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I had been involved with BPD as very close friend for over 16 months, problem is we are working together. Now we are done, and she is one who initiated break up of our friendship. However she is still demanding unreasonable requests to be done at work that I can not accomplish. She had been threatening to kill herself if I don't do it, I doubt she would as she has own kids to take care, she was threatening to sue for sexual harassment and many many other things to manipulate me into do not proper things at work. How do I approach her as she does not separate boundaries Personal vs. Professional? How often BPD people go ahead with their threats and do devastating things?

You shouldn't approach her, you should approach your company's HR department and/or you boss.  If you value your job, and your job values you, it's best to use the resources available to you to fix your workplace situation.  Either that or quit, but you will lose taking on a borderline once things go south; the disorder always wins.

I agree.  She's jeopardizing your job and your livelihood.  It demands action.  I would talk to your HR department and/or boss immediately and have it documented what's been going on.  At the very least that gives you some cover.  They may also take action against her and put a stop to her workplace abuse, and I hope they do.

I should also add that if she is in a supervisor role to you, she's in serious hot water.  The company will almost certainly terminate her if that is the case.  She's too much of a liability - it's a sexual harassment lawsuit waiting to happen.  You need to speak up now, however.