizer Outlet Low Temp Alarm
Reactor ^1
C2H4 Low Pressure Alarm PT-2551 C2H4 Low Flow Alarm FT-71 Cl2 High Flow Alarm FT-74 Low C2H4/Cl2 Ratio Alarm Reactor Low Level Alarm LT-72 Reactor Low Level Alarm LT-72A Reactor High/Low Pressure Alarm PT-1011 Reactor ^1 Shutdown System C2H4 Analyzers Reactor Recycle PumpsS/D Alarm Cl2 High Pressure Alarm PT-56
Reactor ^2
C2H4 High/Low Flow Alarm FT-51 CI2 High/Low Flow Alarm FT-52 Low C2H4/CI2 Ratio Alarm Cl2 High Pressure Alarm PT-56 C2H4 Analyzers Reactor ^2 ShutdownSystem FCV-901 (To Scrubber) FCV-920 Position Alarm Reactor Low Level Alarm LT-72 Reactor Low Level Alarm LT-72A
Reactor ^3
C2H4 HigH/Low Pressure Alarm PT-1005 C2H4 High/Low Flow Alarm FT-1016 Cl2 High/Low Flow Alarm FT-1032 Low ^Hj/C^ Ratio Alarm Cl2 High Pressure Alarm PT-1028 C2H4 Analyz rs Reactor ^3 Shutdown Syst m
LR-2284/7
6 month
6 month
" " " " 1 week 6 month "
6 month " " "
1 week 6 month
" " "
6 month " " " "
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SL 012414
TABLE II (Cont'd.) PROOF TEST SCHEDULE (Cont'd.)
LR-2284/8
Reactor ^3 (Cont'd.)
FCV-900 (To Scrubber) FCV-919 Position Alarm Cooling Tower Water Pump S/D Alarm Stripper Feed Pump S/D Alarm 1064 Reactor Low Level Alarm LT-1037 Reactor Low Level Alarm LT-1037A Reactor High/Low Pressure Alarm PT-3004
Proof Test Interval
6 month
" " " " "
All recommended instrumentation modifications that are accepted and installed should also be proof tested every 6 months.
All other instrumentation that is not involved in hazard frequency calculations should be proof tested according to Operations' schedule.
SL 012415
CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court
No. 91-1145
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Subject^BENTI.U.. of l4t-Lhh JT ud, icPiarol tenC,Ml1tV,e Order
No. si-f^ct Court
SL 012465
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19, TITLE*. EDC 2
20. TOXIC! CL2
21 . location: metcharl
BOUNDARY DISTANCES* BLDG HTS.
1 333 2 318
1 125
3 353
4 564 J 708
1 35
6 819
7 826
8 964
9 1514
3 85
10 1246
11 1092
12 865
13 706
14 783
3 190
15 718
16 639 17 625
18 350
^ *> STACK DIAM <M> 23 STACK HT <N)
0.1016 30
24 BUILDING HT <M>
0
25 GAS RATE < RM3/HR) 5577.24
BLDG DISTANCES
--
(M);
COMPONENT _ CL2
LB /HR
TEMP
*36240.00 25.0
26 GAS MOL, UT.
70.914
27 GAS TEMP (C)
25
28 GAS SP HT (J/KG.C) 484.8
29 TOXIC CONC C/.V/V) 100
30 DURATION (MIN)
0,5
31 SMALL TABLE WIND ' 0
37 SMALL TABLE WTHR. 0
33 SURFACE Fi'NESS(M) 0.1 34 ISOPLETH CONC(PFM) 0 94 EFFLUX ANGLE (DEG) 90.
95 AMBIENT TEMP <*C ) 21
96 AMBIENT FRESS(BAR) 1.013
WHAT NEXT? NEUI20 OLD TOXIC WAS CL2 . 20 . TOXIC? EDC
--- -
--
-----------
------------
ALL EXISTING STACK GAS DATA ZEROED.
GAS NAME NOT FOUND - HAVE YOU MIS-SPELT IT?
CONCS FOR 1 AND 10 MINS. HELP? 4000.2000
' \.l1_
mo MUCH HE IP? N
CATEGORY
CATEGORY CATEGORY
INPUT --EXCESS
1 ? 4000.2000 2 ? 6000.5000 3 f 90nA,RflAA
IGNORED ____
LR-2284/59
SL 012466
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UHAT NTXT? NEW22/23/23
OLD VALUE FOR 22 STACK DIAM <H> UAS 0,1016 NEU VALUE? .2032
-.Mi' i ili-
NEU23/25 Ol.Ii VALUE FOR 23 STACK HT <M) UAS 30 NEU VALUE? 17
NEU25
OLD VALUE FOR 25 GAS RATE (RM3/HR > UAS 0 NEU VALUE? 122.6
UHAT NEXT? NEU26/27/28 OLD VALUE FOR 26 GAS MOL, UT. UAS 0 NEU VALUE? 96.97
NEU27/2B OLD VALUE FOR 27 GAS TEMP <C> UAS 0 NEU VALUE'? 88
HEU28 OLD VALUE FOR 28 GAS SP HT (J/KG.C) UAS 0 NEU VALUE? 951.5
UHAT NEXT? PCD
19.TITLE : EDC 2
20 .TOXIC : FDC
1 MIN
10 MINS
CAT 3 9000.00
8000.00
CAT 2 6000.00
5000.00
CAT 1 4000 00
2000.00
21 .LOCATION! METCHARL
BOUNDARY DISTANCESr BLDG HTSt
i 335
1 125
2 318
3 353
4 56 4
5 70S
1 35
6 819
7 826
8 964
9 1514 10 1246
3 85
11 1092
12 365
13 786
14 7 83
15 718 16 639
3 190
17 6 25
18 350 T-> STACK DtAM (M) 23 STACK HT (M)
0.2032 17
24 BUILDING HT < M) 25 OAF, RATE (RM3/HP 1
0. 127.6
BLDG
DISTANCES
(M)
LR-2284/60
SL 012467
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26 .
HT <J/k(j.C>
29 T,,^(r CONC (XV/V)
30 DURATION (MIN)
SMALL TABLE WINS
32 SMALL TABLE UTHR,
33 SURFACF R'NESS<M>
34 ISOPLETH CONC(PPM)
94 EFFLUX ANGLE (DEG)
95 AMBIENT TEMP (*C>
96 AMBIENT F'RESS(BAR)
9 0
0-5 0 0 0,1 0 90. 21 1.013
WHAT NEXT? URI FILE NAME7 EDC12
o
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UHAT NEXT? C0M02
EXIT VELOCITY (M/S) - 1.2937
APPROX.
. 7 X SONIC VELOCITY
1.1 1.2 1 .3 2.1 2 2 2,3 2.4 .3.1 3.2 3.3 3.4 3.5 . 3.6 4.1 4.2 4.3 4.4 4.5 4.6
[
5.3 5.4
6,1 6,2 6.3
CAT 3 2 1 0
PRGB(X) .000 .000 .000
100.000
CUM.PROB(X) .000 .000 .000
100.000
LIMITING CONC(PPM) 9324.83 6338.51 4928.09 .00
FLOW 122.6 DURN 0,5 EDC 2
UHAT NEXT? C0M03
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ENTER TERMINAL WIDTH . 72 OR 1327 132
- 1 .1 1.2 1.3
2.1 2 * 2 2.3 2. 4
.. 3.1 3.2 3,3 3. 4 3. 5 3. 6 4.1 4.2 4.3 4. 4 4. 5 4. 6
| 5.3 5.4
6.1 6.2 6.3
DIRECTION
'j 1 18 3
.,1---------- DISTANCE
1
---- .
|_
BLUG.
BLDG . XPROB XPROB XPROB XPROB
HT ,
HIST , CAT . 3 CAT . 2 CAT. 1 CAT. 0
318
0 0 .0 .0 .0 4.3
335 350
1 125
.0 .0 .0 7.0
0 0 .0 .0 .0 10.7
353
0 0 .0 .0 .0 3.3
4
564
0 0 .0 .0 .0 2.4
17 16
625 - 639
0 0 .0 .0 .0 5.9
0 0 .0 .0 .0 6.9
5
708
1 35 ,0 .0 .0 2.3
15
718
0 0 .0 .0 ,0 5.8
14 13
783 786
3 190
.0 .0 .0 7.3
0 0 .0 .0 . .0 B.5
6
819
0 0 .0 .0 .0 2.1
7
826
0 0 .0 .0 ,0 2.8
12
865
0 0 .0 ,0 .0 7.6
8 11 10
9
964 1092 1246 1514
0 0 .0 .0 .0 3,3
0 0 .0 .0 .0
6.1
0
0 .0 .0 .0 6.3
3 85 .0 .0 .0
7.3
MAXIMUM CGNC HIST
ESH
LR-2284/61
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CAT, 3
IB ( X ) * 00 0 *000 *000
100*000
CUft*FBOB(Z) *000 * 000 * 000
100*000
(1
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LIHiriNe CONC < F'F'H ) 9 32-1.83 6333 . 5 1
4920.09
.00
FLOW 122.6 BURN 0.5 EDC 2
WHAT NEXT7 NEW34 OLH VALUE FOR 34 ISOPLETH CONC(FFM) WAS 0 NEW VALUE? 28000
WHAT NEXT? C0M02 BUILDING TOP (T). BUILDING WHOLE (W), OR HELP (-999)? W
CO
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--
1.1 2.1 3.1 4.1 5.3 6.1
1.2 2.2 3.2 4,2 5,4
6.2
1.3 2.3 3.3 4.3
6.3
2.4
3.4 4.4
3.5 4.5
3.6 4.6
CAT . 3 2
1 0
PROB< X) ,000 .000 .000
100.000
CUM, PROD! 7.) ,000 ,000 . 000
100.000
LIMITING CONC(PPM) 9324.83 6338.51 4928.09 .00
AREA OF 28000 PPM ISOPLETH BEYOND BOUNDARY (M2) * ACTUAL PRQB- 0
J.
PRGB(X) OF 28000 PPM ISOPLETH STRIKING ANYWHERE ON BUILDING.
SECTOR 1 0 9
14
BLDG.HT. 1 1 3 3
BLDG.BIST. 125 35 85 190
F'ROB .<xf .000 .000 .000 ,000
FLOW 122.6 BURN 0.5 EDC 2
______ . WHAT NEXT? NEW34 '1 OLD VALUE FOR 34 ISOPLETH CONC(PPM) WAS 28000 "i NEW VALUE7 2000
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WHAT NEXT7 C0MG2 BUILDING TOP (T). BUILDING WHOLE (U>, OR HELP (-999)? W
4.i
.. 3.i 4.1
1.2
3.2 4.2
1.3 2.3 3.3 4.3
2.4 3.4 4.4
3.5 4.5
3.6 4.6
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LR -2284/62
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CAT 3
1 0
PROB(X)
.000 .000 .000
100,000
CUM.FRDB(X)
,000 .000 .000
100.000
LIMITING CONC(PPM)
9324.83 6338.51 4928,09
,00
AREA OF 2000 PPM ISOPLETH BEYOND BOUNDARY (M2) * ACTUAL PROB
F'ROB(X) OF 2000 PPM ISOPLETH STRIKING ANYUHERE ON BUILDING.
SECTOR
1 5 9 14
BLDG.HT.
1 1 3 3
FLOU 122.6 BURN 0.5 EDC 2
BLDG.BIST. 125 35 . 85 190
--
PROB.(X) .000
,000 .000 . 000
-------
-- ---------------
WHAT NEXT? NEW34 OLD UALUE FOR 34 ISOPLETH CONC(FFM) WAS 2000
NEW UALUE? 100
WHAT NEXT? C0M02 BUILDING 10P (T)r BUILDING WHOLE (U)> OR.HELP (-999)? U
1.1 2.1
3.1
4.1
5.3
6.1
1.2 2*2
3.2
4.2
5.4
6.2
1.3 2.3 3.3 4.3
6.3
2.4 3.4 4.4
3.5 4.5
3.6 4.6
CAT
3 n
1 0
PROB< X) .000 .000 .000
100.000
CUM,PROB(X) .000 .000 .000
100.000
LIMITING CDNC(FPM)
9324.83 _____
6338.51
4928.09
. --
.00 _
AREA OF 100 FPM ISOPLETH BEYOND BOUNDARY (M2) * ACTUAL PROB =
F'ROB(X) OF 100 PPM ISOPLETH STRIKING ANYUHERE ON BUILDING.
SECTOR 1 5 9
14
BLDG.HT. 1 1 3 3
BLDG.BIST. 125 35 65 190
PROB.(X) .000 ,000 .000 .000
FLOU 122.6
BURN 0.5
EBP 2
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C 01'i FID i;: '?1 . i '. i Subject to Protective Ordsr of 14th Judicial District Court
No. 91-1145
SL 012474