technical planning for on-site...

GUIDELINES FOR

TECHNICAL PLANNING FOR ON-SITE EMERGENCIES

CENTER FOR CHEMICAL PROCESS SAFETY AMERICAN INSTITUTE OF CHEMICAL ENGINEERS 345 East 47th Street New York, New York 10017

dcd-wgC3.jpg

This page intentionally left blank

GUIDELINES FOR


Publications Available from the CENTER FOR CHEMICAL PROCESS SAFETY

of the AMERICAN INSTITUTE OF CHEMICAL ENGINEERS

Guidelines for Technical Planning for On-Site Emergencies Guidelines for Process Safety Documentation Guidelines for Safe Process Operations and Maintenance Guidelines for Process Safety Fundamantals in General Plant Operations Guidelines for Chemical Reactivity Evaluation and Application to Process Design Tools for Making Acute Risk Decisions with Chemical Process Safety Applications Guidelines for Preventing Human Error in Process Safety Guidelines for Evaluating the Characteristics of Vapor Cloud Explosions, Flash Fires,

Guidelines for Implementing Process Safety Management Systems Guidelines for Safe Automation of Chemical Processes Guidelines for Engineering Design for Process Safety Guidelines for Auditing Process Safety Management Systems Guidelines for Investigating Chemical Process Incidents Guidelines for Hazard Evaluation Procedures, Second Edition with Worked Examples Plant Guidelines for Technical Management of Chemical Process Safety, Rev. Ed. Guidelines for Technical Management of Chemical Process Safety Guidelines for Chemical Process Quantitative Risk Analysis Guidelines for Process Equipment Reliability Data, with Data Tables Guidelines for Vapor Release Mitigation Guidelines for Safe Storage and Handling of High Toxic Hazard Materials Guidelines for Use of Vapor Cloud Dispersion Models Understanding Atmospheric Dispersion of Accidental Releases Expert Systems in Process Safety Concentration Fluctuations and Averaging Time in Vapor Clouds Safety, Health, and Loss Prevention in Chemical Processes: Problems for

Undergraduate Engineering Curricula Safety, Health, and Loss Prevention in Chemical Processes: Problems for

Undergraduate Engineering Curricula-Instructor's Guide Workbook of Test Cases for Vapor Cloud Source Dispersion Models Proceedings of the International Symposium and Workshop on Safe Chemical Process

Proceedings of the International Process Safety Management Conference and

Proceedings of the International Conference on Hazard Identification and Risk

Proceedings of the International Conference/Workshop on Modeling and Mitigating

Proceedings of the International Symposium on Runaway Reactions, 1989 CCPS/AIChE Directory of Chemical Process Safety Services

and BLEVEs

Automation, 1994

Workshop, 1993

Analysis, Human Factors, and Human Reliability in Process Safety, 1992

the Consequences of Accidental Releases of Hazardous Materials, 1991.

GUIDELINES FOR


CENTER FOR CHEMICAL PROCESS SAFETY AMERICAN INSTITUTE OF CHEMICAL ENGINEERS 345 East 47th Street New York, New York 10017

Copyright 0 1995 American Institute of Chemical Engineers 345 East 47th Street New York, New York 10017

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or other- wise without the prior permission of the copyright owner.

Library of Congress Cataloging-in Publication Data Guidelines for technical planning for on-site emergencies.

P. cm. Includes bibliographical references and index.

1. Chemical industry-Accidents. Chemical Engineers. Center for Chemical Process Safety.

ISBN 0-8169-0653-X : $130.00 I. American Institute of

TP149.G855 1995 660' .28Opdc20 9446234

CIP

This book is available at a special discount when ordered in bulk quantities. For information, contact the Center for Chemical Process Safety of the American Institute of Chemical Engineers at the address shown above.

I

It i s sincerely hoped that the information presented in th i s docmentwill lead to an even more impressive safety record for the entire industry; however, the American Institute of Chemical Engineers, its consultants, CCPS subcommittee members, their employers, their employers' officers and directors, and Roy F. Weston, Inc. dialaim making or giving any warranties or representations, expressed or implied, including with respect to fitness, intended purpose, use or merchantability and/or correctness or accuracy of the content of the information presented in th i s docment As between (1) the American Institute of Chemical Engineers, its consultants, CCPS subcommittee members, their employers, their employers' officers and directors, and Roy F. Weston, Inc. and (2) the user of this document, the user accepts any legal liability or responsibilitywhatsoever for the consequence of its use or misuse.

CONTENTS

Preface Acknowledgments Acronyms

... X l l l

xv xvii

PART A

PREVENTION

1. PREVENTION THROUGH PROCESS SAFETY MANAGEMENT

1.1. TECHNICAL MANAGEMENT OF CHEMICAL PROCESS SAFETY: BASIC ELEMENTS 3

1.2. THE ROLE OF EMERGENCY PREPAREDNESS 3 REFERENCES CITED 7

2. PREVENTION AND MITIGATION

2.1. INTRODUCTION 2.2. PRINCIPLES OF PREVENTION

2.2.1. Process Hazard Recognition 2.2.2. Inherently Safer Plants 2.2.3. Process Design Modifications

2.3. PRINCIPLES OF MITIGATION 2.3.1. Plant Siting/Buffers 2.3.2. Unit Siting in Plant Design 2.3.3. Principles of Mitigating Chemical Releases 2.3.4. Postrelease Mitigation Systems 2.3.5. Principles of Mitigating Fires and Explosions

REFERENCES CITED

9 11 1 1 13 13 15 15 16 16 17 21 26

V

vi CONTENTS

PART B

PREPAREDNESS

3. IDENTIFICATION OF CREDIBLE INCIDENTS

3.1. INTRODUCTION 3.2. DEFINING CREDIBLE INClDENTS 3.3. SCREENING TECHNIQUES TO IDENTIFY FOCUS AREAS

3.3.1. N FPA Fire Hazard Indices 3.3.2. Toxicity/Mobility/Quantity Index 3.3.3. Chemical Process Risk Indices

FOR EMERGENCY PLANNING 3.4.1. Informal "Expert" Review 3.4.2. Hazard Review to Support Emergency Planning 3.4.3. Using Process Hazard Analysis to Support Emergency Planning

FOR CONSEQUENCE ASSESSMENT

3.6.1. Tools 3.6.2. Criteria for Defining Sensitive Areas 3.6.3. Unexpected Hazards 3.6.4. Other Effects

EMERGENCY PLANNING

3.4. TECHNIQUES FOR IDENTIFYING CREDIBLE INCIDENTS

3.5. PRIORITIZING EMERGENCY PLANNING INCIDENTS

3.6. ASSESSING CONSEQUENCES AND IMPACTS

3.7. CRITERIA FOR SELECTING INCIDENTS FOR

3.8. REVIEWING MITIGATION SYSTEMS REFERENCES CITED APPENDIX A: EMERGENCY PLANNING GUIDELINES: ERPGs/EEPGs

4. CONCEPTUAL APPROACH TO EMERGENCY RESPONSE

4.1. INTRODUCTION 4.2. CAPABILITY AND RESOURCE ASSESSMENT

4.2.1. Trained Personnel 4.2.2. On-Site Response Equipment 4.2.3. Response Equipment Available Off-Site 4.2.4. Facilities 4.2.5. Specialized Supplies and Contractors

4.3.1. Effective Use of Inside and Outside Response 4 .3 .2 . Organizing for Credible Incident 4.3.3. Classification of Emergencies

4.4. REGULATORY CONSIDERATIONS

4.3. DETERMINE CONCEPT OF EMERGENCY OPERATIONS

31 32 33 35 3 7 3 7

38 38 39 4 1

43 47 4 8 52 58 58

59 60 60

62

65 66 6 6 6 7 6 8 6 8 6 9 71 72 77 7 7 79

CONTENTS vii

4.5. THE EFFECT OF CHANGE ON EMERGENCY PREPAREDNESS 80 REFERENCES CITED 81

5. DEVELOPING RESPONSE TACTICS

5.1. INTRODUCTION 5.2. PRINCIPLES OF RESPONDING TO FIRES

5.2.1. Plant Fire Response Organization 5.2.2. Integration of On-Site Fire Brigades and Off-Site Departments 5.2.3. Response Tactics

5.3.1. Hazardous Materials Response Regulations 5.3.2. Hazinat Initial Assessment and Size-Up 5.3.3. Hazinat Reconnaissance

5.3. HAZARDOUS MATERIALS

5.3.4. Work Zones 5.3.5. Hazinat Tactical Action Plan 5.3.6. Continual Reassessinents 5.3.7. Termination

REFERENCES CITED

6. PHYSICAL FACILITIES AND SYSTEMS

6.1. INTRODUCTION 6.2. FACILITIES

6.2.1. Short-Term Shelters and Safe Havens 6.2.2. Emergency Operations Center (EOC) 6.2.3. Incident Scene Areas 6.2.4. Media Information Center (MIC) 6.2.5. Control Rooins 6.2.6. Medical Support Facilities 6.2.7. Adequate Water Supplies

6.3.1. Detection/Early Warning Systems 6.3.2. Coininunications System Design 6.3.3. Coininunity and Site Alerting and Notification Systems 6.3.4. Computer Systems for Emergency Management 6.3.5. Site Maps and Diagrams for Emergency Manageinent 6.3.6. Emergency Power Systems 6.3.7. Weather Stations

6.3. SYSTEMS

REFERENCES CITED

7. RESPONSE EQUIPMENT AND SUPPLIES

7.1. INTRODUCTION 7.2. FIRE APPARATUS

83 84 84 85 86 92 9 2 9 3 94 9 5 96 9 7 9 7 97

99 99

100 101 105 107

111 112 114 114 115 117 120 121 122 123 12.5 125

127 127

viii CONTENTS

7.3. EXTINGUISHING AGENTS 7.3.1. Water 7.3.2. Foams 7.3.3. Dry Chemicals 7.3.4. Dry Powders 7.3.5. Halon 7.3.6. Carbon Dioxide 7.3.7. Miscellaneous Agents

7.4.1. In hi bitors 7.4.2. Neutralizers 7.4.3. Sorbents

7.5.1. Materials for Protective Clothing 7.5.2. Considerations 7.5.3. Flash Protection 7.5.4. Thermal Protection 7.5.5. Choosing Appropriate Levels of Protection 7.5.6. Respiratory Protection

7.4. INHIBITORS, NEUTRALIZERS, SORBENTS

7.5. PERSONAL PROTECTIVE EQUIPMENT

7.6. HEAVY EQUIPMENT 7.7. ADEQUATE INVENTORY AND ALTERNATE/

REFERENCES CITED APPENDIX A. CHANNEL INDUSTRY STANDARDS FOR APPARATUS

OUTSIDE SOURCES OF SUPPLY

8. DEVELOPING A WORKABLE PLAN 8.1. INTRODUCTION 8.2. REVIEW EXISTING PLANS OR PROCEDURES

8.2.1. Review Existing Emergency-Related Facility Plans 8.2.2. Review Neighboring Facility Plans 8.2.3. Review Community Plans

8.3.1. Plan Types 8.3.2. Plans, Procedures, and Instructions 8.3.3. Coordination and Commonalty

8.3. DETERMINING APPROPRIATE PLAN TYPE

8.4. DETERMINING CONTENT 8.5. PREPAREDNESS

8.5.1. Training 8.5.2. Drills and Exercises 8.5.3. Supplies and Equipment 8.5.4. Community Awareness 8.5.5. Medical Surveillance Program

8.6. GENERAL, RESPONSE PROCEDURES

129 129 130 132 133 133 134 135 136 136 136 137 138 138 138 139 140 141 144 146

147 147

148

153 154 154 154 155 156 156 159 160 162 162 162 165 166 167 167 167

CONTENTS ix

8.6.1. Alerting and Warning 168 8.6.2. Communications 168 8.6.3. Management Functions 169 8.6.4. Evacuation and Personnel Accountability 170 8.6.5. Emergency Shutdown Procedures 170 8.6.6. Security 171 8.6.7. Mutual Ad 171 8.6.8. Public Inforrnation/Media 171 8.6.9. Special Notifications and Fatality Procedure 172 8.6.10. Reporting Requirements 172

8.7. HAZARD-SPECIFIC PROCEDURES 172 8.7.1. Fire 172 8.7.2. Chemical Release 173 8.7.3. Medical and Rescue 174 8.7.4. Hurricane 175 8.7.5. Tornado and High Wind 175 8.7.6. Freeze/Winter Storm 177 8.7.7. Flood 177

8.8. WRITING THE PLAN 178 8.9. ENSURE INTEGRATION WITH OTHER PLANS 178 8.10. PLAN REVIEWS AND MAINTENANCE 179 8.1 1. EXERCISE REGULARLY/CRITIQUE TO VERIFY PLANNING ASSUMPTIONS 179

179 181

REFERENCES CITED 181 APPENDIX A. REGULATIONS APPLICABLE TO EMERGENCY EQUIPMENT AND SUPPLIES 184 APPENDIX B. SAMPLE EMERGENCY PROCEDURE FORMAT AND INSTRUCTIONS 187

Table of Contents 187

8.1 1.1. Planning an Exercise 8.1 1.2. Exercising without Interfering with Plant Operations

I . Purpose 188 11. Definitions 189 111. Levels of Emergencies 192 IV. Site Emergency Organization and Responsibilities 192

200 202

VII. Plan for Securing/Obtaining Off-Hour Services 214 VIII. Unit Emergency Plans 215 IX. Environmental Contingency Plans 215 Appendix A. Emergency Call Lists 216 Appendix B. Unit Emergency Plans and Guidelines 218 Appendix C. Description of MIDAS 226 Appendix D. Handling Telephone Bomb Threats 227 Appendix E. Bomb Threat Employee Training Guidelines 230

V. Emergency Equipment and Hardware VI. Topical Index for Emergencies and/or Probable Scenarios

CONTENTS X

9. USING MODELING FOR EMERGENCY PLANNING 9.1. INTRODUCTION 233 9.2. CONSEQUENCE ANALYSIS 233 9.3. USING MODELS FOR DEVELOPING EMERGENCY

RESPONSE PLANS 236 9.3.1. Input Data Needs 236 9.3.2. Interpretation of Results 237

9.4. UTILIZING APPROPRIATE MODELS 238

REFERENCES CITED 239 9.5. REAL-TIME EMERGENCY RESPONSE MODELING SYSTEMS 239

10. TRAINING REQUIREMENTS

10.1. INTRODUCTION 10.2. GENERAL REQUIREMENTS

10.2.1. OSHA Emergency Training Requirements 10.2.2. Basic Emergency Training 10.2.3. Operating Personnel

10.3.1. General 10.3.2. Fire Brigade Training 10.3.3. Hazardous Materials Response Training

10.4. SUPPORT PERSONNEL 10.4.1. Media and Community Relations 10.4.2. Medical 10.4.3. Specialist Employees 10.4.4. Security 10.4.5. Skilled Support Personnel

REFERENCES CITED

10.3. EMERGENCY RESPONSE PERSONNEL

24 1 24 1 242 242 243 244 245 247 250 256 256 257 257 258 258 258

PART C

RESPONSE

11. KEY RESPONSE FUNCTIONS

11.1. INCIDENT COMMAND SYSTEM 11.1 . l . Definition 11.1.2. Characteristics of an ICS 1 1.1.3. Considerations for ICS

11.2. STRATEGY DEVELOPMENT 11.2.1, Assessment and Decision Making 11.2.2. Evaluate Additional Resources Needs

11.3. DETERMINE MITIGATION TACTICS 11.3.1. Evaluate Need for Off-Site Warnings

263 263 265 265 266 267 269 270 270

CONTENTS xi

11.4. lMPLEMENT TACTICAL PLAN AND EVALUATE 11.5. RESPONSE TEAM DECONTAMINATION

11.5.1. Types of Containiiiatioii 11.5.2. Prevention of Containiiiatioii 11.5.3. Decontamination Methods 11.5.4. Determining Effectiveness 11.5.5. Plaiiiiing for Decontamination

1 1.6. MEDICAL DECONTAMINATION/TRIAGE/TREATMENT 11.7. USING DISPERSION MODELING DURING EMERGENCIES 11.8. TERMINATION REFERENCES CITED APPENDIX A. CHANNEL INDUSTRIES MUTUAL AID ICS WORKSHEET

12. SUPPORT FUNCTIONS, SYSTEMS, AND FACILITIES

12.1. INTRODUCTION 12.2. FUNCTIONS

12.2.1. Internal Management and Technical Support 12.2.2. Security 12.2.3. Legal 12.2.4. Outside Technical Support 12.2.5. Reporting Requirements 12.2.6. Public Relations

12.3.1. Mutual Aid 12.3.2. Coininunications System Operation

12.3. SYSTEMS

REFERENCES CITED

270 271 2 72 273 273 2 74 2 74 275 277 278 279

28 1

283 283 283 287 287 288 289 290 29 1 291 294 294

PART D

RECOVERY

13. MANAGING RECOVERY

13.1. INTRODUCTION 13.2. MANAGEMENT DURING RECOVERY 13.3. SCENE SECURITY AND SAFETY 13.4. EMPLOYEE ASSISTANCE

13.4.1. General 13.4.2. Supervisors’ Role 13.4.3. Human Resources Department 13.4.4. Federal Assistance

13.5. DAMAGE ASSESSMENT 13.6. PROCESS DATA COLLECTION

299 300 301 302 302 303 303 3 04 304 305

xii CONTENTS

13.7. INCIDENT INVESTIGATION 13.8. RESTORING SAFETY AND EMERGENCY SYSTEMS 13.9. LEGAL 13.10. INSURANCE 13.1 1. PUBLIC INFORMATION AND COMMUNICATION

REFERENCES CITED APPENDIX A. SAMPLE RECOVERY MANAGEMENT CHECKLIST APPENDIX B. SAMPLE DAMAGE ASSESSMENT CHECKLIST

13.11 .1 . Business Relationships

14. CLEANUP OF FACILITIES 14.1. INTRODUCTION 14.2. TYPES AND FORMS OF CONTAMINATION

14.2.1. Chemical Contamination 14.2.2. Radioactive Contamination

14.3. PREVENTING THE SPREAD OF CONTAMINATION 14.4. DECONTAMINATION METHODS

14.4.1. Small-Scale Decontamination 14.4.2. Large-Scale Decontamination of Facilities

14.5. CONTRACTOR QUALIFICATIONS FOR CLEANUP 14.6. DETERMINING THE EFFECTIVENESS GENERAL REFERENCES

BIBLIOGRAPHY

GLOSSARY

INDEX

305 306 307 307 307 308 308 309 310

315 315 3 16 318 319 319 320 320 32 1 322 323

325

333

345

PREFACE

The Center for Chemical Process Safety (CCPS) was established in 1985 by the American Institute of Chemical Engineers (AIChE) for the express purpose of assisting industry in avoiding or mitigating catastrophic chemical accidents. To acheve this goal, CCPS has focused its work on four areas:

Establishng and publishng the latest scientfic, engineering, and management practices for prevention and mitigation of incidents involving toxic, flammable, and/or reactive material. Encouraging the use of such information by dssemination through publications, seminars, symposia, and continuing education programs for engineers. Advancing the state-of-the-art in engineering practices and technical management through research in prevention and mitigation of catastrophic events. Developing and encouraging the use of undergraduate engineering curricula that will improve the safety knowledge, and consciousness of engineers.

The current book, Guidelines for Technical Planning for On-Site Emergencies, is the result of a project begun in 1992 in whch a group of volunteer professionals representing major chemical and hydrocarbon processing companies worked with professionals from Roy F. Weston, Inc., to develop th s document. The intent was to produce a book that covers the technical knowledge needed for proper planning and effective response to on-site emergencies. The book was to provide information on topics (primarily techcal in nature) not specifically covered by existing documents on emergency planning and to integrate this information into basic emergency planning procedures.

Although this Guideline volume was written to stand alone, it draws on other CCPS publications where emergency planning interfaces with the topics of these publications and upon other sources that discuss emergency planning. T h s book contains not only du-ect references, but a substantial list of other reading resources that will expand on the content of each chapter.

xiii

xiv PREFACE

The book does not provide detailed emergency plans. It does provide information necessary for selecting the most credible incidents, thereby estab- lishing the basis for the emergency plan. The text then aids in applying t h s information, along with information on other aspects of emergency planning, to develop an integrated plan for on-site emergencies.

The guideline is directed at plant personnel involved in developing and managing emergency response plans, staffing and supplying the emergency response organization, designing and selecting equipment, and training response personnel. T h s text should also be useful to off-site emergency planning organizations worlung with industrial facilities.

The book has been organized into the four phases of emergency planning:

0 Prevention Preparedness

0 Response 0 Recovery

Although other CCPS Guidelines focus on the prevention aspects, emergency planners must always be on the lookout for situations, uncovered in their planning activities, where adltional preventative measures may be warranted. Thus, the book briefly lscusses the prevention aspects, whle concentrating on the other three elements.

The book focuses on on-site emergency planning. It does not deal with responsibilities and activities of outside officials (whether local, state, or national) or with response to transportation accidents outside a plant.

ACKNOWLEDGMENTS

The American Institute of Chemical Engineers (AIChE) wishes to thank the Center for Chemical Process Safety (CCPS) and those involved in its operation, includng its many sponsors whose funding made t h s project possible. Thanks are due to the members of its Techca l Steering Committee who conceived the idea and supported this project, and to the members of the Subcommittee on Technical Planning for On-Site Emergencies for their dedcated efforts, technical contributions, and enthusiasm. Thanks are also due to the CCPS Vapor Cloud Subcommittee who assisted with the material presented in Chapter 9 on vapor release modeling used in emergency planning.

The members of tlis subcommittee especially wish to thank their employers for providmg the time to participate in this project and those sponsors and Technical Steering Committee members who reviewed and critiqued this book prior to publication.

The members of the Subcommittee on Technical Planning for On-Site Emergencies are:

Charles R. Dancer, Allied-Signal (Chairman) Hugh Billings, Hoechst-Celanese Corporation H e r m a n Dreher, BASF Corporation William R. Heitzig, The Dow Chemical Coinpany John T. Higgins, Dow Corning Corporation Robert Kelly, Roy F. Weston, Inc. (Project Manager) F. Owen Kubias, CCPS Staff Consultant Robert M. Schisla, Eastman Chemical Company John D. Snell, Occidental Chemical Corporation Marvin F. Specht, Hercules Incorporated

Former Committee Members: Marielle L. Boortz, Chevron Corporation Robert Rosen, BASF Corporation

xv

xvi ACKNOWLEDGMENTS

Peer Reviewers: Daniel Crowl, Michigan Tech Philip Felten, Hercules Thomas Gibson, Dow Chemical Bill Heitzig, Dow Chemical Dennis Hendershot, Rohm & Haas John Hudson, Harris Specialty Peter Lodal, Eastman Chemical Craig Mathiessen, USEPA David Moore, AcuTech David Philley, HalLburton/NUS Isidore Polasek, Occidental Robert Schisla, Eastman Chemical

Roy F. Weston Staff Contributors: Robert Kelly, Edltor and Project Manager Gregg Beatty Jeff Benyo &chard Craig Harry Cusick Michael Harrison John l m b d H. She1 McGee Steve McManus Louis Militano Craig Moylan Peter Puglionesi Stanley Schechter

We also express our appreciation to Thomas W. Carmody, former Director of CCPS; Bob G. Perry, AIChE Managing Director, Technical Activities; and Jack Weaver, former Project Manager for Weston and now Director of CCPS, for their support and guidance.

ACRONYMS

ACGIH American Conference of Governmental and Industrial Hygenists AFFF Aqueous Film-Forming Foam AIChE American Institute of Chemical Engineers AIHA American Industrial Hygiene Association API American Petroleum Institute ASTDR Toxic Disease Registry ASTM BLEVEs BPCS Basic Process Control System CAER CCPS CEI Chemical Exposure Index CEP Comprehensive Emergency Plan CERCLA Comprehensive Environmental Response, Compensation,

CHEMTREC Chemical Transportation Emergency Center

CHRIS CIMA Channel Industries Material A d CMA Chemical Manufacturers Association c 0 2 Carbon Dioxide CP Command Post CPC Chemical Protective Clothing CRZ Contamination Reduction Zone

American Society for Testing and Materials Boiling Liquid Expandmg Vapor Explosions

Community Awareness and Emergency Response Center for Chemical Process Safety

and Liability Acts

(operated by CMA) Chemical Hazard Response Information System

xvi i

xvi i i ACRONYMS

DAP DIERS DOT EBS EHS EMS EOC EPA EPCRA EPSS ER ERPG ERT ETA FBMA F&EI FD FMEA FTA Hazmat HAZOP HF HIV HMIS W A C IC ICP ICS IDLH IRI LAN LEPC LFL LOP medevac

Detailed Action Plan Design Institute for Emergency Relief Systems Department of Transportation’s Emergency Broadcast System Extremely Hazardous Substance Emergency Medical Service Emergency Operations Center Environmental Protection Agency Emergency Planning and Community Right-to-Know Act Emergency Power Supply Systems Emergency Room Emergency Response Planning Guidelines Emergency Response Team Event Tree Analysis Federal Emergency Management Agency Fire and Explosion Index Fire Department Failure Modes and Effects Analysis Fault Tree Analysis Hazardous Material Hazard and Operability Hydrofluoric Acid Human Immunodeficiency Virus Hazardous Material Identification System Heating, Ventilation and Air Conditioning Incident Commander Incident Command Post Incident Command System Immediately Dangerous to Life and Health Industrial k s k Insurors Local Area Network Local Emergency Planning Committee Lower Flammable Limit Level of Protection Medical Evacuation

ACRONYMS xix

MIC MIC MSDS NFPA NRC NRC ORC OSHA P&IDs PBX PCBs PEL PPE PSM RCRA RMP R M P RP

RQ RRI SARA S A R S SCBA SHI TSP UFL UPS UVCEs WAN WIA

Meda Information Center Methylisocyanate Material Safety Data Sheets National Fire Prevention Association National Response Center Nuclear Regulatory Commission Organization Resource Counselors Occupational Safety and Health Administration Piping and Instrumentation Diagrams Private Branch Exchanges Polychlorinated Biphenyls Permissible Exposure Limit Personal Protective Equipment Process Safety Management Resource Conservation and Recovery Act h s k Management Program Risk Management Planning Recommended Practice Reportable Quantity Risk Ranlung Index Superfund Amendments and Reauthorization Act Supplied-air respirators Self-contained Breathing Apparatus Substance Hazard Index Trisodlum Phosphate Upper Flammable Limit Uninterruptible Power Source Unconfined Vapor Cloud Explosions Wide Area Network What-If Analysis

PART A

PREVENTION

I PREVENTION THROUGH PROCESS SAFETY MANAGEMENT

1 .l. TECHNICAL MANAGEMENT OF CHEMICAL PROCESS SAFETY: BASIC ELEMENTS

The Center for Chemical Process Safety (CCPS), founded in 1985 by the American Institute of Chemical Engineers (AIChE), is dedicated to preventing serious accidents in the process industries by publishing gudelines and conducting seminars, courses, and research. This book is a guideline on technical planning for on-site emergencies, and it complements other CCPS guidelines, especially Guide- lines for Technical Management of Chemical Process Safety [l] published in 1989. Along with work by the Organization Resource Counselors [2], the American Petroleum Institute [3], and others, the 1989 CCPS book was a resource used in the development of OSHA’s Process Safety Management standard and the EPA k s k Management Program (RMP). AIChE and the chemical process industry have recognized that accident prevention must include sound technology and management systems to assure safe operating conditions. Table 1.1 presents the key elements and components of process safety management developed by CCPS in Guidelinesfor Technical Management of Chemical Process Safety. The OSHA PSM standard and EPA’s RMP regulation include most of these elements and components.As indicated by the nature of these elements, process safety management systems purposely include more than technological measures. They also broadly encompass policies, procedures, and practices that provide barriers against the technological and human causes of major incidents.

1.2. THE ROLE OF EMERGENCY PREPAREDNESS

Despite the best efforts of responsible facilities to safely manage hazardous chemicals, there may still be incidents that might escalate into catastrophes;

3

4 1. PREVENTION THROUGH PROCESS SAFETY MANAGEMENT

TABLE 1.1 Elements and Components of Process Safety Management - - -

1. Accountability: Objectives and Goals Continuity of operations Continuity of systems (resources and funding) Continuity of organizations Company expectations (vision or master plan) Quality process Control of exceptions Alternative methods (performance vs.

Management accessibility specification)

2. Process Knowledge and Documentation Process definition and design criteria Process and equipment design Company memory (management information) Protective systems Chemical and occupational health hazards

3. Capital Project Review and Design Procedures (for new or existing plants, expansions, and acquisitions) Appropriation request procedures Risk assessment for investment purposes Hazards review (includingworst credible as) Plot plan Project management procedures

4. Process Risk Management Hazard identification Risk assessment of existing operations Residual risk management (in-plant emergency response and mitigation)

Process management during emergencies Encouraging client and supplier companies

Selection of business with acceptable risks to adopt similar risk management practices

5. Management of Change Change of technology Organizational changes that may have an

Variance procedures Temporary changes Permanent changes

impact on process safety

6. Process and Equipment Integrity Reliability engineering Materials of construction Fabrication and inspection procedures Installation procedures Preventive maintenance Process, hardware, and systems inspections

Maintenance procedures Alarm and instrument management Demolition procedures

and testing (pre-startup safety review)

7. Human Factors Human error assessment Operator-process and equipment interfaces Administrative controls versus hardware

8. Training and Performance Definition of skills and knowledge Design of operating and maintenance

Ongoing performance and refresher training Instructor program Records management

procedures

9. Incident Investigation Major incidents Follow-up and resolution Incident recording Third-party participation as needed

0. Standards, Codes, and Laws Internal standards, guidelines, and practices (past history, flexible performance standards, amendments, and upgrades)

External standards, guidelines, and practices Resolution and close-out procedures

1. Enhancement of Process Safety Knowledge Internal and External Research Improved Predictive Systems Process Safety Reference Library

1.2. THE ROLE OF EMERGENCY PREPAREDNESS 5

therefore, facilities must prepare to respond effectively to minimize possible injuries and property damage. Table 1.2 presents a list of selected incidents, from 1974 to 1993, illustrating the range of process industry catastrophes from fire, explosion, and hazardous material release. These incidents demonstrate the ongoing need for high-level competence in emergency preparedness and continued attention to preventing and mitigating such events.

TABLE 1.2 Tragic Events of Two Decades Spur Efforts to Improve Process Safety*

INCIDENTS ABROAD

1974 FLIXBOROUCH, ENculND-Twenty-eight deaths resulted from the explosion of a cyclohexane vapor cloud released when temporary piping failed.

1976 SMSO, ITALY-Thousands affected by dioxin release from a runaway reaction.

CUBATAO, Bwii-Some 508 people killed in Shantytown built over swamp where 700 tons of gasoline leaked from ruptured pipe and ignited

MmlCOcln-An explosion and fire at a liquefied petroleum gas facility in San Juanico suburb killed 542, injured more than 4,000.

1984 BHOPAL, INDiA-More than 2000 died and hundreds of thousands affected by a massive leak R I at a methylisocyanate facility due to a runaway reaction after water contaminated a tank. 11 986 I BASEL, SWITzERLAND-Thirty tons of pesticides from a warehouse fire spilled into the Rhine.

ROSALJUAYMAH, SAUDI Alum-Vapor cloud explosion at the natural gas complex reportedly killed as many as 22 and injured 15 others.

1993 FRANKFURT, cERhtANY-Explosion in polyvinyl alcohol plant killed one and injured one.

INCIDENTS IN THE UNITED STATES

1985 1 INSTITUTE, w-Vapor doud of aldicarb oxime and methylene ddoride from a plant injured 135. TMAS cin, Tx-Vapor cloud of hydrofluoric acid from a refinery drifted through community; 1,000 received medical treatment.

11 1988 I HENDERSON, Nv-Ammonium perchlorate explosion killed two and injured 350. 1989 PASADENA, Tx-Cloud of ethylene and isobutane exploded in a plant, killing 23 and injuring 132

1990 CHANNELVIEW, Tx-Wastewater tank exploded, killing 17 and charring an area the size of a city block.

~~ ~~ 1 1990 I CINCINNATI, OH-Resins plant explosion left =dead, 71 injured. 1991 CHARLESTON, sc-Phosphorus chemicals prlant explosion killed six, injured 33.

1991 PORT LAVA- Tx-Blast at ethylene oxide unit in a plant killed one, injured 19.

1991 STERLINCTON, -Eight deaths, 128 injuries from explosion and fire at a fertilizer facility.

*Adapted from Chemical and hgineering News, November 29, 1993.

6 1. PREVENTION THROUGH PROCESS SAFETY MANAGEMENT

I RECOVERY I I PREPAREDNESS I I

FIGURE 1 .l. Four phases of emergency management.

This book provides technical guidance for plant supervisors and managers to plan for emergency situations that may never happen but are nevertheless possible. Technical guidance in this book provides an understanding of the tools and techniques important to prepare for and manage on-site emergencies; however, the book does not provide detailed specifications on the use of the tools involved.

As Figure 1.1 demonstrates, emergency planning is a continuous, cyclical process, starting with prevention and including preparedness, response, and recovery. The CCPS title Guidelines fm Technical Management of Chemical Process Safety focuses on prevention as the first phase of the emergency management cycle.

However, CCPS recognizes that emergency management must also consider the preparedness and response phases and consider planning for recovery after an incident in order to minimize the effects of incidents that may occur despite a facility's prevention efforts. This book organizes the chapters under major head- ings that correspond to all four phases (prevention, preparedness, response, and recovery) of emergency management. In the prevention section, the book briefly reviews engineering features in plant and process design intended to prevent or mitigate the effect of significant accidental releases. The next section addresses the main features of a preparedness program, including recognizing credble incidents, planning practical approaches and tactics to deal with those incidents, choosing necessary physical support systems and equipment, and developing a complete workable plan. The section on preparedness also discusses using dispersion and other accident-consequence modeling to aid in shaping the plan and summarizes personnel training necessary for a reliable and appropriate response. The response section outlines the various functions implemented during an actual emergency, including the applicability of various support systems. Finally, in the recovery section we review a plant's needs for managing cleanup and restoration of operations.

Since this Guideline focuses on on-site emergency management, it does not deal in any detail with emergency responsibilities and activities of outside officials, either local, state, or national. T h s document also does not deal with response to transportation accidents involving hazardous materials outside the plant or with on-site medical emergencies generally categorized as acute illness.

REFERENCES CITED 7

REFERENCES CITED

1. CCPS. 1989. Guidelinesfor Technical Management of Chemical Process Safety. New

2. Organization Resource Counselors (ORC). December 1988. Remmmendatwns for

3. API. January 1990. Recommended Practice (RP) 750, Management of Process Hazardr,

York: AIChE. ISBN 0-8169-0423-5.

Process Hazards Managment of Substances with Catastrophic Potential.

1st Edition.

Other References CCPS. For other CCPS Guidelines references, please see Chapter 2 of this book. CCPS. 1992. Plant Guidelinesfor Technical Management of Chemical Process Safety. New

York: AIChE. ISBN 0-8169-0499-5. (Provides examples of management systems for the safety elements developed in CCPS, 1993.)

Kelly, Robert B. 1989. Industrial Emergency Preparedness. New York: Van Nostrand Reinhold. ISBN 0-442-20483-3.

technical planning for on-site...

Documents