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LEPCs and Deliberate Releases Are You Ready?: LEPCs and Deliberate Releases Are You Ready? Fayette LEPC Full Committee Meeting Lexington Health Dept. September 19, 2003 LEPC Preparedness Agenda: LEPC Preparedness Agenda Facility Report Card Threat Scenario Preparedness Planning Structural Risk Administrative Risk Overall Facility Risk 1.0 Facility Report Card: 1.0 Facility Report Card Generic Threat Risk Preparedness – Structural Preparedness – Administrative 1.1 Facility Report Card: 1.1 Facility Report Card Facility Scoring Yes = 1 in response column No = 0 in response column Maximum Risk Generic – 21 points Structural – 21 points Administrative – 20 points 2.0 Threat Scenario: 2.0 Threat Scenario 2.1 Threat Source 2.2 Threat Method 2.3 Threat Response Challenges 2.4 Threat Targets) 2.1.1Threat Scenario - Source: 2.1.1Threat Scenario - Source Generic LEPC EHS FACILITY UTILITY - Water, Electric, Gas Chemical / Petroleum / LNG facility Hospitals Municipal Operations Distribution Centers Bulk Material Terminals Slide7: Incident Description On January 13, 2003, a vapor cloud fire erupted at the BLSR Operating Ltd. oilfield waste disposal facility near Rosharon, Texas, south of Houston. The fire occurred as two vacuum trucks were delivering flammable gas condensate waste for disposal at the facility. Two BLSR employees and one truck driver were fatally burned. Two other workers suffered serious burns but survived. 2.1.2 Threat Scenario - Source: 2.1.2 Threat Scenario - Source Accident or Natural Disaster Accident in last 12 months Flood Prone Area Earthquake Zone Tornado or Severe Weather Zone Vulnerability Zone (VZ) Extends Beyond Boundary Slide9: Incident Description On July 20, 2003 there was a release of chlorine gas from the Honeywell chemical plant in Baton Rouge, Louisiana. The accident resulted in the hospitalization of four plant workers and required about 600 nearby residents to shelter in their homes. Several residents also sought medical evaluation. The plant manufactures refrigerants using chlorine and other potentially hazardous materials. 2.2.1 Threat Scenario - Method: 2.2.1 Threat Scenario - Method Use Weapons of Mass Destruction Explosives Chemical Biological Nuclear Release On-site Chemicals Slide11: Incident Description At 9:30 am on August 14, 2002, a 1-inch chlorine transfer hose (CTH) used in a tank car unloading operation at the DPC Enterprises facility, near Festus and Crystal City, Missouri, catastrophically ruptured. The hose rupture initiated a sequence of events that led to the release of 48,000 pounds of chlorine. Sixty-three people sought hospital treatment due to exposure to chlorine gas. 2.2.2 Threat Scenario - Internal: 2.2.2 Threat Scenario - Internal Internal Threat Process Safety Management Plan Required Risk Management Plan Required LEPC EHS Present History of Labor Unrest Slide13: Incident Description On December 11, 2002, one maintenance employee was overcome when he inhaled hydrogen sulfide gas from a waste processing vessel at Environmental Enterprises, a hazardous waste treatment company in Cincinnati, Ohio. No other injuries or damage were reported, and the injured worker was subsequently pulled to safety. 2.3 Threat Scenario – Response Challenges: 2.3 Threat Scenario – Response Challenges Explosives – Normal Local Fire /Emergency Response Chemical – Normal unless release in public gathering Biological – Difficult – agent unknown and effect may multiply as people travel Nuclear – Difficult – with long term effects 2.4 Threat Scenario - Targets: 2.4 Threat Scenario - Targets LEPC – EHS Facilities Large Chemical Inventory / Stockpiles Utility Operations Infrastructure Slide16: Incident Description On April 25, 2002, an explosion occurred at Kaltech Industries, a sign manufacturer in the Chelsea neighborhood of New York City, injuring 31 people seriously enough to seek hospital treatment, including 14 members of the public. The explosion, which was the result of a reaction between waste chemicals, originated in the basement of a mixed-use commercial building and caused damage as high as the fifth floor. 2.4 Threat Scenario - External: 2.4 Threat Scenario - External External Threat to Your Facility PSM Required RMP Required LEPC EHS Present Industrial Concentration Slide18: Incident Description On the morning of April 11, 2003, one worker was killed at the D.D. Williamson food additive plant in Louisville, KY, when a process vessel became overpressurized and failed catastrophically. The failure caused a release of aqueous ammonia as well as extensive damage to the plant, which manufactures caramel coloring. 3.0 Preparedness Planning : 3.0 Preparedness Planning 3.1 Structural Risk 3.2 Administrative Risk 3.3 Overall Risk Slide20: Incident Description On October 13, 2002, a violent explosion occurred in a chemical distillation tower at First Chemical Corporation in Pascagoula, Mississippi, sending heavy debris over a wide area. No one was seriously injured or killed in the incident, which occurred early on a Sunday morning. One nitrotoluene storage tank at the site was punctured by explosion debris, igniting a fire that burned for several hours. 3.1.1 Structural Risk - Security: 3.1.1 Structural Risk - Security Facility Security Fence, Gates, Lighting, TV Surveillance Locked Doors, Key Access to Process Emergency Generator Communication (Battery Powered) Sprinklers / Fire Extinguishers / Systems Monitors 3.1.2 Structural Risk – Mtl. Storage: 3.1.2 Structural Risk – Mtl. Storage Material Storage Risk Passive Secondary Containment Locked Entry to all Bulk Chemicals Walls or Barriers to prevent Line of Sight from External Source to Tanks, Containers All storage containers, supports, buildings, containment Designed to Code Slide23: Incident Description On April 9, 1998, at approximately 11:28 pm, an 18,000-gallon propane tank exploded at the Herrig Brothers Feather Creek Farm (the farm) in Albert City, Buena Vista County, Iowa. The explosion killed two volunteer fire fighters and injured seven other emergency response personnel. Several buildings were also damaged by the blast. 3.1.3 Structural Risk – Response Equip.: 3.1.3 Structural Risk – Response Equip. Response Equipment Risk PPE for all chemicals on site Control Equipment designed to control or neutralize largest inventory of material Spill Kits – Petroleum Spill Kits – Chemicals, Solvents, Haz Wste 3.1.4 Structural Risk – Safe Rooms: 3.1.4 Structural Risk – Safe Rooms Safe Room / Shelter Risk Designed to current building code Will Hold all present staff Can be sealed shut (air lock) Emergency Lighting, Radio (battery) Potable Water Slide26: Incident Description On January 29, 2003, an explosion and fire destroyed the West Pharmaceutical Services plant in Kinston, NC, causing six deaths, dozens of injuries, and hundreds of job losses. The facility produced rubber stoppers and other products for medical use. CSB investigators have found that the fuel for the explosion was a fine plastic powder used in producing rubber goods. Combustible polyethylene dust accumulated above a suspended ceiling over a manufacturing area at the plant and was ignited by an unknown event. 3.2.1 Administrative Risk – Reg. Plans: 3.2.1 Administrative Risk – Reg. Plans Regulatory Plans Needed Mark 0 if not applicable Process Safety Management Plan Risk Management Plan SPCC, GPP, BMP Plans OSHA Emergency Plan – fire, medical Evacuation Plan Slide28: Incident Description On February 19, 1999, a process vessel containing several hundred pounds of hydroxylamine exploded at the Concept Sciences Inc. production facility near Allentown, Pennsylvania. Employees were distilling an aqueous solution of hydroxylamine and potassium sulfate, the first commercial batch to be processed at the facility. After the distillation process was shut down, the HA in the process tank and associated piping explosively decomposed, most likely due to high concentration and temperature. Four CSI employees and a manager of an adjacent business were killed. Two CSI employees survived the blast with moderate-to-serious injuries. Four people in nearby buildings were injured. The explosion also caused significant damage to other buildings in the Lehigh Valley Industrial Park and shattered windows in several nearby homes. 3.2.2 Administrative Risk – MSDS: 3.2.2 Administrative Risk – MSDS Chemical Safety Knowledge and Management Current MSDS in Place Complete Chemical Inventory WMD Planning and Review Action Plan Plant Process Procedures and Housekeeping Slide30: Incident Description At 7.30 am February 20, 2003, an explosion and fire damaged the CTA Acoustics manufacturing plant in Corbin, KY. 44 workers were injured, 12 were flown to critical care hospitals, and 7 died. The facility produced fiberglass insulation for the automotive industry. CSB investigators have found that the explosion was fueled by resin dust accumulated in a production area, likely ignited by flames from a malfunctioning oven. The resin involved was a phenolic binder used in producing fiberglass mats. 3.2.3 Administrative Risk – Training: 3.2.3 Administrative Risk – Training Training Failure Risk Evacuation Training Shelter in Place Training Spill Response Training Decontamination Training 3.2.4 Administrative Risk – Drills: 3.2.4 Administrative Risk – Drills Drills and Exercises Risk Medical, Fire, Bomb Threat Drills Evacuation Drills Shelter in Place Drills Emergency Generator Testing and emergency equipment inventory including PPE, response kits, radios, pagers, fire alarms, process monitors, smoke detectors, etc. Slide33: Incident Description On July 17, 2001, an explosion occurred at the Motiva Enterprises LLC Delaware City Refinery (DCR) in Delaware City, Delaware. Jeffrey Davis, a boilermaker with The Washington Group International, Inc. (WGI), the primary maintenance contractor at DCR, was killed; eight others were injured. A crew of WGI contractors was repairing grating on a catwalk in a sulfuric acid storage tank farm when a spark from their hot work ignited flammable vapors in one of the storage tanks. The tank separated from its floor, instantaneously releasing its contents. Other tanks in the tank farm also released their contents. A fire burned for approximately one-half hour; and sulfuric acid reached the Delaware River, resulting in significant damage to aquatic life. 3.3 Overall Risk: 3.3 Overall Risk Threat Scenario Risk Generic and Typically Controllable Risk > 15 Requires Planning and Preparation Structural Risk Risk Controllable Risk > 15 Requires DIRECT AND IMMEDIATE ACTION Administrative Risk Risk Controllable Risk > 15 Suggests Non-Compliance Potential for OSHA OR EPA Fine and Penalty REQUIRES DIRECT AND IMMEDIATE ACTION 4.0 Summary: 4.0 Summary Risk and Threats Related to Business Internal Risks are Controllable Preparedness Planning Can reduce internal and external risk May be mandatory (compliance) Makes good sense Planning Resources – Local LEPC, OSHA, EPA, Trade Groups, Industry Groups 5.0 References: 5.0 References Prepared by Fayette LEPC Harry Enoch, Ph.D. Chair Fayette LEPC [email protected] J. Frederick Rial, PE Chair Fayette LEPC Response Exercise Subcommittee [email protected]