Appendix F

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Item No. Question Response Recommendatia

I. Spacing Between Process Components 1 Are operating units and the equipment within

units spaced to minimize potential damage from fires or explosions in adjacent areas?

Are there safe exit routes from each unit?

Has equipment been adequately spaced and located to safely permit anticipated maintenance

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3 ~~ -

Facility and Stationary Source Siting Checklist

I 4 Are vessels containing highly hazardous chemi- cals located sufficiently far apart? If not. what hazards are introduced?

Is there adequate access for emergency vehicles (e.g., fire trucks)?

Can adjacent equipment or facilities withstand the overpressure generated by potential explo- sions?

Can adjacent equipment and facilities (e.g.. sup- port structures) withstand flame impingement or radiant heat exposures?

When provisions have been made for relieving explosions in process components, are the vents directed away from personnel and equipment

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93

Revalidating Process Hazard Analyses by Walter L. Frank and David K. Whittle

Copyright 2001 American Institute of Chemical Engineers

94 Appendix F. Facility and Stationary Source Siting Checklist

1 Item I No. Question

11. Location of Large Inventories :+- I Are large inventories of highly hazardous chemi- I cals located away from the process area? and for finished products a t appropriate loca-

t --

storage provided for raw materials

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Are the inventories of highly hazardous chemi-

Where applicable, are reflux tanks, surge drums,

cals held to a minimum?

and rundown tanks located in a way that avoids the concentration of large volumes of highly haz- , ardous chemicals in any one area?

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applicable, has special consideration been given to the storage and transportation of explo-

Have the following been considered in the loca- + _ _ _ ~ _ _ _ ~ . 6 1 tion of material handling areas:

fire hazards? ~ - -

to important buildings and ~

- site exposures? safety devices (e.g., sprinklers)? I- ~ slope and drainage of the area? 1 L

111. Location of the Motor Control Center

Is the motor control center (MCC) located so that 1 it is easily accessible to operators?

Are circuit breakers easy to identify? -~ __

-~

Can operators safely open circuit breakers? Have 1 . - , ~1 b b e e n trained?

11 4 1 Is the MCC designed such that it could not be an ignition source? Are the doors always closed? Is

1 1 no-smoking policy strictly enforced? ~ ~~ ___

5 1 Is the MCC designed and meant to be a safe 1 haven?

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Question

. I

1 - ~ ~ Is the control room built to satisfy current com-

Does the construction basis for the control room 1 satisfy acceptable criteria (e.g., the Factory Mutual recommendations)?

Are workers in the control room (or escape routes from the control room) protected from all of the following:

toxic, corrosive, or flammable sprays, fumes,

thermal radiation from fires (including flares)?

overpressure and projectiles from explosions?

contamination from spills or runoff?

pany overpressure and safe-haven Standards? L - - - ~- - 1 - - I

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- -

- ~ mists, or vapors? - I

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- 1 noise?

contamination of utilities (e.g., breathing air)?

I transport of hazardous materials from other sites? -~

-~ - -

i possibility of long-term exposure to low

odors?

impacts (e.g., from a forklift)?

flooding (e.g.. ruptured storage tank)?

Are vessels containing highly hazardous chemi- cals located sufficiently far from control rooms? 1 Were the following characteristics considered when the control room location was determined: 1

concentrations of process material? -1 - - - - ~

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I

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- - 1 types of construction of the room?

I *directionand velocity of prevailing winds? -

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I

- typeslquantities of materials? -

types of reactions and processes? - - - -

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Response Recommendations

1 operating pressures and temperatures? - 1

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I ~ ~ - - .~ , fire protection? -~

drainaee?

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r u c a t i o n and Construction of the Control Room&)

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96 Appendix F. Facility and Stationary Source Siting Checklist

Item No. Question

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If windows are installed, has proper consider- ation been given to glazing hazards?

Is a t least one exit located in a direction away from the process area? Do exit doors open out- ward? Are emergency exits provided for multi- story control buildings?

Are the ends of horizontal vessels facing away from control rooms?

Are critical pieces of equipment in the control room well protected? Is adequate barricading pro- vided for the control room?

Are open pits, trenches, or other pockets where inert, toxic, or flammable vapors could collect located away from control buildings or equip- ment handling flammable fluids?

Where piping, wiring, and conduit enter the building, is the building sealed a t the point of entry? Have other potential leakage points into the building been adequately sealed?

[s the control room located a sufficient distance From sources of excessive vibration?

[s a positive pressure maintained in control rooms located in hazardous areas?

Could any structures fall on the control room in the event of an accident?

Is the roof of the control room free from heavy :quipment and machinery?

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Response Recommendati

r. Location of Machine Shops, Welding Shops, Electrical Substatlons, Roads, Rail ;purs, and Other Likely Ignition Sources

Are likely ignition sources (e.g., maintenance shops, roads, rail spurs) located away from release points for volatile substances (both liquid and vapor)?

Are process sewers located away from likely sources of ignition?

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Appendix F. Facility and Stationary Source Siting Checklist 97

2

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1 Item 1 NO.

Could specific siting hazards be posed to the site from credible external forces such a s high winds, earthquakes and other earth movement, utility Failure from outside sources, flooding, natural fires, and fog?

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Question

(1 3 I Are all vessels containing highly hazardous

4

chemicals or components containing material above its flash point located away from likely sources of ignition?

Are the flare and fired heater systems located to minimize hazards to personnel and equipment, with consideration given to normal wind direc- tion and wind velocity, as well as heat potential?

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Response Recommendations

cation of Engineering, Lab, Administration, or Other Occupi Have site buildings been screened to identify occupied buildings requiring further review?

Are occupied buildings located away from inven- tories of highly hazardous chemicals?

Are occupied buildings located away from release points for highly hazardous chemicals?

Are workers in occupied buildings protected from all of the following:

toxic, corrosive, or flammable sprays, fumes,

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1

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mists, or vapors? I

contamination of utilities (e.g., water)? ~

contamination from spills or runoff!

noise?

transport of hazardous materials from other sites?

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thermal radiation from ~ fires (including flares)? , - I

overpressure and projectiles from explosions? ~ -

discharges from pressure relief vents?

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flooding (e.g., ruptured storage tank)? I

I Buildings

-:.---- - inI. Unit Layout 1 1 1 Are large inventories or release points for highly 1 hazardous chemicals located away from vehicu-

Appendix F. Facility and Stationary Source Siting Checklist

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1 - T =-- ~ I --- ~ -_-_____ ~

-__ ~ ~ ~~~~ I Response Question Is there adequate access for emergency vehicles (e.g., fire trucks)? Are access roads free of the possibility of being blocked by trains, highway congestion, spotting of rail cars, etc.?

Are access roads well engineered to avoid sharp curves? Are traffic signs urovided?

Is vehicular traffic appropriately restricted from areas where pedestrians could be injured or equipment damaged?

Are cooling towers located such that fog that is generated by them will not be a hazard? Are the ends of horizontal vessels facing away from personnel areas?

Is hydrocarbon-handling equipment located out- doors?

Are pipe bridges located such that they are not over equipment, including control rooms and administration buildings?

Is piping design adequate to withstand potential liquid load?

Recommendations

(IVIII. Location of the Unit Relative to On-site and Off-site Surroundings r--- _ _ ~ . ~

Is a system in place to notify neighboring units, 1 facilities, and residents if a release occurs? Are the detection systems and/or alarms in place to assist in warning neighboring units, facilities, and residents if a release occurs?

Do neighbors (including units, facilities, and resi- I dents) know how to respond when notified of a

and when to evacuate?

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- -~~ - ~ ' release? Do they know how to shelter-in-place lL largeinventoris or release points for highly hazardous chemicals located away from publicly accessible roads?

I Is the unit, or can the unit be, located to mini-

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mize the need for off-site or intrasite transporta- tion of hazardous materials?

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Appendix F. Facility and Stationary Source Siting Checklist 99

6 Are workers in this unit protected from the

following (and vice versa), and are environmental receptors and the public also protected from the following?

releases of highly hazardous chemicals?

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effects of adjacent units or facilities for all of the 1 I

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toxic, corrosive, or flammable sprays, fumes. 1 I I , mists, or vapors? 1 thermal radiation from fires (including flares)?

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overpressure from explosions? c - - ~ - ~ - -

- 1 1 1 contamination from spills or runoff! - I Odor? -

noise? ~ -

1 contamination of utilities (e.g., sewers)? - - -

tranGon - of hazardouGateria&om - other sites?

impacts (e.g., airplane crashes, derailments)? - - - ri - 1

- - I - ~- I flooding (e.g.. ruptured storage tank)?

I I

jl - ~ - - M. Location of Firewater Mains and Backup (e.g., Diesel) Pumps - - I

- ~ 1 Are firewater mains easily accessible?

Are firewater mains and pumps protected from overpressure and blast debris impact?

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- - - I Is an adequate supply of water available for firefighting?

Are the firehouse doors pointed away from the process area so the doors will not be damaged by

~ - I I - I 1 3 1 - an explosion overpressure? 1

~

X. Location and Adequacy of Drains, Spill Basins, Dikes, and Sewers

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inventories and potential sources of fire?

Have precautions been taken to avoid open ditches, pits, sumps, or pockets where inert, toxic, or flammable vapors could collect?

Are process sewers that transport hydrocarbon closed systems?

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I00 Appendix F. Facility and Stationary Source Siting Checklist

4

Question

Are concrete bulkheads, barricades, or berms I , I installed to protect personnel and adjacent equip-

XI. Location of Emergency Stations (Showers, Respirators, Personal Protective I Equipment, etc.) I

__ ~ I -~ Are emergency stations easily accessible?

Are first aid stations prudently located and ade-

Are safety showers heated/freeze protected/wind

Is there a control room alarm for water flow to safety showers and eyewash stations? (Is there a need for such an alarm?)

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I I I I I -1i 1x11. Electrical Classification Is there an electrical classification document?

Does the electrical classification appear correct and complete?

Has the electrical classification document been recently revised?

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I

significant changes made since the system was originally constructed (addition of new materials, new sources of flammable gases or vapors, new low points [e.g.. sumps or trenches] a t grade) been included in the electrical classifi-

_ _ - I cation document? 11; Fie designandmaintenance of ventilation I L I- ~~ - ~ ~ ,--. systems adequate? + - -

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Appendix F. Facility and Stationary Source Siting Checklist 101

heavy items over operating equipment and piping? ~ ~ - 6 - - __

3 Are calculations, charts, and other documents available that verify siting has been considered in

tem Question I Response I Recommendations I 1 No.

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Are ventilation systems being properly main- tained, and are alarms and interlocks on these systems periodically function checked?

Is adequate maintenance being done to function check natural ventilation systems?

Are there technical bases for design changes to the ventilation systems?

Are ventilation systems verified to be adequate for new gas or vapor loads?

Are there adequate cally qualified equipment is replaced with equip- ment of equal or higher classification?

Are boundaries between electrically classified areas physical boundaries?

Are Division 1 areas necessary (if there are any)?

Are there adequate controls (e.g., a hot work permit system) on repair and construction activi- ties, including work by contractor personnel?

Does the electrical classification adequately reflect the effects of different modes of operation (e.g., normal operation, maintenance, startup, infrequent operating modes such as reactor regeneration or operation with a portion of the system bypassed)?

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KlII. Contingency Planning I I

atmospheric dispersion of gases and vapors?

estimated radiant heat intensity that might - exist duringa fire? -

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estimated explosion overpressure?

Appendix F. Facility and Stationary Source Siting Checklist ~ - -~ - -

-I= ~~~~ Question

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Are appropriate security safeguards in place (e.g., I fences, guard stations)?

Are gates located away from the public roadway 1 so that the largest trucks can move completely off the roadway while waiting for the gates to be opened?

Where applicable, are safeguards in place to pro- tect high structures against low-flying aircraft?

Are adequate safeguards in place to protect employees against exposure to excessive noise, considering the cumulative effect of equipment items located close together?

Is adequate emergency lighting provided? Is there adequate redundant backup power for emergency lighting?

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Are procedures in place to restrict nonessential or r untrained personnel from entering areas deemed hazardous?

Are indoor safety control systems (e.g., sprin- klers, fire walls) provided in buildings where per- sonnel will frequently be located, such as control

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