Document 3emw2qz5838ed2kKp1mGpLBpy

ABD00029750 COPY No. 1 CONDEA VISTA COMPANY ABERDEEN EXPRESS, PHASE 3 ABERDEEN, MS PROCESS HAZARD ANALYSIS REPORT RAYTHEON ENGINEERS & CONSTRUCTORS RUST DIVISION PROCESS TECHNOLOGY DEPARTMENT September/October, 1996 ABD00029751 SUMMARY 1. Objectives and Scope The objective of this Process Hazard Analysis (PHA) was to identify potential hazards associated with the Phase 3 of the Aberdeen Express Project of the Aberdeen facility of the Condea Vista Co. The analysis was performed so as to satisfy corporate and plant safety goals. The scope of this PHA covers the expansion to the existing plant, known as Aberdeen Express, Phase 3. This project includes upgrading of the VCM unloading facilities, the addition of two reactors, a resin dryer, a centrate water treatment system, and a two-cell cooling tower, plus upgrading of other equipment as required. 2. Techniques The technique selected for the analysis is the HAZard and OPerability Analysis (HAZOP), which is considered the best identification technique for chemical process systems. It was used to determine the consequences of deviations in the process conditions. The assumptions made for the study are the usual ones in this type of analysis, i.e., the system (including the process, equipment, operating procedures, etc.) has been designed correctly and is suitable for its purpose except for the deviation under consideration, its causes and consequences. This technique, thus, will address, in a systematic manner, only single failure events. Additionally, Siting/Layout and Human Factors were addressed by means of specific checklists, to ensure more complete coverage of these important issues. Previous incidents and deviations of a general nature were also addressed during the meetings. The study addressed both batch processes and steady state operation, and hazards which could arise during other modes such as startup, shutdown, emergency situations, were also identified and analyzed. 3. Conclusions No major hazardous scenarios without significant safeguards were identified by the PHA team. In cases where the potential for fire, explosion, or toxic release exists, the design incorporates safeguards to either reduce the probability or mitigate the consequences of such scenario. Nevertheless, a number of action items are recommended. The number of action items recommended for each priority level are summarized in the following table: ABD00029752 ACTION ITEMS STATISTICS SOURCE RISK (RANKING) HAZOP Table Extreme (2) Excessive (3) Undesirable (4) Intermediate (5) Low (>5) Previous incidents report Siting/layout checklist Human factors checklist General deviations TOTAL QUANTITY 0 1(*> 1 0 11 2 5 8 6 34 The recommendation associated with the only excessive risk scenarios (*) is the following: "Review SOP for recirculating HPSW through initiator pots in the winter to prevent freezing. The concern is that an operator may fail to close the manual valve before charging the initiator pot." A significant number of hazards identified by the PHA team, had a potential cause in "operational error", i.e., error of the operator while performing his duties. In these cases, the PHA team took credit for the operating procedures and the training as safeguards against the hazard. It is important to ascertain that in the operating procedures adequate consideration is given to all the hazardous scenarios identified during the analysis. An adequate mechanism is now required to address all the action items recommended by the PHA team, before start-up of the process. ABD00029753 CONTENTS ABD00029754 CONTENTS 1.0. 1.1. 1.2. INTRODUCTION Objectives General Scope 2.0. 2.1. 2.2. 2.3. 2.4. PROCESS DESCRIPTION General Description Physical Scope Process Safety Information Procedures 3.0. 3.1. 3.2. 3.3. METHODOLOGY Techniques Analytical Scope Risk Assessment 4.0. 4.1. 4.2. 4.3. REVIEWS Meetings PHA Team Analysis Aids 5.0. 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11. 5.12. ANALYSIS Hazards of the Process Potential Safety and Health Effects Background Engineering and Administrative Controls Consequence of Failure of Controls Reactor Operation Previous Relevant Incidents Siting and Layout Human Factors General Deviations Formal Analysis Action Items 6.0. SUMMARY AND CONCLUSIONS APPENDIX A: APPENDIX B: APPENDIX C; APPENDIX D: APPENDIX E: APPENDIX F: APPENDIX G; Previous Relevant Incidents Material Safety Data Sheets Node Definition Tables Siting/Layout Checklist Human Factors Checklist HAZOP Table Drawings ABD00029755 1. INTRODUCTION ABD00029756 1.0. INTRODUCTION 1.1. Objectives The objective of this Process Hazard Analysis (PHA) is to identify potential hazards associated with the Phase 3 of the Aberdeen Express Project of the Aberdeen facility of the Condea Vista Co. The analysis was performed so as to satisfy corporate and plant safety goals. 1.2. General Scope The scope of this PHA covers the expansion to the existing plant, known as Aberdeen Express, Phase 3. 1-1 ABD00029757 2. PROCESS DESCRIPTION N v ABD00029758 2.0. PROCESS DESCRIPTION 2.1. General Description The polymerization reaction of vinyl chloride monomer (VCM) to form polyvinyl chloride (PVC) resin is a batch suspension process in which VCM, water, suspension agents, and reaction initiator are the primary constituents. The exothermic reaction takes place under pressure and is held at a constant temperature throughout the reaction. The mixture is kept in suspension by mechanical agitation. At the conclusion of the reaction, unused VCM is drawn off, compressed, condensed, and stored for reuse. The slurry is steam stripped to decrease the amount of residual VCM. Resin properties can be varied by modifying reaction temperature, suspension agents, initiators, and recovery pressure. This project, Phase 3 of the Aberdeen expansion, includes upgrading of the VCM unloading facilities, the addition of two reactors, a resin dryer, a centrate water treatment system, and a two-cell cooling tower, plus upgrading of other equipment as required. 2.2. Physical Scope The physical scope of the study comprises all the nodes shown colored and numbered in the P&ID's enclosed in the Appendices. 2.3. Process Safety Information The availability of the required process safety information was confirmed by the team leader, as detailed in this section. PROCESS SAFETY INFORMATION # INFORMATION LOCATION DATE RESPONSIB LE 1. PERTAINING TO THE HAZARDS OF THE HIGHLY HAZARDOUS CHEMICALS 1.1 Toxicity information Safety supervisors office G.Uptain i.2 Permissible exposure limits l 1.3 Physical data 1.4 Reactivity data II 11 1.5 Corrosivity data II 1.6 Thermal and chemical stability data II 1.7 Hazardous effects of inadvertent mixing No mixing hazards identified 2. PERTAINING TO THE TECHNOLOGY OF THE PROCESS 2.1 Block flow diagram or Process safety simplified proc. flow diag. information manual 2-1 II 11 11 11 11 J.Minga ABD00029759 PROCESS SAFETY INFORMATION # INFORMATION LOCATION 2.2 Process chemistry II 2.3 Maximum intended inventory II DATE RESPONSIB LE II II 2.4 2.5 Safe upper and lower limits Operating procedures, for process parameters Control room An evaluation of the See HAZOP table consequences of deviations J.Olson/ T.Nolen 3. PERTAINING TO THE EQUIPMENT IN THE PROCESS 3.1 Materials of construction Equipment files, PSM room 3.2 3.3 Piping and instrument diagrams Electrical classification Plant eng. design, drawing file room tl 3.4 3.5 Relief system design and design basis Ventilation system design Equipment files, PSM room N/A {*) J.Heywood H D.Whatey 3.6 Design codes and standards Equipment files, PSM room employed 3.7 Material & energy balances PSM file room for process built after 0526-92 3.8 Safety systems Process safety inform, manual, PSM room NOTES: {*) Compound and lab not covered. The drawings used in the analysis are listed in the following table. Marked-up copies of these drawings are enclosed in the Appendices. LIST OF DRAWINGS NUMBER REV DATE TITLE DY-093100-PID-D F 09-20-96 Large Slurry Blend Tanks DY-093119-PID-D H NO DATE Recycled Centrate Processing DY-09312 8 -PID-D D 05-06-96 Product Storage - 600 Series Silos DY-093129-PID-D D DY-093130-PID-D D 05-06-96 Product Storage - 600 Series Silos 05-06-96 Product Storage - 600 Series Silos 2-2 ABD00029760 LIST OF DRAWINGS NUMBER REV DATE TITLE DY-0 93134 -PID-D C 09-20-96 Plant Cooling Water System DY-093137-PID-D F 09-20-96 Centrifuges and Centrate DY-093140-PID-D E 07-12-96 Screening and Transfer DY-093141-PID-D F 09-20-96 Centrifuges and Centrate DY-093142 -PID-D E 09-20-96 Dryer and Separator DY-0 93143 -PID-D F 09-20-96 Dryer 10 Scrubber DY-093144 -PID-D F 09-20-96 Dryer 10 Transfer DY-094145-PID-D D 05-06-96 Dryer 10 DY-093146-PID-D E 09-20-96 Dryer 11 DY- 0 93147-PID-D B 05-06-96 Product Storage - 600 Series Silos DY-0 9314 8 -PID-D C NO DATE Recycled Centrate Processing DY-0 9314 9-PID-D C NO DATE Recycled Centrate Processing DY-093150-PID-D B NO DATE Recycled Centrate Processing NM-093107-PID-D E 08-02-96 NM Reactor RX-745 NM-093108-PID-D D 08-02-96 NM BME Metering Pot NM-093109-PID-D D 06-07-96 NM Recovery Knock-Out Drums NM-0 93119-PID-D E 08-02-96 NM MSPW System NM-093120-PID-D D 06-06-96 NM Emergency Kill Systems NM-093121-PID-D D NM-093122 -PID-D E 08-02-96 Steam & Reactor Evac. Systems 08-02-96 NM Steam & Reactor Evac. Systems NM-093126-PID-D E 08-02-96 NM Seal Oil System NM-093127-PID-D E 08-02-96 NM Normal Kill Systems NM-09312 8 -PID-D E 08-02-96 NM Clean Wall Supply Systems NM-093133 -PID-D D 08-02-96 Stripper Rinse and Flush System NM-093136-PID-D D 06-06-96 NM Emergency Kill Systems NM-093139-PID-D A 08-02-96 NM Dump Pumps and Strainers NM-093141-PID-D A 08-02-96 NM Low Mole Stripper Feed Tank NM-093143-PID-D E 08-02-96 NM Reactor RX-746 NM-093144 -PID-D E 08-02-96 NM Reactor RX-747 NM-0 93147 -PID-D E 08-02-96 Catalyst Injection Pots NM-093149-PID-D B OM-093101-PID-D E 08-02-96 Hot Water Charge and Rinse Systems 08-02-96 OM Hot Water Charge and Rinse Systems 2-3 ABD00029761 LIST of drawings NUMBER REV DATE TITLE 0M-093137-PID-D E 08-02-96 Recycled Centrate Distribution UT-093113-PID-D E 08-02-96 Plant Cooling Water System UT-093118-PID-D B NO DATE Fire Water Deluge System UT-093122-PID-D F 08-02-96 Plant Cooling Water System VS-093105-PID-D C 08-02-96 VCM Sphere VS-093107-PID-D D 06-06-96 East VCM Tank Farm Compressors VS-093108-PID-D E 08-02-96 East VCM Tank Car Unloading VS-093110-PID-D C 06-06-96 East VCM Unloading KO Tanks 2.4. Procedures Operating and maintenance procedures are currently in use in the existing facilities. 2-4 ABD00029762 1- 3. METODOLOGY N ABD00029763 3.0, METHODOLOGY 3.1. Techniques The technique selected for the analysis is the HAZard and OPerability Analysis (HAZOP), which is considered the best identification technique for chemical process systems. It was used to determine the consequences of deviations in the process conditions. The HAZOP technique was specifically developed for chemical processes, such as the one being considered here. The P&ID's are divided in nodes or sections, colored and numbered for -easy identification. A set of deviations is then postulated for each type of node by the team. These deviations are obtained by application of the HAZOP guidewords to the design intention of each node and to its attributes. Each deviation is then analyzed by the team to determine if there is a credible cause for it, and if so, to determine if the consequences are of concern. When both probable cause and consequences of concern are present, a potential hazard is identified. Safeguards for reducing the probability associated with the causes, or mitigating the consequences are then identified. If these safeguards are deemed insufficient by the PHA team, then recommendations or "action items" are listed to reduce the risk associated with the hazard. The following are the guidelines used for the definition of nodes and deviations: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Each major process component is defined as a node. Any component in which a level has to be maintained is defined as a node. Each tank or vessel with considerable volume is defined as a node. Each component in which a motor is attached (e.g., for an agitator) is defined as a node (with exception of fans and pumps). At least a line node is defined between component nodes. Each line with a process stream is defined as a node. Only one line node is defined for a series of components if there are no other flow paths (thus the line node may include pumps, fans, heat exchangers, valves, condensers, etc., unless any of these components must be defined as a node due to other guidelines. Each line branching off a process line is defined as a node. Only one node is defined for multiple equipment in identical service. Nevertheless, note that any action items recommended for the equipment analyzed will also apply to the other which were not analyzed for being in identical service. If two or more streams of different substances come together, the resulting stream is defined as a node, unless one of the lines is water for dilution, in which case the resulting stream is considered continuation of the non water stream. If two or more streams of similar substances come together, the resulting stream is not defined as a new node, but it is considered as continuation of one of the converging streams. Lines representing feeds of a given substance to different points of a piece of equipment are considered a single node. Utilities lines are not defined as nodes. For each type of node, at least a set of applicable deviations is defined, but more than one set may be defined for a given type of node, if there are substantial differences between sub-types, e.g., a set may be defined for a simple line (without pumps or heat exchangers) and a different set for a complex line (which includes pumps,...). In addition to the deviations obtained from applying the guidewords to the design intention and to its attributes, deviations of a general nature are also used (e.g., internal/external leak/rupture, external fire, sampling, thermal expansion in long lines, venting systems, etc.). The application of these guidelines leads, in some cases, to redundant 3-1 ABD00029764 17. nodes which are the "same as" other nodes, and do not need to be analyzed. These nodes are identified by the HAZOP team during the team meetings. The initial definitions of nodes and deviations prepared by the facilitator constitute a proposal. These definitions were modified by the HAZOP team as needed, based on their knowledge and experience on the process. To further facilitate the selection of deviations, and ensuring that no relevant deviations were missed, the team members were issued one form for each type of node with the default deviations shaded, and were encouraged to add other deviations as needed. A copy of this form is shown in the next page. In the case of the reactor, since its operation is of the batch type, each step of the sequence was analyzed together with the physical nodes involved in such step. Additionally, Siting/Layout and Human Factors were addressed by means of specific checklists, to ensure more complete coverage of these important issues. 3-2 ABD00029765 ABD00029766 3.2. Analytical Scope The study addressed both batch processes and steady state operation, and hazards which could arise during other modes such as startup, shutdown, emergency situations, were also identified and analyzed. The assumptions made for the study are the usual ones in this type of analysis, i.e., the system (including the process, equipment, operating procedures, etc.) has been designed correctly and is suitable for its purpose except for the deviation under consideration, its causes and consequences. This technique, thus, will address, in a systematic manner, only single failure events. 3.3. Risk Assessment The categories used for estimating frequencies of the possible causes for the deviations, and magnitude of the consequences of those deviations are shown in the enclosed table. CRITICALITY RANKING 1 MAJOR 2 HIGH 3 MEDIUM 4 LOW/NONE FREQUENCY RANKING 1 FREQUENT 2 PROBABLE 3 POSSIBLE 4 REMOTE RISK RANKING 2 EXTREME RISK ASSESSMENT Loss of life. Severe injury or health effects. Damage or losses in excess of $1,000,000. Damage or injuries to community and/or environment, widespread evacuation. Moderate injury or health effects. Damage or losses of $100,000 to $1,000,000. Minor damage or health effects on community. Large reportable release. Minor injury or health effects. Damage or losses of $10,000 to $100,000, significant operating nuisance or problem. Irritant / nuisance. Small reportable release. No impact on employee safety, community, environment. Less than $10,000 in equipment / production losses. Expected to occur once per year or more. Expected to occur a number of times during the life of a facility. The chance of it occurring this year is between 1 in 2 and 1 in 100. Expected to occur no more than once during the life of a facility. The chance of it occurring this year is between 1 in 100 and 1 in 10,000. Unlikely to occur in the life of the facility. Less than 1 in 10,000 chance of occurring this year. Immediate mitigation is required or shutdown is required. 3-4 ABD00029767 3 EXCESSIVE 4 UNDESIRABLE 5 INTERMEDIATE >5 LOW Mitigation planning should begin immediately. Corrective action should be taken within three months. Mitigation should be initiated within 12 months. Review existing safety controls and/or procedures to ensure their proper use and adequacy. No mitigation required. Where the risk is determined as a function of criticality and frequency by means of the following risk matrix: RISK MATRIX CRITICALITY FREQUENCY 1234 12345 23456 34567 4 5678 3-5 ABD00029768 4. REVIEWS ABD00029769 4.0. REVIEWS 4.1. Meetings The meetings were conducted at the Aberdeen, MS, plant of the Condea Vista Co., from September 30th to October 3rd, 1996. 4.2. PHA Team The participants in a PHA team are the following: * LEADER (or CHAIRMAN), representative of the owner of the process or plant, who assumes the responsibility for determining the physical and analytical scope of the study, for the availability of the process safety information, and for the final report. * FACILITATORS/SCRIBES, the persons knowledgeable in the methodology to be used, and who will record the proceedings of the PHA. * MEMBERS, selected by the leader, who, together with those mentioned above, brainstorms about ways in which the process can generate hazardous scenarios. The following table lists the team members (not all the team members were present at all meetings). FUNCTION Chairman Facilitators /Scribes Members MEMBERS OF HAZOP TEAM NAME COMPANY DEPARTMENT/FUNCTION Reed MacKay Condea Vista Co. Engineering Enrique Susemihl Bharat Shah Raytheon E. & C. II Process Technology Process Technology Houston Smith Ken Campbell Deevie Rambus Luke Threadgill Steve Wilkes Rodney Strickland Dean Honeycutt Janice Minga Condea Vista Co. It It ft tt II rr ii Lead Operator Field operator Instrument technician Maintenance Field operator Field operator Yard supervisor PSM coordinator 4.3. Analysis Aids To facilitate the recording of the proceedings and the participation of all team members in the preparation of the tables, a special purpose software was used. This software is LEADER V2.3, from JBF Associates. The software was run on a laptop computer, and the computer screen was projected on a wall screen by means of a projection device. In this way all team members could see and participate in the edition of the tables as they were being prepared. An initial proposal for all nodes and deviations was prepared before the start of the meetings. The software was also set up with these nodes and deviations in 4-1 ABDTO29770 preparation for the meetings. Team members were provided with a package containing copies of the marked up P&ID's, with the nodes, as initially defined, colored and numbered. This initial definition of nodes was modified by the PHA team as deemed adequate. The package also included preliminary answers from the client on the "human factors" and "siting and layout" checklist, to be reviewed by the team. This careful preaparation for the meeetings allowed for a very efficient discussion and analysis of the process. 4-2 ABD00029771 i 5. ANALYSIS ABD00029772 5.0. ANALYSIS 5.1. Hazards of the Process The hazards associated with the process are the usual ones, i.e.f * Loss of containment of a potentially hazardous chemical, with consequent exposure of personnel. * Loss of containment of a flammable and/or explosive chemicals, with consequent fire and/or explosion. * Loss of containment of a environmentally hazardous chemical, with the consequent environmental impact. There are a number of chemicals, part of the process, which were identified as potentially hazardous from a safety and/or environmental point of view. The hazards associated with each of these chemicals is summarized in the next section. The potential scenarios leading to the hazards shown above were extensively analyzed during the formal HAZOP sessions, and their causes and consequences are shown in the HAZOP table. 5.2. Potential Safety and Health Effects In estimating the effects of the potential hazards, the properties of the chemicals involved were considered. These properties are shown in the Material Safety Data Sheets included in the Appendices of this report. The effects of inadvertent mixing of the chemicals has also been analyzed, but no hazards were identified. 5.3. Background This expansion is similar to currently existing facilities. These existing facilities have undergone several process hazard analyses, and there is considerable experience in their operation. The design of the expansion incorporates all the previous experience, and the recommendations of the previous hazard analyses. 5.4. Engineering and Administrative Controls The following engineering controls were identified as relevant: * Instrumentation, controls, alarms, interlocks * Area detection and analyzer devices * Emergency shutdown system of the generating facility, to a safe condition * Emergency shutdown button * Relief system to safe header (in some places) * Ventilation system in control room * Fire fighting equipment (both within the plant, and from the local fire department) * HAZMAT gear * Dikes on storage area * Explosion hatches on the storage tanks, bag houses * Overflow lines on storage tanks * Vent lines to safe location * Deluge systems * Backup emergency power system * Breathing equipment throughout the plant 5-1 ABD00029773 Backup cooling water (firewater) A number of administrative controls intended to provide a safe work place were identified, such as: * Safe work practices (lockout/tagout, hot work permit, use of respirators in hazardous areas, use of personal detection badges, etc.) * Emergency response plan/team * Preventive/predictive/proactive maintenance program and procedures * Operating procedures * Maintenance procedures * Training program for operators, maintenance personnel, contractors, firefighting activities, emergency personnel, etc * Restricted access to hazardous areas, thus reducing potential exposure * HAZMAT training and procedures * Management of change system * Evacuation procedures after maintenance * Color coding of utilities lines * Use of generally accepted standards (for engineering, piping, painting, etc. ) * Company standards, based in years of experience in working with the chemicals involved in this process, for its safe handling, storage, and processing. * Annual physicals for all employees * Use of hand held detection devices * Periodic noise surveys During the PHA meetings, credit was taken for the safeguards provided by specific and generic controls, as shown in the HAZOP table. 5.5 Consequence of Failure of Controls The potentially hazardous conditions which could lead to the hazards identified in 5.1 are systematically addressed in the formal HAZOP processes, and listed in the table shown in the Appendices of this report. The consequences listed in this table assumes failure of controls, which are then listed as safeguards for either reducing the probability of the event or mitigating its consequences. Whenever these safeguards were deemed insufficient by the team members, action items were included to further improve the safety of the system. Refer to the enclosed HAZOP table for specific scenarios of potential hazards, the risk associated with them, and the engineering and administrative controls, listed under safeguards, which reduce the associated risk. 5.6. Reactor Operation Since the reactor operation is a batch operation, each of the steps involved was analyzed together with the nodes involved in the step. The following is a description of the operation used during the analysis: * STEP 1: EVACUATION Design intent: To remove air from the reactor. Activity: By means of steam jet eductors, the reactor is evacuated to 27-28" Hg in about 8 minutes. Parameters: Flow, pressure. Nodes: 201A, 216 Notes: Skip this step in the case of "closed dump". STEP 2: CHARGE Design intent: Activity: To charge ingredients to the reactor. Reaction ingredients are charged into the reactor using an automatic sequencing control system, as follows: 5-2 ABD00029774 Parameters: Nodes: 1. Water (continues to the end of the step) 2. Suspending agents 3. Fresh VCM 4. Recovered VCM Flow, time, composition, sequence (all considered for each ingredient), pressure, temperature, agitation. 201B, 203, 204, 205, 206, 207, 208, 210 STEP 3: INITIATION Design intent: To initiate the polymerization reaction. Activity: When the charge of the ingredients is complete, initiator is manually charged to the reactor. Parameters: Flow, composition, temperature, pressure. Nodes: 201C, 211 the STEP 4: REACTOR HEATUP Design intent: To heat reactor contents to reaction temperature. Activity: Steam is mixed to the reactor jacket cooling water in external eductors. Steam flow is stopped once the desired temperature has been reached. Parameters: Temperature, pressure. Nodes: 201D STEP 5: POLYMERIZATION Design intent To polymerize the VCM into PVC. Activity: The exothermic reaction is kept under control, by monitoring and controlling the following: 1. Temperature in the reactor 2. Temperature in the condenser 3. Agitation 4. Inert venting 5. Chain transfer addition 6. Post addition of suspending agents Parameters: The above, composition of added chemicals, time, reaction. Nodes: 201E, 205, 208, 213 STEP 6: NORMAL KILL Design intent To stop the polymerization reaction. Activity: When the polymerization slows down, as signaled by the reactor pressure dropping off, a chain terminating kill agent is transferred to the reactor. Parameters: Flow, composition, pressure, temperature. Nodes: 201F, 214 STEP 7: IN REACTOR RECOVERY AND STRIPPING Design intent To recover excess monomer for later use, residual VCM to an acceptable level. and to reduce Activity: The reactor is vented to the vinyl recovery system, and when the reactor pressure drops below 40 psig, steam is added to the slurry to raise its temperature and vaporize more vinyl. This recovery process is continued until the slurry has reached 160F, and then the temperature is held for a designated time. Parameters: Flow, pressure, temperature. Nodes: 201G, 202, 215 Notes: Skip this step in the case of "closed dump". STEP 8a: ATMOSPHERIC DUMP Design intent: To transfer slurry to the blend tank. Activity: The atmospheric vent valve of the reactor is opened, the slurry drains by gravity to a head tank, and is pumped ABD00029775 Parameters: Nodes: Notes: to the blend tank. Flow, pressure. 201H, 217, 217a Alternative to step 8b, "closed dump". * STEP 8b: CLOSED DUMP Design intent: To transfer unstripped slurry to dump tank for continuous stripping operation. Activity: The slurry is transferred from the reactor to the dump tank by means of the dump pump. Parameters: Flow, pressure. Nodes: 2011, 218 Notes: Alternative to step 8a, "atmospheric dump". * STEP 9: RINSE Design intent: Activity: Parameters: Nodes: To clean the reactor for the next batch. Typically three complete cycles of rinsing and draining are performed. The need for additional rinses is determined by visual inspection. Flow, pressure. 201J, 219 STEP 10: CLEAN WALL Design intent: To prevent polymer buildup on the internal surfaces. Activity: A buildup suppresant solution is injected with steam to the reactor and to the condenser. Parameters: Flow, composition Nodes: 201K, 219, 220 * STEP 11: EMERGENCY KILL Design intent: Kill the reaction to prevent a release. Activity: AMS is injected to the reactor. Parameters: Flow, composition, pressure, temperature Nodes: 201L, 221, 223 Notes: This is an emergency procedure, typically in case of power failure affecting agitation, loss of cooling water, or excess initiator. * GENERAL PARAMETERS/DEVIATIONS: Deviations: Step/sequence, Nodes: 201M internal leak/rupture 5.7. Previous Relevant Incidents A list of previous relevant incidents is enclosed in Appendices of this report. The action items arising from the analysis of the previous incidents are included in the Action Items Tables. 5.8. Siting and Layout The possible safety considerations associated with layout and siting were addressed by means of a Siting Checklist. The completed checklist is shown in the Appendices of this report. The action items arising from the analysis of this checklist are included in the Action Items Tables. 5.9. Human Factors Human factors and their impact on the safe operation and maintenance of the process were addressed at all stages of the analysis. To insure more complete 5-4 ABD00029776 coverage of this important issue, two human factors checklists were also used and are shown in the Appendices of this report. The action items arising from the analysis of these checklists are included in the Action Items Tables. 5.10. General Deviations In addition to the deviations listed in the HAZOP table, some deviations of a general nature were also considered, e.g., compatibility of vent streams, external leak and rupture, contamination, external fire, external events, effects of emergency operation, shutdown, etc. The team discussion led to the recommendation of some action items, which are listed in the Action Items Table. 5.11. Formal Analysis The software generated tables for the formal analysis using the HAZOP technique are shown in the Appendices. 5.12. Action Items The action items identified during the HAZOP procedure are listed in the tables generated by the software LEADER V2.3. Also shown are tables for additional action items identified as follows: * analysis of previous incidents * analysis of the siting checklist * analysis of the human factors checklists * analysis of general deviations Two types of action items were identified during the meetings: those which are project (Phase III) specific, and those which are general plant issues involving existing processes and/or procedures. Project issues will be addressed by Reed MacKay, whereas the remaining issues not related to the project will be communicated to the plant for review by the Plant Safety Committee. The responsible party is shown next to each action item in the tables enclosed. 5-5 ABD00029777 REF. # PI-1 PI-2 SL-1.7 SL-7.7 SL-10.2 SL-11.3 SL-11.8 HF-1.03 HF-1.05 HF-2.03 HF-3.02 HF-3.05 HF-5.03 ADDITIONAL ACTION ITEMS TABLE DESCRIPTION P ANALYSIS OF PREVIOUS INCIDENTS Consider catches on bottom manways on all reactors. Consider emergency backup power for walk-in freezers. ANALYSIS OF THE SITING/LAYOUT CHECKLIST Overpressure design parameters for control room was not available. Review parameters. Consider better enforcement of applicable vehicle procedures to prevent accidents and near misses. Review equiment and capability of existing first aid station to determine if it is adequate for its purpose. Adequate documentation related to facility siting and unit layout was not available. It should be prepared and maintained. Review emergency lighting to insure that it is adequate. ANALYSIS OF THE HUMAN FACTORS CHECKLIST (1) Consider more appropriate summer clothing. Nomex clothing is too hot in summer. Consider reducing electrical lights during daytime. Automatic detectors often fail. Review maintenance tool availability. Determine whether a better system than the one presently used should be developed to insure availability of proper tools for field work. Also determine whether the check out system in the tool room is working as intended. Consider better labeling of equipment, instruments and piping. Not all equipment and lines are currently labeled. A system should be in place to install, maintain, and update equipment and instrument labels. Consider better training on DCS equipment, specifically about the different screens: diagnostic screens, controller screens, trio screens. RESPONS. Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Reed MacKay Plant Safety Committee Plant Safety Committe Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee 5-6 ABD00029778 REF. # HF-7.01 HF-7.05 GD-1 GD-2 GD-3 GD-4 GD-5 GD-6 ADDITIONAL ACTION ITEMS TABLE DESCRIPTION Review panel operator activities and requirements in view of current expansion. Determine whether the operator has enough screens to monitor all equipment, the kind and quantity of new tasks, whether more automation and safeguards can be added to reduce tha amount of input required to run the new equipment. Consider whether a better system than the one currently in place is required to handle operator overtime. ANALYSIS OF GENERAL DEVIATIONS Loss of instrument and plant air: Consider adding secondary backup for instrument air dryer, considering this summer incident with the instrument air dryer and the dessicant getting into the instrument air system. Loss of instrument and plant air: Consider adding backup filter for maintenance. Loss of instrument and plant air: Consider new solutions to prevent PVC settling down and getting into piping on loss of sparging in blend tanks. Loss of steam: Consider adding emergency power to the boiler area to keep boilers running during power failures. Loss of seal oil: Review level control on seal oil storage tanks (reactor seal oil system). Communications: Review internal communications systems. PA system does not reach some areas. P RESPONS. Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee Plant Safety Committee 5-7 ABD00029779 44 JJ a IuB 3 (J <c01u IB 01 ;* u eO 01 0) 0) IB -H 3 -a 0) -a m w4) .u* mu 3n T3 O 41 U0 uzj 5Q4, U41 0C1J T03` eo IQ 4J c a> m ZcJ >ZzJi H IB <0 E in H Uc >Oz. O0 pi u a 3Ou II 11 > E-J </} C -4 a. -h an i3n m 0) C IN tn 5i (B h C U E IN -H 4-1 iJ 41 *I3-D4 UCV ZJ iE4->1 O > 4) M 54 41 in " H 54 0 U Q,r-4 ZJ > o3 U Na >B 4> 01 0) -- 4) O au ae IB 4) > CO *041 Ho U <B IV a -h in 4-> 54 ZJ om*-' -H *' -- 4) 01 01 u >01 -5H4 <B N -H 3 4) U 4) O' 41 iB zj T03) 4U-i z54) m-- 44 C -H H Ct, zj > O 01 D 25 C 14 U 0033 U) H ZJ ZJ M 4-> IB IB irtIt 451 lIIi u 3 aa 41 W E E C 41 41 U -H Zl ZJ o a 3 in *B O E 0 -*5Hl 0) 54 *-4 B iJ -h CO3 iB ioBi in 1014 54 -H z<Bi 341 zi 3 C 44 5j 4) Oa 54 44 z0) ZJ O ~*H (J 1) u IB 19 Cd r41 H I H a in in -4 in C 0H> ZIBJ T5 01 IB -CH 41 ~ o IN 1D8 5O4 r- 44 T-4 54 IN 41 V) O U - -HOE in oi GO 4J MzJ U ZJ -- IN 0c1 -HO co -H a zj IB IB 5* Co 4hO1 0EE1 in o cu Uo 4541 41 41 54 0E 44 3 ABD00029780 -HU 0ca<0n3 (>0so2 2 CC <4vut) * o 1 X>mud 2 Uz><u<1So3 VQ1aC>> a44a>:) Tt443t3) Eom C --ma> ki JCJ n<N V 41 T3 > .. H 4> 8 n u it c Q> U oM oo . AJ 03 T3 It 1 o Jj > o H jj AJ 4) cM 6 cn *o c-a tn 0 a id H 3 H jj 43 43 43 U id -H V JJ E 43 a 0 ctn O u H o .* 4) 0 HEo o 4) :, u o 03 E 4) >, O id 03 id <u id 41 tcn id JJ H 0 <o a jj s0 o id 0 <4-1 Ui o <0 id 41 a o 4) jj u -- H w Id oE d-H 43 d-d O QO Q, Id Sa 43 E 3 43 -H "2 0 c 03 --i 3 <M O 0O JJ tn cG H H oN a 43 tn 4) U c U H H 4-1 1) H 4) M 4-1 u c H >. 8 4-< U *H H U 4J 11 11 > -a 43 T3 O jj 03 r--i ** mm u p*i H E 43 8 0) V 4J 4) w i--< O >. 43 O Vd 41 3 id o 4) uU 41 0 jj Id <0 a 3 tn cjh O H OT d-H a co a <0 X 3 id 43 43 -H a > 43 0u Od 43 3 JJ T3 rH H id <U <0 <0 H <M TJ o 4E3 03 03 43 O rH jj dH Id o 0 ro <4-1 43 03 ON E <0 r*> <0 (J r> Id S' c 0u *H 6 1 ac 0 H 43 -H Jj jj <0 id tn 41 a i> G a jj dH o 03 JJ rl id tn 1-1 43 c 3 o -H rt id C 03 3 43 C 0 o C3 5 u 03 ABD00029781 67^UMMSRY^ND CONCLUSIONS ABD00029782 6.0. SUMMARY AND CONCLUSIONS No major hazardous scenarios without significant safeguards were identified by the PHA team. In cases where the potential for fire, explosion, or toxic release exists, the design incorporates safeguards to either reduce the probability or mitigate the consequences of such scenario. Nevertheless, a number of action items are recommended. The number of action items recommended for each priority level are summarized in the following table: ACTION ITEMS STATISTICS SOURCE RISK (RANKING) HAZOP Table Extreme (2) Excessive (3) Undesirable (4) Intermediate (5) Low (>5) Previous incidents report Siting/layout checklist Human factors checklist General deviations TOTAL QUANTITY 0 1 (*) 1 0 11 2 5 8 6 34 The recommendation associated with the only excessive risk scenarios (*) is the following: "Review SOP for recirculating HPSW through initiator pots in the winter to prevent freezing. The concern is that an operator may fail to close the manual valve before charging the initiator pot." A significant number of hazards identified by the PHA team, had a potential cause in "operational error", i.e., error of the operator while performing his duties. In these cases, the PHA team took credit for the operating procedures and the training as safeguards against the hazard. It is now important to ascertain that in the operating procedures adequate consideration is given to all the hazardous scenarios identified during the analysis. An adequate mechanism is now required to address all the action items recommended by the PHA team, before start-up of the process. Addressing the action items does not necessarily require following the recommendation of the team, but rather giving it adequate consideration and documenting the decisions taken. 6-1 ABD00029783 ------- ATTREVTOUS RELEVANT INCIDENTS ABD00029784 APPENDIX A PREVIOUS RELEVANT INCIDENTS ABD00029785 INCIDENTS AT CONDEA VISTA ABERDEEN PLANT: 1. Incident: Date : Cause: Injuries: Mitigation: Reference: Worker got something in his eye while opening bottom reactor manway. February 6, 1987. Insufficient eye protection. One, eye irritation. Eye goggles must be worn while opening reactor bottom manways. Herbert Jackson eye injury, March 23, 1987. 2. Incident: Date: Cause: Injuries: Mitigation: Reference: Near miss crane accident on SOI blend tank. May 28, 1986. Lack of communication and planning. None. A Vista maintenance supervisor oversees all personnel lifting operations. Near miss accident, 501 Blend Tank cleaning, June 26, 1986. 3. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker pinched the skin on his finger while repositioning the global drilling rig on RX-745. September 22, 1983. Inadequate procedure for safely setting up the drilling rig. One, pinched skin on finger. 1) Install secondary lifting davit on RX-700 and RX-745; 2) Discuss incident with employees; and 3) Modify lighting for crane operator visibility. Accident investigation, William Moore, October 14, 1983. 4. Incident: Date: Cause: Injuries: Mitigation: Reference: Catalyst bottles melted down while in a storage freezer. July 24, 1984. Improper freezer upkeep, freezer location in direct sunlight, and freezer abuse. None. Freezer were put underneath open-side awnings to get the freezers out of direct sunlight. New freezer maintenance procedure. 5. Incident: Date: Cause: Injuries: Mitigation: Reference: An air hose connected to a jackhammer came loose, and as it whipped around uncontrollably, hit a bystander in the knee. April 11, 1983. Equipment failure. One, bruised knee. Ban all non-locking-Thor air fittings from the plant. Lander Keaton injury, April 22, 1983. 6. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker cut finger on rupture disk tag while opening a valve. July 6, 1991. Employee was not wearing gloves and all rupture disks tags have sharp edges. One, cut finger. 1) Check all safety disks to see if they can be arranged more safely; and 2) Wear gloves while working in the field. Accident investigation report # 91-3. 7. Incident: Worker was loading empty catalyst cardboard boxes in a dumpster. Instead of folding the empty boxes up before ABD00029786 Date: Cause: Injuries: Mitigation: Reference: 8. Incident: Date: Cause: Injuries: Mitigation: Reference: 9. Incident: Date: Cause: Injuries: Mitigation: Reference: disposal, the worker was throwing several unfolded boxes in at a time. While doing so, a box knocked his-glasses off. In his attempt to catch the glasses a box flap hit him in the eye cutting the lens. March 2, 1991. The worker was in a hurry to beat the rain. In addition, he did not want his glasses to hit the ground. One, eye. 1) Fold boxes before disposal; 2) Do not hurry doing a job; 3) Inform employees and discuss accident. Accident investigation report # 91-2. Worker pinched a nerve in his back while working on a pump from a squatting position. July 3, 1989. Excessive pulling and straining while trying to loosen some bolts. One, pinched nerve in worker's back. 1) Pump couplings halves are to be sprayed with an anti seize solution at all subsequent similar maintenance; and 2} if more than normal effort is required to do a job of this nature, the pump is to be pulled and taken to the shop. Herbert Jackson back injury, July 21, 1989. RX-700 evacuation valve failed to close resulting in a VCM release. February 20, 1992. This particular type of actuator and valve stem connection was not properly assembled. The type in question has a recessed valve stem and a transition piece between the valve stem and actuator. None. 1) Identify, check, all valves of this type. Eventually replacing them with valves without recessed stems and transition pieces during shutdowns and downtime; 2) Added and interlock to shut the reactor evacuation valve if more than 8 psig is seen on the reactor; and 3) Add pressure switches and interlocks on evacuation header to look for leaking valves. Investigation of RX-700 evacuation valve malfunction. March 23, 1992. INCIDENTS AT OTHER CONDEA VISTA PLANTS: 1. Incident: Date: Cause: Injuries: Mitigation: Reference: A 695 lb release occurred when a threaded pipe spool sheared off an unloading compressor head in the tank farm. May 20, 1996 Fatigue induced by compressor vibration. None Replace Sch. 80 piping with Sch. 160. Include pipe spools in inspection program. C-102 VCM release. 2. Incident: Date: Cause: A reactor was not fully drained after a test and was overfilled during charge. The safety pressure interlock shut down the charge and prevented a release. May 15, 1996 Too many activities in progress at the same time. Panel operator was distracted and did not answer the DCS question to rerinse or continue. ABD00029787 Injuries: Mitigation: Reference: 3. incident: Date: Cause: Injuries: Mitigation: Reference: 4. Incident: Date: . Cause: Injuries: Mitigation: Reference: 5. Incident: Date: Cause: Injuries: Mitigation: Reference: 6. Incident: Date : Cause: Injuries: Mitigation: Reference: None Evaluate need for low level switch and permissive to ensure the reactor is liquid empty. D-306 charge. Near miss accident when operator steamed a line and a valve containing organic peroxide. The organic peroxide rapidly decomposed and split the piping. January 21, 1996 A valve started to open but closed immediately due to low pressure on the HPSW line. A small amount of organic peroxide was trapped between two valves. None Various, such as modifying DCS graphic to show low pressure on the HPSW. F-364 organic peroxide piping Electrical fire in the New control room mechanical room. June 28, 1995 A ground fault occurred at a motor. The surge suppressors were the wrong type for this application. None Remove surge suppressors, follow up with manufacturer regarding inspection and testing, ensure that the Management of Change System addresses electrical components for future installations and modifications. New control room mechanical room electrical fire. 46 lb of VCM were released to the atmosphere when the anti foam injection line failed and pulled away from the slurry feed line. January 7, 1996 Failure of the weld connecting the anti foam line and the slurry feed line. None Various procedural, design and maintenance actions (see original report). W-622 VCM release A small flash fire occurred while welding on a stripper feed line at the stripper area. July 29, 1996 The piping contained VCM vapor residue, which collected and created a flammable vapor/air mixture. None Operations personned to check jobs closer to the actual performance of hot work, permit writers to be aware of long runs of piping which may allow residual vapors to build up, include requirements for accessible flanges and bleeders for long runs of piping. Stripper feed line flash fire ABD00029788 B. MATERIAL SAFETY ] DATA SHEETS ABD00029789 APPENDIX B MATERIAL SAFETY DATA SHEETS ABD00029790 ^ h U.si DEPARTMENT ______ Occupational. Safety and Health Administration MATERIAL SAFETY DATA SHEET Required under USOL Safety and Health Reflations for Ship Repairing Shipbuilding, end Shipbreattng (29 OPR 1915. 1916/19171 oie ha. aa-nut** Iz. [yner SECTION II - HAZARDOUS INGREDIENTS ~>AWT*.RRSSSRVAYIVES. fc SOLVSKTS etQMCNT* J % - 1i TLV RMffd ALLOYS AND METALLIC COAT1MQS N/ . * \ RASE METAL CAT*0.VST * ALLOYS. VEHICLE SOLVENTS AOOtTlVCS others 1 n METALLIC COATIMOS TILLER METAL RUTS COATING OR CORC RLUX a | OTHERS ft , e^ HAZARDOUS MIXTURES OR OTHER UOOtOS. SOUPS. OR CASES | None | * \ nJJJj ' . J^/ji 1" o 0 i 1* |H 1N |1" rrl TLV (UMtd || * i ||' OiHAfNO NT l*f4 VA*0* N(tWI RM VMOI OCNSttV 1*10*1) SOLURfUtV IN WATER AMtAMAHCC ANflOOOR SECTION III * PHYSICAL DATA axwrrc euvirv S RCSNT. VOLATRJK V VOLUME w EVAPORATION RATS 1 *1) Ho Lloi^ White* powder with no odor 1.2-1. at less t m 5i y . I SECTION IV FIRE AND EXPLOSION HAZARD DATA eomr IMrinee mai) riAMMAlVX LIMIT! CXtlNeUISMINO MtOt*' Water alcohol foan drv S*tc>*w ric richtinc eeoccouacs None especially rm uNujuAt. mt and titruotioH hazaroi None especially PAGE Ml (Continued on reverse tide) Form CSHAi **. M*r n ABD00029791 SECVION V . HEALTH HAZARD DATA THREiHOUpL^X VALUE None determined T "TF^cLrs op vi ki6ju*T It may happen to effect the resoiratorvorgans as sam. as dust In case of inhaling fine powder for a long time. I Ml WSI.MC* AWO *VT AIQ MOCCOUMU _______It is not considered a toxic hazard. Eyes: to wash out without rubbing Skin: to. eliminate after handling klAtlbiTV UNSTABLE SECTION VI - REACTIVITY DATA CONDITIONS TO AVOID STABLE incomaatability (Alsicnm t*t trmd) X HAZAROOUS OCCCMVOKTIOn NtUOUCTS - MPOA/L.AYRMOEORUIZSATION MAY OCCUR WILL NOT OCCUR CONOtTIONS TO AVOID X . ... - .. *- SECTION VII.- SPILL OR LEAK PROCEDURES STEPS TO RC TAKEN in cask MATERIAL is released or spilled. *PVA is water soluble and makes a sticky solution, so scattered or spilled PVA powder should be swept uo ( not be washed out with .water )._______ WASTE DISPOSAL MCTHOO t.o burn un * - .... SECTION VII! . SPECIAL PROTECTION INFORMATION respirator* protection fSpm/r t*rpr') It i.s d, es,ireb. ,le t. o wear filt,er mask, VENTILATION '"localtxKAuift--iflfc very ousty g^ad^'is Special MECHANICAL ? OTHER when pmoicctive cloves None especially cvt PROTECTION None especially oTMkM.pMurtcnvc iquomcwt None especially SECTION IX*. SPECIAL PRECAUTIONS .PRECAUTIONS TO BE TAKEN IN HAMOUNC AND STORINO Mnnp pflnAraUv ; AnaUfrTM does not /*hn1pa.llv change * temperature and humidity OTMLR PRCCAUTIONS None generally . zt room FAGS (2) c - c >. Form OSHA*2 IH NIPPON SYNTHETIC CHMICALINDUSTRYCa.UU. r**.nt7* - NO.S-5NO2AKI-CK0. KITA-KU -OSAKA, JAPAN ABD00029792 ,, US, DEPARTMENT OF______ Occupation**. S*fty and Health Administration MATERIAL SAFETY DATA SHEET om . ______________________ ____________ SECTION 1 _P*e Nippon Synthetic Chemical -Industry Co.r, Ltd.) 1106-3 !--*1^962^** SECTION II HAZARDOUS INGREDIENTS ' . PUNTS,fHfSCKVATIvn.S soivcnti X 1 TLV fU^wl ALLOYS AMD MSTAUJC COATtMOS FfOMCMTS N/ % BAIIMCTA CATALV*T m AULOVS. VCHtCLC n - MCTALUC COATIMOS SOLVCMTS it fills* mctal fu eoATtMO o* eo*c flux AOOtTlVCS OTMC AS n OTHSIKS M. * KAZAffOOUS MCXTUftCS OF OTKffff UQUtOS. SOUPS. Off GAStS None \ TLV * l/A% I tUMMl 1 \n 1 mJ | .- -1 1 it J % TLV* 1 CUnHrf f MHUA -eMt (*4 VA0i **CSW*C M|4 v*^o ocMsriY ia*ii IQUAtU rv IM WAK* AAFCAeAMCt AMO OOP* SECTION III - PHYSICAL DATA . MfV* **Avrr KCSNT, VOLATILE rrmuwf m CVAFO*ATIO*y MATS - No Llal^ White' powder with no odor 1.2-1. at 20M less t iso 5% | 1 #e . SECTION IV FIRE AND EXPLOSION HAZARD DATA flash omr (m*i** vmi FLAMMASLt LIMITS C1iN6Ut}HtN6 MCOlA' Water alcohol foam, dry <hMraT S'tClAL F|*c FIGHTING **occou*cs None especially unusual ** amo cxn.osioM mazaaos ^one especially {Continued ofl iwf*e tide) Form CSHA* Ptft. M*r ** ABD00029793 . . SECTION V . HEALTH HAZARD OATA THREiMOLpL'MU VA(.Ut ,, ,T ' None determined : *vi mLxpoSmrI "" It may happen to effect the respiratoryorgan;s as ssr as dust in case of inhaling fine powder for a long time. I MI UUI.NCV ANn I M$T An VNOCCOURU It is not considered a toxic hazard. " Eyes: to wash out without rubbing. Skin: to. eliminate after handling_______________________________ si AICITV UNSTABLE SECTION VI - REACTIVITY DATA CONDITIONS TO AVOtO STABLE iMCO*#ArAMiLfTV (Usimtk m grxud) X OIARDOVS OCCOm*OSiTM>N AmUOUCTS MA/.AROOUS POLYMERIZATION MAY OCCUR WILL NOT OCCUR CONDITIONS TO AVOIO X * ( j .i A SECTION yil - SPILL OR LEAK PROCEDURES STEPS TO SE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED- *PVA is water soluble and makes a sticky solution, so scattered or spilled PVA powder should be sweet ud ( not be washed out with water )._________ WASTE OlSPOSAL MCTHOO ____________ __ to burn up________________I___:_______________ - i - SECTION vm * SPECIAL PROTECTION INFORMATION ARCSPiRAfOHv PROTECTION /5pcc*/r trpcj ^ ITt. i.s d. es.ireble to wear filter mas,k, w,hen VLN1 ILAflON --Cnelocal exhaust veryous zy graae ist special MECHANICAL (Urncnl) r OTHCA ., PHOICClIVi, CLOYES None especially OTttkH PHOrkCT.Vt lQu.CNT EYE PROTECTION None esoeeTailv y SECTION IX - SPECIAL PRECAUTIONS PRECAUTIONS TO SC TAKEN IN HANOUNC ANO STORING Nohp ; Dus 1 ^ ( not * temperature and humidity. - ohanye. at room _________________ _ OTHLR PRECAUTIONS None generally PAGE (2) C'C IB.) Fonr CSHA2 THE NIPPON SYNTHETIC CHEMICAL INDUSTRY CU..L1 L). R. m.t ti N0.S-5N0ZAK;-CH0. kita-ku OSAKA. JAPAN ABD00029794 Material Safety Data Sheet Tb* Oow Chemical Company Midland, Michigan 48674 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 53940 Page: 1 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Oate: 02/10/92 Oate Printed: 04/14/95 MSDS:000055 1. INGREDIENTS: (X w/w, unless otherwise noted) Hydroxypropy1 methylcellulose Water Sodium chloride CAS# 009004-65-3 85-99* CAS# 007732-18-5 1-10* CAS# 007647-14-5 0.5"5* This document is prepared pursuant to the OSHA Hazard Communication Standard (29 CFR 1910.1200). In addition, other substances not 'Hazardous1 per this OSHA Standard may be listed. Where proprietary ingredient shows, the identity may be made available as provided in this standard. 2. PHYSICAL DATA: BOILING POINT: Not applicable. VAP PRESS: Not applicable. VAP DENSITY: Not applicable. SOL. IN WATER: See section 9SP. GRAVITY: Not applicable. APPEARANCE: White to slightly off-white free-flowing powder. ODOR: Not available. 3. FIRE AND EXPLOSION HAZARD DATA: FLASH POINT: N/A METHOD USED: N/A FLAMMABLE LIMITS LFL: Not deter. UFL: Not deter. EXTINGUISHING MEDIA: Water fog. FIRE & EXPLOSION HAZARDS: Minimum explosive dust concentration 0.03 oz/cu ft. Similar to flour or grain dusts: keep clouds of such dust away from possible ignition sources. FIRE-FIGHTING EQUIPMENT: Use positive-pressure, self-contained breathing apparatus. (Continued on page 2 , over) (R) Indicates a Trademark of The Dow Chemical Company Printed on Recycled and Recyclable Paper ABD00029795 The Dow Chemical Company, Midland, Ml 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: 2 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: 04/14/95 M$DS:000055 4. REACTIVITY DATA: STABILITY: (CONDITIONS TO AV0I0) Avoid dust clouds or layers. INCOMPATIBILITY: (SPECIFIC MATERIALS TO AVOID) Oxidizing material. HAZARDOUS DECOMPOSITION PRODUCTS: Same as for wood or paper. HAZARDOUS POLYMERIZATION: Will not occur. 5. ENVIRONMENTAL AND DISPOSAL INFORMATION: ACTION TO TAKE FOR SPILLS/LEAKS: Sweep up and use if possible, or discard using disposal method listed below. DISPOSAL METHOD: Preferable method is to dispose in landfill. Oisposal can also be accomplished by incineration under controlled conditions to eliminate dust explosions. In both methods, disposal techniques should be in compliance with applicable federal, state, and local laws and regulations regarding management, use, handling, treatment, storage, disposal, and transportation of used chemicals. 6. HEALTH HAZARD DATA: EYE: Solid or dust may cause irritation or corneal injury due to mechanical action. SKIN CONTACT: Essentially nonirritating to skin. SKIN ABSORPTION: A single prolonged exposure is not likely to result in the material being absorbed through skin in harmful amounts. INGESTION: Single dose oral toxicity is low. No hazards anticipated from ingestion incidental to industrial exposure. The oral L05O for rats is >10,000 mg/kg. INHALATION: Single exposure to dust is not likely to be hazardous. SYSTEMIC & OTHER EFFECTS: Based on available data, repeated exposures are not anticipated to cause any significant adverse effects. Birth defects are unlikely.' Exposures having no (Continued on page 3) (R) indicates a Trademark of The Oow Chemical Company ABD00029796 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^*0 Page: 3 Product Name: MEJHOCEL (R) F50 HYOROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: OL/lL/95 M$DS:000055 6. HEALTH HAZARD DATA: (CONTINUED) adverse effects on the mother should have no effect on the fetus. 7. FIRST AID: EYES: Irrigate immediately with water for at least five minutes. Mechanical effects only. SKIN: No adverse effects anticipated by this route of exposure. INGESTION: No adverse effects anticipated by this route of exposure. INHALATION: No adverse effects anticipated by this route of exposure. 8. HANDLING PRECAUTIONS: EXPOSURE GUIDELINE (S): Dow Industrial Hygiene Guide is 10 mg/m3* VENTILATION: Provide general and/or local exhaust ventilation to control airborne levels below the exposure guidelines. RESPIRATORY PROTECTION: In dusty atmospheres, use an approved dust respirator. SKIN PROTECTION: No precautions other than clean body-covering clothing should be needed. EYE PROTECTION: Use safety glasses. !_f there is a potential for exposure to particles which could cause mechanical injury to the eye, wear chemical goggles. 9. ADDITIONAL INFORMATION: SPECIAL PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE: Use reasonable caution and personal cleanliness. Cellulose ethers are water-soluble polymers which form aqueous dispersions by swelling and by successive hydration of their structural layers. There is no sharp solubility limit. CAUTION: (1) Under certain conditions a fine dust of this material in (Continued on page k , over) (R) Indicates a Trademark of The Dow Chemical Company ABD00029797 The Dow Chemical Company, Midland, Ml 48674 Emergency Phone:517-636-4400 Product Code: 53940 Page: 4 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Oate: 02/10/92 Oate Printed: 04/14/95 hS0S:QQQO55 9. ADDITIONAL INFORMATION: (CONTINUED) air may cause a dust explosion when exposed to heat, sparks, and open flame. (2) If material spills and gets wet, could cause slipping hazard. MSOS STATUS: Revised regsheet (WHMIS) information. For information regarding state/provincial and federal regulations see The Regulatory Information Section. (R) Indicates a trademark of The Dow Chemical Company ABD00029798 The Dow Chemical Company. Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 53940 Page: R-1 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: 04/14/95 MSOS-.000055 REGULATORY INFORMATION: (Not meant to be all-inclusive--selected regulations represented.) NOTICE: The information herein is presented in good faith and believed to be accurate as of the effective date shown above. However, no warranty, express or implied, is given. Regulatory requirements are subject to change and may differ from one location to another: it is the buyer's responsibility to ensure that its activities comply with federal, state or provincial, and local laws. The following specific information is made for the purpose of complying with numerous federal, state or provincial, and local laws and regulations. See MSD Sheet for health and safety information. U.S. REGULATIONS SARA HAZAR0 CATEGORY: This product has been reviewed according to the EPA "Hazard Categories" promulgated under Sections $\\ and 312 of the Superfund Amendment and Reauthorization Act of 1986 (SARA Title III) andis considered, under applicable definitions, to meet the following categories: Afire hazard Hazard categories are listed solely to assist with federal reporting under Title III. They are not intended and are not appropriate for evaluating safe product handling and use. To review health and safety information, refer to the body of this material safety data sheet. CANADIAN REGULATIONS WHMIS INFORMATION: The Canadian Workplace Hazardous Materials Information System (WHMIS) Classification for this product is: This product is not a "Controlled Product" under WHMIS. CANAOI AN TOG INFORMATION: For guidance, the Transportation of Dangerous Goods Classification for this product is: Not regulated. (R) Indicates a Trademark of The Dow Chemical Company The Information Herein Is Given In Good Faith, But No Warranty, Express Or Implied, Is Made. Consult The Dow Chemical Company For Further Information. ABD00029799 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: R-1 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: 04/14/95 MSDS:000055 REGULATORY INFORMATION: (Not meant to be all-inclusive'-selected regulations represented.) NOTICE: The information herein is presented in good faith and believed to be accurate as of the effective date shown above. However, no warranty, express or implied, is given. Regulatory requirements are subject to change and may differ from one location to another; it is the buyer's responsibility to ensure that its activities comply with federal, state or provincial, and local laws. The following specific information is made for the purpose of complying with numerous federal, state or provincial, and local laws and regulations. See MSD Sheet for health and safety information. U.S. REGULATIONS SARA HAZARO CATEGORY: This product has been reviewed according to the EPA "Hazard Categories" promulgated under Sections 311 and 312 of the Superfund Amendment and Reauthorization Act of 1986 (SARA Title III) and is considered, under applicable definitions, to meet the following categories: A fire hazard Hazard categories are listed solely to assist with federal reporting under Title III. They are not intended and are not appropriate for evaluating safe product handling and use. To review health and safety information, refer to the body of this material safety data sheet. CANADIAN REGULATIONS WHMIS INFORMATION: The Canadian Workplace Hazardous Materials Information System (WHMIS) Classification for this product is: This product is not a "Controlled Product" under WHMIS. CANAOI AN TOG INFORMATION: For guidance, the Transportation of Dangerous Goods Classification for this product is: Not regulated. (R) Indicates a Trademark of The Oow Chemical Company The Information Herein is Given In Good Faith, But No Warranty, Express Or Implied, Is Made. Consult The Oow Chemical Company For Further Information. ABD00029800 26/02 '04 16:06 0279 412964 REVERTEI LTD @1002/003 Harco MATERIAL SAFETY DATA SHEET Conforms to EC Directive 91/1SS/EEC Alcotex 78 1. CHEMICAL IDENTITY Alcotex 78 Is a 78% hydrolysed poly(vtny1 alcohol): CAS NO. 25213*24.$. CHEMICAL FORMULA:* (CHJ-CHOH)a7l(CHJ*CH(OCOCHl)4,J 2. COMPOSITION Poly(vinyl acetate, vinyl alcohol) total solids content 96.5% (min). 3. HA2ARD IDENTIFICATION Alcotex 78 should be treated as a low hazard product and requires no specific precautions for transport or handling. Spill Alcotex 78 Is slippery under wet conditions. 4 FIRST AID MEASURES SKIN:* Wash thoroughly with warm soapy water. EYES:* Wash eyes with running water for at least 10 minutes gently prising open eyelids lo ensure sufficient washing. Eye injuries from chemicals should be referred to a doctor. INGESTION:- Wash mouth with water. Seek immediate medical help. Show this data sheet to the doctor. INHALATION: Remove the person from exposure. 5. FIREFIGHTING MEASURES No special fire precautions are necessary, in case of fire use water, foam or dry powder extinguishers. 6. ACCIDENTAL RELEASE MEASURES POWOER: Sweep up If dry or If wet clean up with hot or cold water. SOLUTIONS: Soak up with Inert absorbent. 7. HANDLING AND STORAGE Alcotex 78 should be treated as a low hazard product but local exhaust ventilation is recommended where generation of dust Is unavoidable, if a pneumatic conveying system is employed the equipment should be grounded to avoid build up of static electricity. Alcotex 78 should be stored indoors away from wet areas and naked flames. 6. EXPOSURE CONTROLS AND PERSONAL PROTECTION Local exhaust ventilation is recommended as in 7 above. PERSONAL PROTECTION RESPIRATORY: If local exhaust ventilation is impractical and dust generation unavoidable a suitable dust mask should be worn. HAND: PVC or rubber gloves. EYE; If dust generation is unavoidable wear dust tight SKIN: goggles. Standard Industrial overalls. 9. PHYSICAL AND CHEMICAL PROPERTIES APPEARANCE: Pale yellow powder. ODOUR Slight characteristic. pH 6-7 (4% aqueous solution) BOILING POINT: MELTING POINT: About 165*C (decomposes) FLASH POINT: FLAMMABILITY; >40*C (Pensky Marten Closed Cup).' Does not support combustion as measured by SI 917/1972 Test Method Schedule 2 Rg. 2(2).* AUTO FLAMMABILITY;- EXPLOSIVE PROPERTIES; St Class 1 (Kst approx 20 bar m/s)* VAPOUR PRESSURE: BULK DENSITY: 0.7g cm 3 SOLUBILITY IN WATER: Soluble. OTHER SOLVENTS: Not soluble. 28/02 84 16:08 0279 412984 ABD00029801 REVERTEI LTD &1003/OQ3 10. STABILITY AND REACTIVITY Hazardous decomposition products at temperatures above 200*C include aldehydes and acetic acid. 11. TOXICOLOGICAL INFORMATION Polyvinyl alcohol Is of a low order of acute toxicity. Similar products nave been shown to have LO 50 (RAT) > 2 g/kg. Experience In manufacture and handling and by comparison with similar materials does not indicate any lonQ term health hazards related to inhalation, skin and eye contact. * Values are actual results for analagous material Alcotex 72.5 12. ECOLOGICAL INFORMATION Polyvinyl alcohol Is readily degraded by adapted sewage sludges. 13. DISPOSAL CONSIDERATIONS Solid waste of polyvinyl alcohol or packaging should be disposed of by incineration or landfill in accordance with national or local regulations. In biological purification plants, polyvinyl afcohol solutions can also be degraded into carbon dioxide and water by adapted micro-organisms. Tests with dilute polyvinyl alcohol solutions have also shown that sensitive fish varieties (gulden orfe and guppies) are not affected even at polyvinyl alcohol concentrations of 500 mg/litre of water, 14. TRANSPORT INFORMATION Not classified as dangerous for transport purposes. 15. REGULATORY INFORMATION This material is not classified as dangerous under EC labelling directives. WORKER EXPOSURE LIMIT: Material should be considered as a nuisance dust. Polyvinyl alcohol is listed in the USA TSCA inventory but being a polymer was exempted from inclusion irt EINECS. The information contained herein does not constitute the user's own assessment of workplace risk required by other health and safety legislation. 16. OTHER INFORMATION CONTACT: Or S Ormondroyd Hariow Chemical Company Ltd Tempiefieids Hariow Essex CM20 2BH England Tel No. International + 44 279 436211 Fax: + 44 279 444025 DATE OF ISSUE 25/06/93 . ISSUE NO. 1 The information contained herein is based on the present state of our knowledge and is intended to describe our products from the point of view of health and safety requirements. It should not be construed as guaranteeing specific propenies. i ABD00029802 [aterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 1 SECTION 1: PRODUCT INFORMATION___________________________________ NAME: 2-MERCAPTOETHANOL DESCRIPTION: 2-MERCAPTOETHANOL CAS NUMBER: 60-24-2 USE: CHEMICAL INTERMEDIATE MSDS NUMBER: P001249-MCDWDK APPEARANCE AND ODOR: WATER-WHITE LIQUID; MERCAPTAN ODOR EMERGENCY TELEPHONE: 800-424-9300 24-KOURS - CHEMTREC PRODUCT INFORMATION: 800-251-5952 EFFECTIVE DATE: 01/27/92 SUPERCEDES DATE: 04/15/91 PRODUCT CODE: 1217000019 SECTION 2: HAZARDOUS INGREDIENTS A HAZARD EVALUATION OF THIS PRODUCT HAS BEEN PERFORMED. THE COMPONENT LISTED BELOW IS IDENTIFIED AS A HAZARDOUS CHEMICAL UNDER THE CRITERIA OF THE OSHA HAZARD COMMUNICATION STANDARD (29 CFR 1910.1200). COMMON NAME/CHEMICAL NAME CAS NUMBER APPROXIMATE X 2-MERCAPT0ETHAN0L/THI0GLYC0L 60-24-2 90 - 100 SECTION 3: EMERGENCY AND FIRST AID PROCEDURES EYE CONTACT: FLUSH EYES WITH WATER FOR AT LEAST 15 MINUTES. GET PROMPT MEDICAL ATTENTION. LIFT EYE LIDS FREQUENTLY. SKIN CONTACT: . FROMPTLY REMOVE CONTAMINATED CLOTHING AND SHOES. FLUSH AFFECTED AREA WITH WATER FOR 15 MINUTES. CLEANSE SKIN WITH SOAP AND WATER. GET PROMPT MEDICAL ATTENTION. WASH CONTAMINATED CLOTHING SEPARATELY BEFORE REUSE. INHALATION: REMOVE TO FRESH AIR. IF SYMPTOMS DEVELOP, SEEK IMMEDIATE MEDICAL ATTENTION. IF NOT BREATHING, GIVE ARTIFICIAL RESPIRATION, PREFERABLY MOUTH TO MOUTH. INGESTION: SEEK MEDICAL ATTENTION. UNLESS ADVISED OTHERWISE, INDUCE VOMITING BY GIVING EITHER SYRUP OF IPECAC FOLLOWED BY 2 GLASSES OF WATER OR BY STICKING FINGER DOWN THROAT. DO NOT GIVE ANYTHING BY MOUTH IF THE PERSON IS DROWSY, UNCONSCIOUS, OR HAS NO GAG REFLEX. NOTE TO PHYSICIAN: TREATMENT SHOULD BE DIRECTED AT PREVENTING ABSORPTION, ADMINISTERING TO THE SYMPTOMS AS THEY OCCUR, AND PROVIDING SUPPORTIVE THERAPY. Morton International I 9 i r/>o m/ooi i/Wi ABD00029803 Material Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 2 j. SECTION Hi HEALTH EFFECTS SUMMARY PRIMARY ROUTE(S) OF EXPOSURE: EYE - YES SKIN - YES INHALATION * YES EYE CONTACT: CAUSES SEVERE IRRITATION. VAPORS AND/OR MISTS CAN CAUSE MILD TO MODERATE IRRITATION. THE SEVERITY OF REACTION DEPENDS ON DURATION OF EXPOSURE AND FIRST AID PROCEDURES ADMINISTERED. SKIN CONTACT: CAUSES SEVERE IRRITATION. HARMFUL WHEN ABSORBED THROUGH THE SKIN IN SUFFICIENT AMOUNTS. THE SEVERITY OF REACTION DEPENDS ON DURATION OF EXPOSURE AND FIRST AID PROCEDURES ADMINISTERED. INHALATION: CAN BE IRRITATING TO MUCOUS MEMBRANES, ESPECIALLY FOLLOWING PROLONGED EXPOSURE TO MISTS AND/OR VAPORS. INHALATION CAN CAUSE DIZZINESS, HEADACHES, AND INCOORDINATION. NAUSEA, VOMITING, AND GASTROINTESTINAL UPSET CAN OCCUR. INGESTION: INGESTION CAUSES SEVERE IRRITATION OF THE MOUTH, THROAT, AND ESOPHAGUS. CAN CAUSE NAUSEA, VOMITING, AND GASTROINTESTINAL UPSET. ADDITIONAL EFFECTS: DEPENDING ON THE ROUTE, FREQUENCY, AND DURATION OF EXPOSURE, TOXICITY MAY EFFECT IN THE FOLLOWING ORGANS AND/OR SYSTEMS: RESPIRATORY SYSTEM. EYE. SKIN. AGGRAVATION OF EXISTING CONDITIONS: SOME OF THE COMPONENTS IN THIS PRODUCT MAY AGGRAVATE EXISTING MEDICAL CONDITIONS. INDIVIDUALS WITH MEDICAL CONDITIONS INVOLVING THE FOLLOWING ORGAN(S) AND/OR SYSTEM(S) SHOULD TAKE APPROPRIATE PRECAUTIONS WHEN HANDLING THIS PRODUCT: LIVER. KIDNEY. ALWAYS WEAR APPROPRIATE PROTECTIVE EQUIPMENT, AS RECOMMENDED BY YOUR Morton International ;/vi u or..- /~L;--- - n AAAAA fro* ABD00029804 aterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 3 A INDUSTRIAL HYGIENE OR SAFETY PERSONNEL, WHEN EXPOSURE TO THIS PRODUCT CAN OCCUR. SECTION S: TOXICOLOGIC INFORMATION THE INFORMATION IN THIS SECTION, THOUGH DETAILED, CAN BE SUBJECT TO MISINTERPRETATION. THEREFORE, IT IS ESSENTIAL THE FOLLOWING INFORMATION BE INTERPRETED BY INDIVIDUALS TRAINED IN ITS EVALUATION. 2-MERCAPTOETHANOL/THIOGLYCOL TOXIC EFFECTS: EYE AND SKIN CONTACT CAN CAUSE SEVERE IRRITATION. MAY BE ABSORBED CAUSING HEADACHE, DIZZINESS, NAUSEA, VOMITING, WHEEZING. INGESTION MAY CAUSE GASTROINTESTINAL IRRITATION, CNS DEPRESSION. INHALATION OF VAPORS MAY PRODUCE SEVERE IRRITATION OF THE UPPER RESPIRATORY TRACT AND SYMPTOMS AS FOR ABSORPTION. RENAL AND HEPATIC DAMAGE AND HEMOLYTIC ANEMIA HAVE BEEN REPORTED. ACUTE TOXICITY STUDIES: ORAL-RAT ORAL-MOUSE DERMAL-RABBIT DERMAL-GUINEA PIG INHALATION-MOUSE LD50: LD50: LD50: LD50: LC50: 300 ag/kff 345 g/kg 150 mg/kg 300 g/kg 13,200 g/3 OTHER TOXICITY STUDIES: 2-ME WAS FOUND TO BE MUTAGENIC IN SEVERAL TEST SYSTEMS, INCLUDING THE KICRONUCLEUS TEST(MOUSE), DNA INHIBITION(RAT-LIVER), UNSCHEDULED DNA SYNTHESIS(MOUSE), AND CYTOGENIC ANALYSIS(HUMAN LEUKOCYTE). HOWEVER, 2-ME WAS FOUND NOT TO BE MUTAGENIC IN THE AMES TEST OR THE MOUSE LYMPHOMA ASSAY. CARCINOGENICITY - LISTED BY: ACGIH: NO IARC MONOGRAPHS: NO NTP ANNUAL REPORT: NO OSHA: NO SECTION 6: OCCUPATIONAL CONTROL PROCEDURES EYE PROTECTION: WEAR CHEMICAL SPLASH GOGGLES. AN EYE WASH FACILITY SHOULD BE READILY AVAILABLE. SKIN PROTECTION: WEAR RUBBER BOOTS AND APRON, PROTECTIVE CLOTHING, AND IMPERVIOUS GLOVES. BECAUSE A VARIETY OF PROTECTIVE GLOVES EXIST, ALWAYS CONSULT GLOVE MANUFACTURER TO DETERMINE THE PROPER TYPE FOR SPECIFIC OPERATION. Morton International 1 ^ ^/W> ABD00029805 Material Safety Data Sheet 2-MERCAPTOETHAHOL PAGE: 4 RESPIRATORY PROTECTION: WHEN AIRBORNE CONCENTRATIONS ARE EXCESSIVE, WEAR NIOSH/MSHA APPROVED EQUIPMENT. DETERMINE THE APPROPRIATE TYPE BY CONSULTING THE RESPIRATOR MANUFACTURER. OBSERVE THE RESPIRATOR USE LIMITATIONS SPECIFIED BY NIOSH/MSHA OR THE MANUFACTURER. HIGH AIRBORNE CONCENTRATIONS MAY NECESSITATE THE USE OF SELF-CONTAINED BREATHING APPARATUS (SCBA) OR A SUPPLIED AIR RESPIRATOR. IN ADDITION, RESPIRATORY PROTECTION PROGRAMS MUST BE IN COMPLIANCE WITH 29 CFR 1910.134. VENTILATION: MINIMIZE EXPOSURE BY PROVIDING ADEQUATE VENTILATION. GENERAL (DILUTION) VENTILATION MAY BE ACCEPTABLE. HOWEVER, LOCAL EXHAUST VENTILATION IS RECOMMENDED WHEN VAPORS, MISTS, OR DUSTS CAN BE RELEASED. PERSONAL HYGIENE: WASH THOROUGHLY AFTER HANDLING, ESPECIALLY BEFORE EATING, DRINKING, SMOKING, OR USING RESTROOM FACILITIES. CONTAMINATED CLOTHING AND SHOES SHOULD BE THOROUGHLY CLEANED AND DRIED BEFORE REUSE. AIRBORNE EXPOSURE LIMITS 2-MERCAPT0ETHAN0L/THI0GLYC0L ACGIH TLV-TWA: NOT ESTABLISHED OSHA PEL: NOT ESTABLISHED SECTION 7: FIRE PROTECTION INFORMATION___ _________________________________________ __________ FLASH POINT: 150 F, 66 C TEST METHOD: SETAFLASH CLOSED CUP EXPLOSIVE LIMITS: LEL (X) - NOT ESTABLISHED UEL (X) - NOT ESTABLISHED AUTOIGNITION TEMPERATURE: NOT ESTABLISHED EXTINGUISHING MEDIA: SMALL FIRES: USE AGENTS APPROVED FOR CLASS B HAZARDS (E.G. DRY CHEMICAL, CARBON DIOXIDE, HALON, FOAM, STEAM) OR WATER FOG. LARGE FIRES: USE WATER SPRAY, FOG, OR ALCOHOL FOAM. SPECIAL FIRE FIGHTING PROCEDURES: FIRE FIGHTERS AND OTHERS WHO MAY BE EXPOSED TO THE PRODUCTS OF COMBUSTION SHOULD BE EQUIPPED WITH NIOSH APPROVED POSITIVE PRESSURE SELF-CONTAINED BREATHING APPARATUS (SCBA) AND FULL PROTECTIVE CLOTHING. UNUSUAL FIRE AND EXPLOSION HAZARDS: WHEN EXPOSED TO FLAMES OR HIGH TEMPERATURES ENCOUNTERED DURING FIRE Morton International ABD00029806 material Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 5 CONDITIONS, SEALED CONTAINERS MAY RUPTURE BECAUSE OF THE BUILD UP OF INTERNAL PRESSURE. COOL CONTAINERS WITH WATER. VAPORS MAY BE HEAVIER THAN AIR AND MAY TRAVEL CONSIDERABLE DISTANCES FROM THE MATERIAL HANDLING POINT. VAPORS CAN BE IGNITED BY A SPARE, FLAME, CIGARETTE, ELECTRIC MOTOR, STATIC DISCHARGE, ENGINE, PILOT LIGHT, HOT SURFACE, OR OTHER IGNITION SOURCE. SECTION S: REACTIVITY DATA; STABLE UNDER NORMAL CONDITIONS OF STORtAGE AND USE: YES MATERIALS TO AVOID: OXIDIZING AGENTS. STRONG BASES. CHEMICALLY ACTIVE METALSCE.G., NICXEL, COBALT, IRON, COPPER) HAZARDOUS POLYMERIZATION: HAZARDOUS POLYMERIZATION WILL NOT OCCUR. THERMAL DECOMPOSITION PRODUCTS: IF HEATED TO HIGH TEMPERATURES, THIS PRODUCT MAY EMIT THE FOLLOWING COMPOUNDS: OXIDES OF SULFUR. SMOKE, SOOT, & TOXIC FUMES (e.g. CARBON DIOXIDE ft CARBON MONOXIDE). SUPPLEMENTAL SECTION 8 INFORMATION: 2-ME DECOMPOSES AT 157-158 DEGREES C AT 742 mm Hg. SECTION 9: SPILL AND LEAK PROCEDURES: RESPONSE TO SPILLS: STOP DISCHARGE, IF IT CAN BE PERFORMED SAFELY, AND CONTAIN MATERIAL. IF A SUBSTANTIAL QUANTITY IS SPILLED, RECOVER WITH PUMP OR VACUUM TRUCK. EXPLOSION-PROOF EQUIPMENT SHOULD BE USED IF THIS PRODUCT IS FLAMMABLE OR COMBUSTIBLE(SEE SECTION 7). OTHERWISE, USE AN ABSORBENT SUCH AS FULLER'S EARTH, CLAY, OR OTHER APPROPRIATE SYNTHETIC ABSORBENT. PLACE CONTAMINATED MATERIAL IN A SUITABLE CONTAINER FOR DISPOSAL. APPROPRIATE SAFETY MEASURES AND PROTECTIVE EQUIPMENT SHOULD BE USED (SEE SECTION 6). DO NOT FLUSH TO SEWER, STREAM, OR OTHER BODIES OF WATER. PRECAUTIONS: ELIMINATE ALL SOURCES OF IGNITION. DISPOSAL METHODS: IF DISCARDED IN ITS ORIGINAL UNUSED FORM, THIS PRODUCT DOES NOT MEET THE DEFINITION OF A RCRA HAZARDOUS WASTE UNDER 40 CFR 261. Morton International inn oi. u. ot..~ /~u: n An*nA itoa 7 imnrt J/VY) ABD00029807 aterial Safety Data Sheet 2-MERCAPT0ETHAN0L PAGE: 6 NEVERTHELESS, IT SHOULD BE MANAGED (STORED/TREATED/DISPOSED/ETC.) AT AN AUTHORIZED FACILITY, IN COMPLIANCE WITH ALL APPLICABLE FEDERAL, STATE, AND LOCAL REQUIREMENTS. BE SURE TO CONTACT APPROPRIATE GOVERNMENT ENVIRONMENTAL AGENCIES IF FURTHER DISPOSAL GUIDANCE IS REQUIRED. OF THE METHODS OF DISPOSAL CURRENTLY AVAILABLE, IT IS RECOMMENDED THAT AN ALTERNATIVE BE SELECTED ACCORDING TO THE FOLLOWING ORDER OF PREFERENCE, BASED UPON ENVIRONMENTAL ACCEPTABILITY: (1) RECYCLE OR REWORK IF AT ALL FEASIBLE, (2) INCINERATE AT AN AUTHORIZED FACILITY, OR (3) TREAT AT AN ACCEPTABLE WASTE TREATMENT FACILITY. SECTION 10: SPECIAL PRECAUTIONS RECOMMENDED STORAGE PRACTICE AND CONDITIONS: STORE IN COOL, DRY, WELL VENTILATED AREA. DO NOT STORE NEAR HEAT OR IGNITION SOURCES, OR IN DIRECT SUNLIGHT. ALWAYS KEEP CONTAINERS TIGHTLY CLOSED TO AVOID CONTAMINATION. SPECIAL WARNING: HOT ORGANIC CHEMICAL VAPORS OR MISTS CAN SUDDENLY AND WITHOUT WARNING COMBUST WHEN MIXED WITH AIR. IGNITION CAN OCCUR AT TYPICAL ELEVATED TEMPERATURE PROCESS CONDITIONS. ANY PROPOSED USE IN SUCH PROCESSES SHOULD BE EVALUATED THOROUGHLY TO ASSURE SAFE OPERATING CONDITIONS. DO NOT STORE ABOVE: 150 F, 66 C CONTAINER USE PROCEDURES: CONTAINERS SHOULD BE SUPPORTED AND GROUNDED BEFORE OPENING, DISPENSING, MIXING, POURING, AND EMPTYING. OPEN WITH NON-SPARKING TOOLS. IF THE CONTAINER IS WARM, OPEN BUNG SLOWLY TO RELEASE INTERNAL PRESSURE. EMPTY CONTAINER PRECAUTIONS: THIS CONTAINER IS HAZARDOUS WHEN EMPTY. DO NOT USE HEAT, SPARKS, OPEN FLAMES, TORCHES, OR CIGARETTES ON OR NEAR EMPTY CONTAINER. EMPTY CONTAINERS CAN RETAIN PRODUCT RESIDUES. DO NOT REUSE EMPTY CONTAINER FOR FOOD, CLOTHING, OR PRODUCTS FOR HUMAN OR ANIMAL CONSUMPTION OR WHERE SKIN CONTACT MAY OCCUR. SECTION 1U PHYSICAL DATA____ % NON-VOLATILES (BY WEIGHT): pH; VAPOR DENSITY (AIR=1): SOLUBILITY IN WATER: EVAPORATION RATE (n-BUTYL ACETATE=1) < 0.1 7.0 NOT ESTABLISHED DISPERSIBLE <1 Morton International ABD00029808 aterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 7 * VAPOR PRESSURE (mmHg 3 25 DEGREES C): 1.6-1.8 SPECIFIC GRAVITY (WATER=1): 1.12 APPROXIMATE BOILING POINT: NOT ESTABLISHED SUPPLEMENTAL SECTION 11 INFORMATION: PURITY: TYPICALLY > 99X NOTE: THE PHYSICAL DATA PRESENTED ABOVE ARE TYPICAL VALUES AND SHOULD NOT BE CONSTRUED AS A SPECIFICATION. SECTION 12: LABEL ANO_TRANSPORTATION INFORMATION___________ DOT SHIPPING NAME: POISONOUS LIQUID N.O.S. (THIOGLYCOL) DOT LABEL: POISON DOT IDENTIFICATION NO. : UN 2810 MORTON PRECAUTIONARY LABEL NO.: L483 SUPPLEMENTAL SECTION 12 INFORMATION: FOR CANADIAN SHIPMENTS: F483. SHIPMENTS BY AIR UNDER 49 CFR - PROPER SHIPPING NAME: POISONOUS LIQUID, N.O.S. (THIOGLYCOL); HAZARD CLASS: POISON; SUBSIDIARY RISK: NONE; UN NO.: 2810; LABELCS): POISON. HM-181, IATA/ICAO AND IMO - PROPER SHIPPING NAME: THIOGLYCOL; HAZARD CLASS: 6.1; SUBSIDIARY RISK: NONE; UN NO.: 2966; PACKAGING GROUP: II; LABELCS): POISON. SECTION 13: REGULATORY INFORMATION----------------------------------------------------!---------------------------TOXIC SUBSTANCE CONTROL ACT CTSCA) THE CHEMICAL COMPONENTS OF THIS PRODUCT ARE CONTAINED ON THE SECTION 8(B) CHEMICAL SUBSTANCE INVENTORY LIST (40 CFR 710). SARA TITLE III INFORMATION SECTION 313 - TOXIC CHEMICALS PURSUANT TO SECTION 313 OF SARA TITLE III, THIS PRODUCT DOES NOT CONTAIN A TOXIC CHEMICAL IN EXCESS OF 1 PERCENT OF THE MIXTURE (0.1 PERCENT, IF THE LISTED TOXIC CHEMICAL IS A CARCINOGEN). SECTION 302 - EXTREMELY HAZARDOUS SUBSTANCES PURSUANT TO SECTION 302 OF SARA TITLE III, THIS PRODUCT DOES NOT CONTAIN AN EXTREMELY HAZARDOUS SUBSTANCE. SECTION 311/312 - HAZARD CATEGORIES PURSUANT TO SECTION 311/312 OF SARA TITLE III, THE PHYSICAL AND HEALTH HAZARD CATEGORIES FOR THIS PRODUCT ARE IDENTIFIED BELOW: Morton International ABD00029809 Material Safety Data Sheet 2-MERCAPT0ETHAN0L PAGE: 8 FIRE HAZARD: YES SUDDEN RELEASE OF PRESSURE HAZARD: NO REACTIVITY HAZARD: NO IMMEDIATE (ACUTE) HEALTH HAZARD: YES DELAYED (CHRONIC) HEALTH HAZARD: NO HAZARDOUS MATERIALS INFORMATION REVIEW REGULATIONS - CANADA THIS MATERIAL SAFETY DATA SHEET PROVIDES INFORMATION THAT COMPLIES WITH THE REQUIREMENTS SETFORTH UNDER THE CANADIAN WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM (WHMIS). CLAIM FOR EXEMPTION REGISTRY NO.: NOT APPLICABLE EXPIRATION DATE: NOT APPLICABLE SECTION. 14: USERS RESPONSIBILITY: A BULLETIN SUCH AS THIS CANNOT BE EXPECTED TO COVER ALL POSSIBLE INDIVIDUAL SITUATIONS. AS THE USER HAS THE RESPONSIBILITY TO PROVIDE A SAFE WORKPLACE, ALL ASPECTS OF AN INDIVIDUAL OPERATION SHOULD BE EXAMINED TO DETERMINE IF, OR WHERE, PRECAUTIONS - IN ADDITION TO THOSE DESCRIBED HEREIN - ARE REQUIRED. ANY HEALTH HAZARD AND SAFETY INFORMATION CONTAINED HEREIN SHOULD BE PASSED ON TO YOUR CUSTOMERS OR EMPLOYEES, AS THE CASE MAY BE. DISCLAIMER OF LIABILITY THE INFORMATION CONTAINED HEREIN IS, TO THE BEST OF OUR KNOWLEDGE AND BELIEF, ACCURATE. HOWEVER, SINCE THE CONDITIONS OF HANDLING AND USE ARE BEYOND OUR CONTROL, WE MAKE NO GUARANTEE OF RESULTS, AND ASSUME NO LIABILITY FOR DAMAGES INCURRED BY USE OF THIS MATERIAL. ALL CHEMICALS MAY PRESENT UNKNOWN HEALTH HAZARDS AND SHOULD BE USED WITH CAUTION. ALTHOUGH CERTAIN HAZARDS ARE DESCRIBED HEREIN, WE CANNOT GUARANTEE THAT THESE ARE THE ONLY HAZARDS WHICH EXIST. FINAL DETERMINATION OF SUITABILITY OF THE CHEMICAL IS THE SOLE RESPONSIBILITY OF THE USER. NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER NATURE ARE MADE HEREUNDER WITH RESPECT TO THE INFORMATION CONTAINED HEREIN OR THE CHEMICAL TO WHICH THE INFORMATION REFERS. IT IS THE RESPONSIBILITY OF THE USER TO COMPLY WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. IF YOU HAVE QUESTIONS WITH REGARD TO HEALTH EFFECTS, OR OTHER INFORMATION PRESENTED IN THIS DOCUMENT, CONTACT: DAVID B. WIENCKOWSKI, D.A.B.T. MANAGER, PRODUCT SAFETY AND TOXICOLOGY MORTON INTERNATIONAL, INC. 100 N. RIVERSIDE PLAZA Morton International ABD00029810 Material Safety Data Sheet CHICAGO, IL 60606 312-807*3422 2-MERCAPTOETHANOL PAGE: 9 * Morton International tOO North Rivenld* Pl/rrn. Chlrnoo fL 60606-1598 312/807-2000 ABD00029811 aterial safety data sheet 01.17.95 01/04 3J^INC.-P.0.DRAW.Y PENNY ROYAL RD-GEORGETOWN SC 29440,(803)546-8556 P jUCT NAME: POLIVIC S 202 35% 1.00 SECTION I. IDENTIFICATION CHEMICAL CHARACTERIZATION: in methanol solution. Form : Liquid Color; Limp id-yellow Odor ; Sweet Vinyl alcohol-^iavl acetate copolymer 2.00 SECTION II. INGREDIENTS/HAZARD STATEMENTS CHEMICAL IDENTITY `Methanol Msthy.l Acetate Proprietary CAS NO. 67-56-1 79-20-9 PEL TLV 200 ppm 200 ppm PERCENT 47% mar 12% 7ARMING STATEMENTS: The product is tonic by inhalation, ingestion and repeated or prolonged skin contact. After 6-30 hours, dizziness, headache, nausea, abdominal pains, visual disturbances may occur. A 30-120 ml ingestion dose can be lethal. Irritating effect on mucous membranes may occ.: '"his component is listed under Section 313 SARA TITLE III. The maximum con centration in the product is 47%. 3.00 SECTION III. PHYSICAL DATA MELTING POINT <fC) DENSITY (g/ml ' VAPOR PRESSURE fan Hg at 20*C) ?H Liquid 0.38-0.93 114 6-7 BOILING POINT (*C) : BULK DENSITY (g/ml); VISCOSITY Cep at 2 0 ** C ) : SOLUBILITY IN WATER: 57- 54 n.d. 60-120 Incomplete 4.00 SECTION IV. FIRE AND EXPLOSION HAZARDS FLASH POINT < METHOD) s -1.89 *C(TCC) LEL: 6.7% UEL: 36% EXTINGUISHING MEDIA:- (X) C02 (X) Dry chemical (X) Alcohol-resistant Foam (X) Water spray SPECIAL FIRE FIGHTING PROCEDURES: Fire fighters should wear full protective clothing and SCBA when potential for exposure to products of combustion exists. In case of fire, keep containers cool by spraying water. , . 7E MEASURES TO AVOID FIRE/EXPLOSION: Do not store or air with o zi dinars. This product is flammable. Keep away from sources of ignition and heat. Do not smoke. Take precautionary measures against static discharges. Vapor/air mixture can be e z ? 1 o s i v e. Vapor is heavier than air and can travel a ABD00029812 *5 V ATERIAL SAFETY DATA SHEET 01.17.S5 0Z/Q4 P UCT NAME: POLIVIC S 202 35% considerable distance to a source o ignition and flashback. NFPA HAZARD RATING INDEX: (1) Health (3) Flammability <0* Reactivity (NA> Special 5.00 SECTION V. REACTIVITY DATA STABILITY: <x> Stable r ) Unstable CONDITIONS TO AVOID: None under normal conditions o use. INCOMPATIBILITY ( ) water ' ) strong acids ( ) strong bases (s) oxidizers ( ) reducers ( ) combustibles fx> other: Keep away from alcohol reacting substances. HAZARDOUS DECOMPOSITION PRODUCT On burning carbon oxides can be evolved. SECTION VI. HEALTH HAZARD INFORMATION ACUTE EFFECTS: Skin irritation frabbit) eye irritation rrabbit): 40 mg LDL0 (oral, oar.) : S422 mg/kg Abo^e health effects are for methanol. 500 mg/24H CHP.ONIC EFFECTS: The product is toxic by inhalation, ingestion and repeated or prolonged skin contact. After 6-30 hours dizziness, headache,, nausea, abdominal pains, visual disturbances may occur# MEDICAL CONDITIONS THAT MAT BE AGGRAVATED BY EXPOSURE: Unknown FIRST AID PROCEDURES SWALLOWING: Wash out mouth with water. If conscious, induce vomiting with a spoon of lukewarm salted water. Then drink bicarbonate in solution. Keep person warm and in a lying DERMAL EXPOSURE position. Immediately remove contaminated clothing, wash with soap and water. Contact a physician if irritation develops. EYE EXPOSURE: Rinse eyes under flowing water for 15 minutes. If irritation develops, contact a INHALATION: physician. Mo"* to fresh air. Administer oxygen and seek medical assistance if difficulty breathing. 7.00 SECTION VII. PRECAUTION FOR SAFE HANDLING AND USE ABD00029813 3V :aterial safety P*UCT NAME: data sheet POLIVIC S -202 35% 01.17.95 03/04 STEPS TO sand, or residues methanol TAKE IN CASE OF SPILL OR RELEASE: Absorb with sawdust, similar and collect in a suitable container, wash with water. Do not breathe vapors due to residual content. WASTE DISPOSAL METHODS: Dispose in accordance with federal, state and local regulations. HANDLING AND STORAGE: Keep containers tightly closed. Ensure good ventilation and exhaustion o the working area. Protect from frost. Stare in a cool place, OTHER PRECAUTIONS: Do not breathe vapors due to residual methanol content. Particular care should be taken when containers are opened after prolonged storage due to vapors from residual methanol content. Do not open containers in proximity of flame and sparks. Do not smoke. Do not use compressed air t: empty containers. 9.00 SECTION VIII. CONTROL MEASURES RESPIRATORY PROTECTION: No respirator is required at methanol concentrations below 2QQ?pm. Supplied air respirator is required at methan cl concentrations above ZQQppm. Refer to NIOSH "Pocket Guide t : Chemical Ha cards" for proper selection for methanol. DERMAL PROTECTION: Rubber gloves, rubber apron and boots ETE PROTECTION: Chemical safety goggles VENTILATION: .Ensure- good vgntilation and exhaustion for the working area . PROTECTIVE EQUIPMENT: Eye wash safety shower within 25 ft. 9.00 SECTION IX. ENVIROMENTAL AND REGULATORY INFORMATION ECOLOGICAL EFFETS: Do not discharge into drains or CERCLA RQ (lbs): 5000 for methanol TSCA STATUS: On Inventory SARA 313 LIST: Methanol is listed on SARA 313 list SARA 3Q4 LIST: Not listed DOT STATUS: Not listed NEW JERSEY RIGHT TO KNOW: Methanol is listed MASSACHUSETTS RIGHT TO KNOW: Methanol is listed PENNSYLVANIA RIGHT TO KNOW: Methanol is listed. waterways. rUr. = not applicable n.d. = net determined "FOR CHEMICAL EMERGENCY" Spill, Leak, Fire, Exposure or Accident Call CHEMTREC - Day or Night 1-800-424-9300 The statements made herein are intended to provide product safety ABD00029814 1ATERIAL SAFETY P^JUCT NAME: DATA SHEET POLIVIC S -202 35% 01.17.95 04/04 ormation. This material safety data sheet has been prepared with information currently a"ailabie. Although care has been taken to provide accurate information, nc warranties either expressed or implied are being made as a result of the presentation of this information. ABD00029815 MSOSCOOC: REVISION: VCM 01/96 Vista Chemical Company f>. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PfUNT DATE: 03/21/96 MATERIAL SAFETY DATA SHEET 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION TRADE NAME: SYNONYMS: VINYL CHLORIDE MONOMER VCM, Chloroethene MANUFACTURER: ADDRESS: Vista Chemical Company 900 ThreadneedJe Houston, TX 77079 TELEPHONE NUMBERS: CHEMTREC - Transportation Emergency (24-hr) Other Emergendes (24-hrs) MSDS and Product Information (8:00am-4:30pm CST) Health and Safety Information (7:30am-5:00pm CST) (800) 424-9300 (318) 494-5142 (713) 588-3491 (318) 494-5039 2. COMPOSITION / INFORMATION ON INGREDIENTS Components Weight% VINYL CHLORIDE 75-01-4 99.99 . See Section 8 for Exposure Guidelines and Section 15 for OSHA Classification 3. HAZARDS IDENTIFICATION Emergency Overview Colorless gas. Liquid under pressure. Faint, sweet odor. CANCER SUSPECT AGENT. FIRE OR EXPLOSION: DANGER! EXTREMELY FLAMMABLE GAS UNDER PRESSURE. MAY CAUSE FLASH FIRE. Keep away from heat, sparks and flame. Keep container dosed. In case of fire, allow gas to bum if flow cannot be shut off immediately. Apply water from a safe distance. HEALTH HAZARDS: Exposure to gas may cause irritation of eyes. Asphyxiant and anesthetic at high concentrations. Contact with liquid form may cause bums or frostbite of eyes and skin. Potential Health Effects EYES: Excessive exposure to gas may cause irritation. Contact with liquid may cause bums or frostbite. Page 1 of 10 ABD00029816 MSOSCOOC: REVISION: VCM 01/96 Vista Otemical Compony P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 HUNT DATE: 03/21/96 SKIN: Prolonged exposure may cause hardening of the skin (scleroderma). Contact with liquid vinyl chloride may cause bums or frostbite. INHALATION: Short-term, high level exposure may lead to smothering (asphyxia), inability to sense pain (anesthesia), dryness of nose and throat,' headache, rapid respiration, mental dullness, incoordination, nausea, unconsciousness and death. Damage to the liver and kidneys has been reported in animals following short term, high level exposure to vinyl chloride. Prolonged exposure of animals or people to vinyl chloride has been associated with toxicity to the liver, kidney, brain, bones of the hands, circulatory system, testis and lungs. Vinyl chloride can also cause cancer in humans (see Cancer below). Cancer: There is evidence that repeated, high level exposure to vinyl chloride can cause angiosarcoma (blood vessel tumors) to the liver in humans. Certain studies of vinyl chloride exposed individuals have also shown an increased incidence of other forms of cancer, i.e., hepatocellular carcinoma, brain tumors, lung tumors, gastric and gastrointestinal cancer, melanoma, and malignancies of the lymphatic and hemtopoiedc system. However, for various reasons, these studies do not conclusively link these tumor increases directly with vinyl chloride exposure. INGESTION: This product is a gas at room temperature and should not be a significant hazard via ingestion. (See Section 11 for Toxicological Information) 4. FIRST AID MEASURES EYES: Immediately flush eyes with large amounts of water for 15 to 30 minutes. Seek medical attention. Remove contaminated dothing. Apply loose, dry, sterile bandages. Call a physician. SKIN: Immediately flush skin with plenty of water. Remove contaminated dothing. Wash affected area with mild soap. Call a physician if irritation occurs. INHALATION: Remove to fresh air. If not breathing, give artifida] respiration. If breathing is difficult, give oxygen. Call a physician immediately. (Medical Toxicology, 1988). INGESTION: If swallowed, call a physician immediately. ONLY induce vomiting at the instruction of a physician. Never give anything by mouth to an unconscious person. Page 2 of 10 ABD00029817 MSOSCOOC: REVISION: VCM 01/9* p. O. Box 19029 Houston, Txos 77224-9029 VINYL CHLORIDE MONOMER V1S1A REVISION DATE: 03/03/9* PWNT DATE: 03/21/9* 5. FIRE FIGHTING MEASURES Flammable Properties FLASH POINT / METHOD: -108*? (-78*C) / PM AUTOIGNmON TEMPERATURE: 882*F (472*C) FLAMMABLE LIMITS IN AIR % BY VOLUME: LOWER: 4.0 UPPER: 22.0 FIRE AND EXPLOSION HAZARD: Vapors can form flammable mixtures in air at normal ambient conditons. Burning VCM generates hydrogen chloride gas. EXTINGUISHING MEDIA: Water spray, C02, dry chemical. FIRE FIGHTING INSTRUCTIONS: Stop flow of gas. Cool exposed equipment with water spray until well after fire is out Use self-contained breathing apparatus (SCBA) if fighting fires in confined spaces. 6. ACCIDENTAL RELEASE MEASURES STEPS TO BE TAKEN IN CASE OF SPILL OR LEAK: Evacuate the area and eliminate ignition sources. Contain die spill. Wet down die area with large quantities of water. Dissipate vapor with water spray. Increase ventilation if in an enclosed area. Stop leak or remove leaking cylinders. Do not attempt recovery of spilled material. Material will vaporize rapidly. Prevent liquid or vapors from entering sewers or other low areas. CERCLA HAZARDOUS SUBSTANCE: Component CERCLA RO Maximum Wt. % VINYL CHLORIDE 1 lb. 99.99 Page 3 of 10 ABD00029818 MSOSCOOE: REVISION: VCM 01/96 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VISTA REVISION OATE: 03/03/96 PRUT DATE: 03/21/96 7. HANDLING AND STORAGE ELECTROSTATIC ACCUMMULATION HAZARD; None. USUAL SHIPPING CONTAINERS: Tank can, ships and barges. STORAGE / TRANSPORT TEMPERATURE: Ambient STORAGE / TRANSPORT PRESSURE: Dependent on ambient temperature. See Section 9. LOAD / UNLOAD TEMPERATURE: Ambient. STORAGE AND HANDLING MATERIALS: Carbon steel is suitable. Aluminum or aluminum alloys, and other acetylide-forming metals are unsuitable. 8. EXPOSURE CONTROLS / PERSONAL PROTECTION Engineering Controls Provide adequate explosion-proof, general and exhaust ventilation to meet TLV requirements and keep out of explosive range. Ventilate low-lying areas such as sumps and confined spaces. Personal Protective Equipment EYES: Chemical goggles or safety shield. SKIN: Full protective dothing, boots, and gloves. RESPIRATORY PROTECTION: Wear NIOSH-approved air-supplied or self-contained breathing apparatus for non-routine and emergency work. Page 4 of 10 ABD00029819 MSOSCOOE: REVISION: VCM 01/96 Villa Chemical Company P O. Box 19029 Houston, Texot 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PRUT DATE: 03/21/96 Exposure Guidelines: Component VINYL CHLORIDE OSHA PEL 1.0 ppm, 8-hour TWA 5.0 ppm peak exposure for 15-min. ACGIH TLV 5.0 ppm, 8-hour TWA PEL Peraftafbl* Exposure ifaftt TIV Threshold Halt Value TUA Tfm Weighted Averse* (6 hr.) ST6L Short Tera Exposure Halt (IS aln.) Carcinogenicity VINYL CHLORIDE Carcinogen according to the NTP Annual Report. Carcinogen according to OSHA. Carcinogenic to humans according to IARC 9. PHYSICAL AND CHEMICAL PROPERTIES APPEARANCE: Colorless gas. Liquid under pressure. VISCOSITY: 0.281 cp -4*F/-20*C ODOR: Faint, sweet odor: PHYSICAL STATE: Gas, liquid under pressure. VAPOR PRESSURE (nun Hg.): 1,293 32*F/0*C 2,943 77T/25X VAPOR DENSITY (Air-1): 2.15 BOILING POINT: 7.0*F (-14*Q MELTING POINT: -245*F (-153*C) SOLUBILITY IN WATER: 1.1 ml/l 77*F/25*C SPECfflC GRAVITY (H20-1): 0.912 68*F/20*C 10. STABILITY AND REACTIVITY CONDITIONS TO AVOID: Exposure to air, oxygen, sunlight, moisture, heat, and all sources of ignition. Page 5 of 10 ABD00029820 Vista Chemical Company P O. Bo* 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A MSOSCOOC: REVISION: VCM 01/96 REVISION OATE: 03/00/96 HUNT OATE: 03/21/96 D INCOMPATABUJTY WITH OTHER MATERIALS: Oxidizing materials, copper or copper alloys, aluminum or aluminum alloys, other metals which form acetylides. HAZARDOUS DECOMPOSITION PRODUCTS: Hydrogen chloride, carbon monoxide. HAZARDOUS POLYMERIZATION: Polymerizes slowly in presence of air, sunlight, or oxygen and rapidly in the presence of peroxides, generates considerable heat. 11. TOXICOLOGICAL INFORMATION EYES: Dryness of eyes has been reported in humans exposed to 500 ppm vinyl chloride. SKIN: No known data. INHALATION: Short-term inhalation exposure to high concentrations (> 500 ppm) of vinyl chloride has been shown to cause mucosal irritation and impairment of the central nervous system in humans and liver damage in mice. INGESTION: Ingestion is not an expected route of exposure. 12. ECOLOGICAL INFORMATION ECOTOXICOLOC3CAL INFORMATION: Not available. CHEMICAL FATE INFORMATION: Not available. Page 6 of 10 ABD00029821 MSOSCOOC: REVISION: VCM 01/96 Vista Ckemical Company P. O. Sox 19029 Houston, Texas 77221-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PfUNT DATE: 03/21/96 13. DISPOSAL CONSIDERATIONS SPECIAL INSTRUCTIONS: Evacuate the area and eliminate ignition sources. Contain the sptfl. Wet down the area with large quantities of water. Dissipate vapor with water spray. Increase ventilation if in an enclosed area. Stop leak or remove leaking cylinders. Do not attempt recovery of spilled material. Material will vaporize rapidly. Prevent liquid or vapors from entering sewers or other low areas. WASTE CLASSIFICATION: If discarded in its purchased form, this product would have the EPA Hazardous Waste Number of U043. Re-evaluation of the product may be required by the user at die time of disposal, since the product uses, transformations, and mixtures may change the classifications. EMPTY CONTAINERS: Empty containers retain product residue (liquid and/or vapor) and can be dangerous. DO NOT PRESSURIZE, CUT, WELD, BRAZE, SOLDER, DRILL, GRIND, OR EXPOSE SUCH CONTAINERS TO HEAT, FLAME, SPARKS, STATIC ELECTRICITY, OR OTHER SOURCES OF IGNITION; THEY MAY EXPLODE AND CAUSE INJURY OR DEATH. Empty drums should be completely drained, properly bunged and promptly returned to a drum reconditioner, or properly disposed of. (See Section 6 for CERCLA Reporting Requirements) 14. TRANSPORT INFORMATION DOT DESCRIPTION: This product is regulated as a hazardous material as defined by die Department of Transportation. PROPER SHIPPING NAME: Vinyl Chloride HAZARD CLASS: 2.1 IDENTIFICATION NUMBER: NA 1086 PACKING GROUP: None ADDITIONAL INFORMATION: RQ (Vinyl Chloride) - 1 lb. ICAO / IATA DESCRIPTION: This product is regulated as a dangerous good as defined by IATA for air transportation. PROPER SHIPPING NAME: Liquefied gas, flammable, n.o.s. HAZARD CLASS: 2.1 UN NUMBER: UN 3161 PACKING GROUP: None ADDITIONAL INFORMATION: RQ (Vinyl Chloride) * 1 lb. (vinyl chloride) Page 7 of 10 ABD00029822 MSOSCOOC: REVISION: VCM 01/96 Vijta Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 HUNT DATE: 03/21/96 IMO DESCRIPTION (IMDG CODE): This product is regulated as a dangerous good as defined by the IMDG Code for marine transport. PROPER SHIPPING NAME: Vinyl Chloride, inhibited HAZARD CLASS: Class 2.1 IDENTIFICATION NUMBER: UN 1086 PACKING GROUP: None ADDITIONAL INFORMATION: RQ (Vinyl Chloride) - 1 lb. 15. REGULATORY INFORMATION U.S. Federal Regulations OSHA HAZARD COMMUNICATION STANDARD CLASSIFICATION: Toxic, carcinogen, pyrophoric, and compressed gas as defined by the OSHA Hazard Communication Standard. TSCA INVENTORY LISTING: Component. CAS Number Vinyl Chloride 7541-4 SARA 302 STATUS: Component. CAS Number Mavlmtim WtT % Contains no chemicals subject to SARA 302 reporting. SARA 311/312 CLASSIFICATION: SARA 311/312 "Immediate (acute) health hazard", "Delayed (chronic) health hazard", "Fire hazard", "Pressure hazard". SARA 313 CHEMICALS: Component CAS Number Maximum Wt. % VINYL CHLORIDE 75-01-4 99.99 (See Section 6 for CERCLA Reporting Requirements.) Page 8 of 10 ABD00029823 MSOSCOO& VCM REVISION: 01/96 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VISTA REVISION DATE: 03/03/96 FRMT DATE: 03/21/96 International Regulations WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM (WHMIS) CLASSIFICATION: Cass D, Division 2, Subdivision A: Very toxic material. Class D, Division 2, Subdivision B: Toxic material. Class A, Compressed Gas Class B, Division 6: Reactive flammable material. CANADIAN DOMESTIC SUBSTANCE LIST (DSL) INVENTORY LISTING: Chemical Name CAS Number Vinyl Chloride 75-01-4 EUROPEAN INVENTORY OF EXISTING COMMERCIAL CHEMICAL SUBSTANCES (EINECS) LISTING: Chemlal Name EINECS Number Ethene, Chloro- (C2H3CL) 2008310 JAPANESE MINISTER OF INTERNATIONAL TRADE AND INDUSTRY (Mm) INVENTORY LISTING: rWilrel Name SECTION STRUCTURE Vinyl Chloride 2-117 AUSTRALIAN INVENTORY OF CHEMICAL SUBSTANCES (AICS) LISTING: Chemical Name CAS Number Vinyl Chloride 75-01-4 State Regulations CALIFORNIA SAFE DRINKING WATER ACT (PROP 65) LISTING: Component CAS Number VINYL CHLORIDE 7501-4 Page 9 of 10 ABD00029824 MSOSCOOC: REVISION: VCM 01/96 Vista Chemical Company P O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION OATE: 03/03/96 PRMT DATE: 03/21 /96 16. OTHER INFORMATION Hazard Ratines NfPA HEALTH: FLAMMABILITY: REACTIVITY: 4 4 1 HMIS 4. 4 1 THE DATA AND INFORMATION CONTAINED HEREIN ARE BEING FURNISHED FOR INFORMATIONAL PURPOSES OHY, UPON THE EXPRESS CONDITION THAT EACH CUSTOMER SHALL MAKE ITS OWNASSESSMENT OFAPPROPRIATE USE AND APPROPRIATE SHIPPING, TRANSFER AND STORAGE MATERIALS AND PROCEDURES FOR VISTA CHEMICAL COMPANTS PRODUCTS. ALTHOUGH BASED ON INFORMATION SOURCES WHICH VISTA CONSIDERS ACCURATE AND RELIABLE. VISTA MAKES NO WARRANTY. EITHER EXPRESS OR IMPLIED. INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, REGARDING THE VALIDITY OF THIS INFORMATION. THE INFORMATION SOURCES UPON WHICH THE SAME ARE BASED, OR THE RESULTS TO BE OBTAINED, AND EXPRESSLY DISCLAIMS LIABILITIES FOR DAMAGES OR INJURIES RESULTING FROM THE USE THEREOF. PREPARED BY: PHONE NUMBER: Vista Safety, Health and Environmental Department (713) 588-3491 Page 10 of 10 ABD00029825 HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: 05/05/93 PAGE 01 CAS # 000098-83-9 FORMULA: C(6)H(5)C(CH(3)):CH(2) CHEMICAL FAMILY: Aromatic Hydrocarbon CHEMICAL NAME AND SYNONYMS: Alpha-Methylstyrene; Isopropenylbenzene; 1-Methyl-l-Phenyletfiylene? 2-Phenylpropylene. MANUFACTURERS NAME: Allied Corporation SUPPLIERS NAME: Harcros Chemicals Inc 5200 Speaker Rd Kansas City Ks SUPPLIERS PHONE NUMBER: 913-321-3131 TRANSPROTATION EMERGENCY PHONE NUMBER: 1-800-424-9300 66106 S.A.R.A. INFORMATION HAZARDS: Fire:Yes Pressure:No Reactivity:No Agut$: Yes Chronic:Yes PHYSICAL DATA: Mixture:No Pure:Yes Solia:No Liquid:Yes Gas:No TION I Hazardous Ingredients INGREDIENTS PERCENT Alpha Methyl Styrene Approx 100 AIR CONTAMINANT LEVELS TLV/TWA 8Hr 50 ppm STEL 8Hr 100 ppm ACGIH/OSHA SECTION II Health Hazards Threshold Limit Value: As given in Section I. Potential Effects of Exposyre (listed by primary routes of entry) Unusual Chronic Toxicity: Systemic Effects: No systemic effects have been noted m workers repeatedly exposed to low concentrations of alpha-methylstyrene monomer. Eyes: Liquid alpjia-tpethylsty rene monomer and concentrated vapors are extremely irritating t o the eyes. IRDS: Eye-Rabbit 91 mg MLD. Skin: Prolonged skin contact can cause severe irritation, rashes swelling and blistering. Repeated skin contact with alpha-methylstyrene monomer may produce dermatitis. nhalation: In concentration above 400 ppm, alph^-methylstyrene monomer is irritating to all parts of the respiratory tract. TXDS: INH-HMN TCL(o)=600 ppm, LC(50) (Mouse):3020 mg/m(3). nqestion: When taken by mouth, alpha-methylstyrene monomer causes a pronounced irritation or mouth, esophagus and stomach ral LD(50) (Rati: 4900 g/kg CONTINUED ON PAGE 02 ABD00029826 HARCROS CHEMICALS INC KANSAS CITY, KANSAS t- MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: 05/05/93 PAGE 02 / SECTION II Health Hazards First aid: CONTINUED Eye?: Wash eyes copiously with water for 15 minytes occasionally lifting the lower and upper lids. Obtain medical attention promptly. Skin: Immediately wa?h skin with soap and water while removing contaminated clothing. Launder contaminated clothing before reuse. Obtain medical attention promptly. Inhalation: Remove the patient fyom contaminated atmosphere to fresh air. If not breathing, give artificial respiration, preferably moyth-to-mguth. If breathing is difficult, give oxygen which i? administered only by trained personnel. Obtain medical attention promptly. Ingestion: If swallowed, DO NOT INDUCE VOMITING. Get medical attention immediately. Keep patient warm and quiet. Other Information: None SECTION III Special Protection Information Respiratory Protection: Less than 1,000 ppm; Chemical cartridge respirator with an organic vapor cartridge and with a full face piece. More than 1,000 ppm: Self-contained breathing apparatus with a full face piece. Escape: Self-contained breathing apparatus. Ventilation Required: Ventilation must be adequate to keep the . , atmospheric concentration of aipha-metnylstyrene monomer below PEL/TLV limitations Protective Clothing: Eyes: If liquid contact likely: Wear safety glasse? with cup-type side shields or chemical goggles, and face shield. If vapor contact likely: Wear personal protective equipment described under "respiratory protection. Skin: Natural rubber gloves? safety shoes and hard hat, where gross contact with liquid unavoidable the handler should also include a natural rubber jacket, trousers, as well as the above. Additional Protective Measures: Rubber carrier for glass containers. Natural rubber jacket, trousers and shoes or boots. Emergency showers, emergency eye wash fountains and fire blankets. CONTINUED ON PAGE 03 ABD00029827 HARCROS CHEMICALS INC KANSAS CITY, KANSAS PRODUCT NAME: PRODUCT CODE: MATERIAL SAFETY DATA SHEET ALPHA METHYL STYRENE 420# 16-00446-02 DATE: 05/05/93 PAGE 03 SECTION IV Fire & Explosion Hazard Data Flash Point (Method): 118 deg. F. (Closed cup) Autoignition Temperature: 574 deg. C. Flammable Limits (% Volume in Air): Upper: 6.1% Lower: 1.9% Extinguishing Media: Agents Recommended: Small Fire: Use dry chemical or carbon dioxide Large Fire: Use water spray or foams. Agents to Avoid: No standard agent. Special Fire Fighting Procedures: Wear self-contained breathing apparatus approved by NIOSH. Use water spray to cool tenks. Fight fire from safe distance or from a protected location. BEWARE: Vapor is heavier than ajr en$ may travel (i.e., crawl) along the ground to a source of ignition and flash back. Unusual Fire and Explosion Hazards: Alpha-methylstyrene monpmer ;s a combustible liquid and can form explosive mixtures with.air. Open flames, local hot spots, friction, static electricity and ajl other sources of ignition are to be avoided when working with this material. SECTION V Physical Data Boiling Point: 329 deg. F. Melting Point: 9.4 deg. F. Specific Gravity (H(2)0=l): 0.914 @ 60/60 deg. F. Vapor Pressure (MM HG.): 1.9 Vapor Density (AIR=1): 4.1 Evaporation Rate (Butyl Acetate=l): Approx. 0.4 Solubility in Water: 0.043 wt. % @ 77 deg. F. Percent Volatile by Volume: (@ 68 deg. F.): Approx. 7 pH: Approx. 7.0 Molecular Weight: 118.19 CONTINUED ON PAGE 04 \ ABD00029828 HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: 05/05/93 PAGE 04 '' SECTION V Physical Data Material is (At Normal Conditions): Liquid CONTINUED Appearance and Odor: Water white liquid - characteristic sharp, aromatic odor. SECTION VI Reactivity Data Stability: Stable Conditions to Avoid: Combustible liquid. Keep $way frpm heat, sparks and flame. Electrically ground all handling equipment. I ncompatibi1ity: Materials to Avoid; Strong oxidizing agents (including halogens and peroxides); oleum; sulfuric acid. . Hazardous Decomposition Product?: Complete combustion results in formation of carbon dioxide ana water vapor; incomplete combusion can yield carbon monoxide. Avoid breathing vapors or gases released on exposure to high temperature or fire.. Hazardous Polymerization: May Occur Exhibits little tendency to polymerize thermally at temperatures up to ?92 aeg. F. Strong acids (e.g., concentrated sulfuric acid) cause polymerization at room temperature. SECTION VII Spill and Leak Procedures Steps to be taken if material is released or spilled: Eliminate all sources of ignition in the viciyity of spill 9* released vapors. Isolate and adequately yentilate the spill area. Permit only trained personnel wearing full personal protective clothing and equipment (see "NORMAL HANDLING in Spc. x) to enter the $pill area. Terminate the leak immediately, if possible. Contain the spill; do not allow alpha-methylstyrene to enter sewer or waterway. If necessary, dike with ary sand, earth or vermiculite. Spills of alpha-methylstyrene.should be reported to appropriate federal, state and local Enyironmental Agencies, including The National Response Center I800-4?4-8802). It absorbed with earth, dry sand,or vermicylite, place in drums, seal dryms and lybel drums and dispose of in approved hazardous waste disposal site. Waste Disposal Method: The waste material should be treated and/or disposed of at a site authorized to handle hazardous chemical waste., . . Appropriate federal, state and local regulatory authorities should be contacted before discharge, treatment or disposal of waste material. Disposer must comply with federal, state and local disposal or discharge laws. It disposed of as shipped, this material is a RCRA igmtable waste having a hazardous CONTINUED ON PAGE 05 ABD00029829 w. HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: SECTION VII Spill and Leak Procedures waste ID No. D001 (40 CFR 261.21) 05/05/93 PAGE 05 CONTINUED SECTION VIII D.O.T. Shipping Information Proper Shipping Name: Hazard Class: ID Number: Label Requirements: Reportable Quantity: Other Information: NONE NONE NONE NONE NONE SECTION IX Additional Information This information may be of importance to you: NORMAL HANDLING: CAUTION! Combystible liquid. Keep away froip heat, sparks and flame, Electrically ground all handling equipment. Keep container closed, yse,adequate ventilation (cf. Section III Respiratory protection). Observe OSHA Regulations on exposure limits. Avo;d prolonged or frequently repeated breathing of vapors. Avoid prolonged or frequent contact with skin. Wear protective gear as described in Section III. STORAGE: Protect container against physical damage. Store in accordance with QSHA Regulation 29 CFR 1910.106 in a cool, well-ventilated location equipped with automatic sprinklers or fife extinguishing system. Keep away frgm sources of ignition and oxidizing materials. "Empty" containers, unless thoroughly cleaned, must be assumed to have the same hazards as full ones. Allied Corporation Product Label Wording. CAUTION! COMBUSTIBLE Empty Container Warning Label. SPECIAL PRECAUTIONS/PROCEDURES: Care should be exercised when transporting material to prevent leaks. Keep drums containing alpha-methylstyrene tightly closed and away from heat, sparks and open flame?. vent drum or shipping tank before unloading. Wear protective clothing and equipment (see Section III.) when unloading. DEGRADABILITY: No pertinent data on file. CONTINUED ON PAGE 06 ABD00029830 HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: SECTION IX Additional Information OCTANOL/WATER PARTITION COEFFICIENT: 2,238 05/05/93 PAGE 06 CONTINUED REFERENCES: Permissible Concentration References: OSHA Regulation 29 CFR 1910.1000. TLV and STEL recommendations - ACGiH 86/87. Regulatory Standards: OSHA Regulation 29 CFR 1910.106. D.O.T. Regulations 49 CFR 172.544 and 49 CFR 172.402 MANUFACTURER'S NAME: Allied Corporation Chemical Sector ADDRESS; Morristown, N.J. 07960 EMERGENCY PHONE NUMBER: (201) 455-4157 ********* END OF REPORT ********* NAME GENE TURNER DATE ISSUED: 01/02/1986 DATE REVISED: 08/23/1989 < LESS THAN > MORE THAN . N/A = NOT APPLICABLE N/D NOT DETERMINED N/E * NOT ESTABLISHED UNK = UNKNOWN The information provided in this Materia}. Safety Data Sheet has been obtained from sources believed to be. reliable. . Harcros Chemicals Inc provides no warranties, either expressed or implied and assumes no responsibility for.the.accuracy or completeness of the data contained herein. This information is offer$d for your infor mation, consideration and investigation. You should satisfy yourself that Sou have all current data relevant to.your particular use. . . arcros Chemicals Inc knows of no medical condition, other than those noted on this material safety,data sheet, which ^regenerally recognized as being aggravated by exposure to this product. ABD00029831 MATERIAL SAFETY DATA SHEET GENIUM PUBLISHING CORPORATION IMS CATALYN STREET SCHENECTADY, NY 12303-1636 USA (518) 377-8855 SECTION I, MATERIAL IDENTIFICATION <SP nnnwmwMacom. NO. -US. SOOIUM HYPOCHLORITE AQUEOUS SOLUTION is-m> OAft February 1983 MATERIAL NAME: SOOIUM HYPOCHLORITE, AQUEOUS SOLUTION (5-12%) OTHER DESIGNATIONS: Soda Bleach Liquor Bleach Solution* Hypochlorite Solution. yaoci Solution, SUNNY SOL Bleach (Jones Chemicals), Household Bleach (i.e. CLOROx^ Ptnp3&> MANUFACTURER: Available from many suppliers, including: ' '' Canadian Industries Limited fSftS*1* Jones Chemicals. Inc. i&kmM ttHi Montreal, Quebec H3C 2R3 Tel: (716) 538-2311 SECTION II. INGREDIENTS AND HAZAROS Sodium hypochlorite (CAS 1007 681 529) Water, sodium chloride and sodium hydroxide (if present in excess). (Excess NaOH will pose an increased alkalinity hazard.) "Solution concentration can also be stated in terms of "available chlorine" which is- about 95% of NaOCl content by weight. % HAZARD OATA :a 5-li No TLV Established balance Rat, Oral (12% Solution) ^50 c* 12 *5% soln is reported to be much less toxic. SECTION 111. PHYSICAL DATA Boiling point -- decomposes (see Sect V) Vapor pressure, 20 C, m Hg ------ 17.5 Water solubility ---------- complete pH ("neutral" solution)* ----------------9-10 Molecular weight ---------- 74,4 Specific gravity (20/4C): 5,25% (Household bleach) 8.0%------------------------------------------------------------ 12.0% --------------------------- Freezing point, 12.0%, deg C - .1.09 1.15 1.21 ca -25 Appearance fc Odor: Clear, pale yellow or greenish liquid with a chlorine odor. Some products may contain an axcese of NaOH and have a higher pH. SECTION IV. FIRE AND EXPLOSION OATA floth fowM AMlWOWitln Tny, T FlefWMfclaty IwfNtt in A* Lower Upper Nonflammable Use extinguishing media that is approprlats for-surrounding firs. Use water spray from a safe distance to cool fire-exposed containers, to dilute liquid, and control vapors. It is an oxidizing agent. Vigorous reactions can occur with oxidicable materials in a firs situation. It can be decomposed by heat. Chlorine liberated oh contact with acid. If safe, remove containers from firs arse to prevent pressure rupture. Firefighters should wear full protective clothing and self-contained breathing apparatus. (Protection is needed against corrosive fumes and liquid if released.) SECTION V. REACTIVITY DATA anhydrous material Is unstable, but these water solutions can be satisfactorily stable for months under proper storage conditions. Rats of decomposition increases with the concen tration and with the temperature. (12% NaOCl solution decomposes slowly at-40 C to yield NaCl and NaclO.) . Exposure to sunliqht accelerates decomposition. It is incompatible with acids (liberates chlorine), ammonia, urea, oxidicable matarials, and metals such as nickel, copper, tin, manganese and iron (which cause liberation of oxygen). GENIUM PUBUSHING ABD00029832 NO. 115 Additional ef facts hava included circulatory collapse and deliriia. Liquid contact can rS2d??S.irritation of riRST AID: *** Y* * ^in with blistering and aczama (especially at 124) tya contact? Irrigate ayes with running water fr at least IS minutes. Including under eyelids. Then contact physician at once (ophthalmologist preferred). Skin Contact: Remove contaminated clothing. Plush affected areas with copious amounts of water, or shower. If irritation persists or if large areas of body are affected, contact physician. Treat burns as needed* Inhalation: Remove to fresh air and obtain medical help. IngastionT Have physician contacted immediately. Rinse mouth with water. Give large tuantities of water or milk to drink. Induce vomiting. Repeat. Do not use acidic antiotas or sodium bicarbonate. An ounce of 1% sodium thiosulfate or milk of magnesia is helpful. SECTION VII. SPILL, LEAK. ANO OISPOSAL PROCEDURES notify safety personnel of major spill. Clean-up personnel need protection against contact with liquid and inhalation of mists and fumes. Contain spill and pick up when possible for recovery or disposal. Keep concentrated hypochlorite solutions out of sewers and waterways. Do not use combustible absorbents (such as sawdust) to pick up hypochlorite solutions. Small spills and residues can usually be flushed to a suitable holding area, and then with high dilution to the sewer. DISPOSALi When necessary hypochlorite can be neutralized with weak reducing agents, and then the waste landfilled. Follow Federal, State and Local regulations. SPA (CWA) BQ Is 100 lb. (40CFR 117). Hypochlorite can be harmful to aquatic life. SECTION VIII. SPECIAL PROTECTION INFORMATION Provide general and local exhaust ventilation in the workplace to maintain fumes and mists at a minimum. (Workers should not have irritation effects from exposure.) Respiratory devices should be available for use in non-routine or emergency situations. Use canister1 type respirators suitable for chlorine (See MSDS S3) with mist filters. Kvoid eye contact by use of chemical safety goggles. Use rubber gloves, apron, and other protective clothing appropriate for the work situation to prevent skin contact. Clothing contaminated with liquid to be removed prosptly and rinsed with water. Launder before reuse. Syewash fountains# washing facilities and safety showers should be available in areas of handling and uSe. SECTION IX. SPECIAL PRECAUTIONS ANO COMMITS Store in closed, vented containers in a cool, (below BSF), dry, well-ventilated area away from direct sunlight, heat.and incompatible materials (see Sect V). Keep separate from acids and organics. Use adequate ventilation. Protect containers from physical damage. Do not mix with acidic cleaning agents which can llberata chlorine gas/Avoid Inhalation of vapors, mists and fines. Prevent eye and skin contact. DOT Classification: <7% Available Chlorine,* ORM-B I.D. No. NA 1791 Label: None - (49 CTR 172 101) >7% Available Chlorine, CORROSIVE. 1.0. No UN 1791 Label: CORROSIVE /\ Available Chlorine is about 7.35% NaOCl. . Incompatibls with bowl cleaners containing 0ATA SOURCES) COOC: 1,3-11,14,25,34,37,48,49 bisulfatas. , JiHqwxi no i.lie* f TPW APPROVALS: MIS/CRO INOUST. HYOICNC/ J'27-U MC04CAL REVIEW? 9 March 1983 GENIUM PUBLISHING ABD00029833 c. node" Definition7 TABLES ABD00029834 APPENDIX C NODE DEFINITION TABLES ABD00029835 ABD00029836 ATTRIBUTES OF THE DESIGN GUIOEUORDS ABD00029837 ABD00029838 ABD00029839 ABD00029840 ABD00029841 D. SITING/LAYOUT CHECKLIST ABD00029842 APPENDIX D SITING/LAYOUT CHECKLIST ABD00029843 1 CHECKLIST 23: LAYOUT AND SITTING 1. SPACING BETWEEN PROCESS COMPONENTS 1. Have adequate provisions been made for relieving explosions in process components? Individual pieces of equipment and connecting systems are designed to prevent over pressure situations and/or relief if high pressure occurs. 2. Are operating units and equipment within units spaced to minimize potential damage from fires or explosions in adjacent areas? Yes, the PVC plant is divided into three operating areas. These areas are spaced to minimize disruption from one another. 3. Are there safe exit routes from each unit? Yes, the units are open. 4. Has equipment been adequately spaced and located to safely permit anticipated maintenance (e.g., pulling heat exchanger bundles, dumping catalyst, lifting with cranes) and hot work? Yes, part of design review is a review of the 3D model to check equipment for maintenance access. 5. Are vessels containing highly hazardous chemicals located sufficiently far apart? If not what hazards are introduced? Yes 6. Is there adequate access for emergency vehicles (e.g., fire trucks)? Roadways are kept clear. 7. Can adjacent equipment and facilities withstand the overpressure generated by potential explosions? 8. Can adjacent equipment and facilities (e.g. support structures) withstand flame impingement? Fire protection has been reviewed and approved by insurance carrier. ABD00029844 2 LOCATION OF LARGE INVENTORIES Are large inventories of highly hazardous chemicals located away from the process area? Yes, plant lay out has the unloading and storage area away from process areas. Units are designed to hold less VCM than is needed for a reactor change. Is temporary storage provided for raw materials and finished products at appropriate locations? Yes Are the inventories for highly hazardous chemicals held to a minimum? Yes Where applicable, are reflux tanks, surge drums and rundown tanks located in a way that avoids large volume concentration of highly hazardous chemicals in any one area? Yes, receivers minimize the amount of VCM stored in each unit. Where applicable, has special consideration been given to storage and transportation of explosives? Yes, catalysts are not explosives, but because of their exothermic decomposition properties special handling and storage is required. Have the following been considered in the location of material handling areas: - Fire hazards - Location relative to important buildings - Safety devices (e.g., sprinklers) - Slope of area (is it level?) Yes Yes Yes Yes LOCATION OF MOTOR CONTROL CENTER Is the motor control center located so that it is easily accessible to operators? Yes Are circuit breakers easy to identify? Yes, for the Express Project. ABD00029845 3 3. Can operators safety open circuit breakers? Have they been trained? Only qualified electricians. 4. Is the motor control center designed such that it could not be an ignition source? Yes Are the doors always closed? No, some of existing buildings do not have adequate ventilation. Is a no smoking policy strictly enforced? Yes 5. Is the motor control center designed and meant to be a safe haven? No 4. LOCATION AND CONSTRUCTION OF CONTROL ROOM(S) Express Phase 3 does not have any effect on the design of the existing control room. Hazoping of the control room is not in the scope of this project. This section is left for a plant hazop. Earlier the location of the new unloading station relative to the control room was examined. The method in the dow fire and explosion index was used. The new unloading stations do not pose an increased risk. 1. Is the control room built to satisfy current corporate overpressure and safe-haven standards? 2. Does the construction basis for the control room satisfy acceptable criteria (e.g., the Factory Mutual recommendations)? 3. Are workers protected in the control room (or their escape routes) from all of the following: - Toxic, corrosive or flammable sprays, fumes, mists or vapors - Thermal radiation from fires (including flares) - Overpressure and projectiles from explosions - Contamination from spills or runoff - Noise - Contamination of utilities (e.g., breathing air) - Transport of hazardous materials from other sites - Possibility of long-term exposure of employees to low concentration of process material ABD00029846 4 - Odors - Impacts (e.g., from a forklift) - Flooding (e g., ruptured storage tank) 5. Were the following characteristics considered when the control room location was determined: - Types of room construction - Types/quantities of materials - Direction and velocity of prevailing winds - Types of reactions and processes - Operating pressures and temperatures - Ignition sources - Fire protection facilities - Drainage facilities 6. If windows are installed, are they of rigid construction with sturdy panes (e.g., woven wire reinforced glass)? 7. Is at least one exit located in a direction away from the process area? Do exit doors open outward? Are emergency exits provided for multistoried control buildings? 8. Are ends of horizontal vessels facing away from control rooms? 9. Are critical pieces of equipment in the control room well protected? Is adequate barricading provided for the control room? 10. Are open pits, trenches or other pockets where inert, toxic or flammable vapors could collect located away from the control buildings or equipment handling flammable fluids? 11. Where piping, wiring and conduit enter the building, is the building sealed at the point of entry? Have other potential leakage points into the building been adequately sealed? 12. Is the control room located a sufficient distance from excessive vibration sources? 13. Is positive pressure maintained in control rooms located in hazardous areas? 14. Could any structures fall on the control room in an accident? ABD00029847 5 15. Is the control room roof free from heavy equipment and machinery? 5. LOCATION OF MACHINE SHOPS, WELDING SHOPS, ELECTRICAL SUBSTATIONS AND OTHER LIKELY IGNITION SOURCES 1. Are likely ignition sources (e.g., maintenance shops, roads, rail spurs) located away from release points for volatile substances (both liquid and vapor)? Yes 2. Are process sewers located away from likely ignition sources? Yes 3. Are all vessels containing highly hazardous chemicals or components containing material above its flash point located away from likely ignition sources? Yes 4. Are the flare and fired-heater systems located to minimize hazards to personnel and equipment, with consideration given to normal wind direction and wind velocity and heat potential? Yes 6. LOCATION OF ENGINEERING, LAB, ADMINISTRATION OR OTHER BUILDINGS 1. Are administration buildings located away from inventories of highly hazardous chemicals? Yes 2. Are administration buildings located away from release points for highly hazardous chemicals? Yes 3. Are workers in administration buildings protected from all of the following? - Toxic, corrosive or flammable sprays, fumes, mists, or vapors - Thermal radiation from fires (including flares) - Overpressure and projectiles from explosions - Contamination of utilities (e.g., water) - Contamination from spills or runoff - Noise Yes Yes Yes Yes Yes Yes ABD00029848 6 - Transport of hazardous materials from other sites - Flooding (e.g., ruptured storage tank) - Odors Yes Yes Yes UNIT LAYOUT AND LOCATION OF FACILITY RELATIVE TO NEIGHBORS Are large inventories or release points for highly hazardous chemicals located away - from public access roads? - vehicular traffic within the plant? Yes Yes Is the unit, or can the unit be, located to minimize the need for offsite or intrasite transportation of hazardous materials? VCM comes from the Lake Charles plant. It is unloaed safely. Are workers in adjacent units protected and workers in this unit protected from the effects of adjacent units or facilities from all of the following? - Releases of highly hazardous chemicals - Toxic, corrosive or flammable sprays, fumes, mists or vapors - Thermal radiation from fires (including flares) - Overpressure from explosions - Contamination from spills or runoff -Odors -Noise - Contamination of utilities (e.g., sewers) - Transport of hazardous materials from other sites - Impacts (e.g., airplane crashes, derailments) - Flooding (e.g., ruptured storage tanks) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Could specific siting hazards be posed to the site from credible external forces such as high winds, earth movement, utility failure from outside sources, flooding, natural fires and fog? This area is susceptible to high winds and tornadoes. Designs are per applicable codes, e.g., ASCE. Is there adequate access for emergency vehicles (e.g., fire trucks)? Yes Are access roads free of the possibility of being blocked by trains, highway congestion, spotting of rail cars, etc? ABD00029849 7 Railcars do cross some roads and at certain times of day could block roads. 6. Are access roads well engineered to avoid sharp curves? Yes, there are no sharp curves. Roads and plant layout are designed to allow crane access to equipment in the units. Are traffic signs provided? Yes 7. Is vehicular traffic appropriately restricted from areas where pedestrians could be injured or equipment damaged? Roads going into the unit have swing gates. A permit is required for vehicle to enter the operating unit. Contractors do not always follow procedures. 8. Are cooling towers located such that fog, generated by them, will not be a hazard? Yes 9. Are the ends ofhorizontal vessels facing away from personnel areas? Yes 10. Is hydrocarbon-handling equipment located outdoors? All equipment is out doors. 11. Are pipe bridges located such that they are not over equipment, including control rooms and administration buildings? Yes, away from major equipment. 12. Is piping design adequate to withstand potential liquid loads? Yes 8. LOCATION OF FIREWATER MAINS AND BACKUP (E.G., DIESEL PUMPS) 1. Are firewater mains easily accessible? Firewater mains are located throughout the plant. ABD00029850 8 2. Are firewater mains and pumps protected from overpressure and blast debris impact? Yes, firewater pumps are in buildings and located away from units. 3. Is an adequate water supply available for fire-fighting? Yes, a study was done to determine present flow rates and plan for needs of the expansion. 4. Are the firehouse doors pinged away from the process area so that doors will not be damaged by an explosion overpessure? There is not a firehouse in the plant. 9. LOCATION AND ADEQUACY OF DRAINS, SPILLS, BASINS, DIKES AND SEWER 1. Are spill containments sloped away from process inventories and potential fire sources? Dike areas contain a spill and can be collected or drained to the process sewer. Non tank areas have concrete surfaces that slope to the process sewer. Tanks have dikes. 2. Have precautions been taken to avoid open ditches, pits, sumps or pockets where inert, toxic or flammable vapors could collect? Pits, sumps, etc., are kept to a minimum. Where there are pits and sumps procedures are in place to manage activities in these areas. 3. Are process sewers that transport hydrocarbons closed systems? Yes 4. Are concrete bulkheads, barricades or berms installed to protect personnel and adjacent equipment from explosion and/or fire hazards? Barricades and berms are not used in this plant. 5. Are vehicle barriers installed to prevent impact to critical equipment adjacent to high traffic areas? Yes, vehicle barriers are placed anywere a vehicle may run into equipment or structures. ABD00029851 9 6. Do drains empty to areas where material cannot pool? Yes 7. Can dikes hold the largest tank's capacity? Yes, dikes are sized based on tank capacity and rainfall. 8. Is there access in and out of dikes, pits, etc.? Yes, ramps are used to provide access in and out of diked areas. 10. LOCATION OF EMERGENCY STATIONS (SHOWERS, RESPIRATORS, PERSONNEL PROTECTIVE EQUIPMENT, ETC.) 1. Are emergency stations easily accessible? Yes 2. Are first-aid stations prudently located and adequately equipped? Yes, there is one station at the Lab. 3. Are safety showers heated/freeze-protected/wind-protected? Plant is discussing ways to adequately protect safety showers during cool weather. 4. Is there a control room alarm for water flow from a safety shower and eyewash station? No Is there a need for such an alarm? No 11. PLANNING 1. What expansion or modification plans are there for the facility? Express Phase 1 added an external stripping columns, a new dryer and additional unloading capacity. Express Phase 2 adds two more stripping columns. External stripping lowers hydrocarbon emissions. Express Phase 3 adds two more reactors, another dryer, and utilities such as water recycle and cooling water. ABD00029852 10 2. Can the unit be built and maintained without lifting heavy items over operating equipment and piping? All except for the OM stripper. Extra precautions were taken during construction. 3. Are calculations, charts and other documents available that verify facility siting has been considered in the unit layout? Facility siting was done but the documentation was not kept. Do these documents show that consideration has been given to the following: - Normal direction and velocity of wind - Atmospheric dispersion of gases and vapors - Estimated radiant heat density that might exist during a fire - estimated overpressure 4. Are appropriate security safeguards in place (e.g., fences, guard stations)? Yes 5. Are gates located away from the public roadway so that the largest truck can move completely of the roadway while waiting for the gates to be opened? Yes 6. Where applicable, are safeguards in place to protect high structures against low flying aircraft? Not required by Code. 7. Are adequate safeguards in place to protect employees against exposure to excessive noise, considering the commutative effect of equipment items located close together? Noise is considered in equipment design. Efforts are made to design and purchase equipment with low noise levels. The plant does noise level surveys, where necessary signs are posted requiring ear plugs. 8. Is adequate emergency lighting provided? Is there adequate redundant backup power for this lighting? 9. Are procedures in place to restrict nonessential or untrained personnel from entering hazardous areas? Yes, plant policy requires training before entering units. ABD00029853 11 10. Are indoor safety-control systems such as sprinklers and fire walls provided in buildings where personnel will frequently be located, such as control rooms and administrative buildings? Yes 11. Are evacuation plans (from buildings, units, etc.) adequate and accessible to personnel? Yes 12. Are evacuation drills conducted routinely? Yes ABD00029854 E. HUMAN FACTORS CHECKLIST ABD00029855 APPENDIX E HUMAN FACTORS CHECKLISTS ABD00029856 1 CHECKLIST 24: HUMAN FACTORS HOUSEKEEPING AND GENERAL WORK ENVIRONMENT 1.01 Are working areas generally clean? Yes, employees are responsible for keeping their area clean. Work areas are regularly checked and feedback given. 1.02 Are adequate signs posted in cleanup and maintenance? Yes, housekeeping notices in specific areas are posted. 1.03 Is the ambient temperature normally within comfortable bounds? Special winter clothing is provided when appropriate. 1.04 Is noise maintained at a tolerable level? Yes, noise us considered when purchasing new equipment. Safety periodically does a noise level survey throughout the plant. Hearing protection is provided and required in certain areas of plant. These areas are clearly marked. 1.05 Is the lighting sufficient for all facility operations? Yes, adequate lighting was addressed as part of the design. 1.06 Is the general environment conducive to efficient performance? Yes. ACCESSIBILITY/AVAILABILITY OF CONTROLS AND EQUIPMENT 2.01 Are adequate supplies of protective gear readily available for routine and emergency use? Yes, there are procedures for employees to get personal protective equipment to perform tasks. Procedures state what PPE is required for given tasks. Policies require when PPE is to be replaced. There are procedures for maintaining emergency gear and having it located at appropriate locations throughout the plant. ABD00029857 2 2.02 Is communications equipment adequate and easily accessible? How would others know that a worker is incapacitated in the process area? There are several types of communication systems: radios, phones and gaitronics. Operators in the field carry radios to coordinate tasks with panel operations and request assistance when necessary. Permit systems coordinates maintenance acitivies in the field. 2.03 Are the right tools available and used when needed? Maintenance procedures cover proper tools and procedures for using tools. 2.04 Are special tools required to perform any tasks safely or efficiently? Yes, the plant has purchased special tools when appropriate to improve safety. Examples are: power torque wrench for working on reactor condenser seals. Process safety information is kept updated and available. 2.05 What steps are taken to identify and provide special tools? When problems are identified they are brought to supervisors and possible solutions are discussed. Or employees come to supervisors with suggestions for improvements in doing routine tasks. 2.06 Is the whole workplace arranged so that the workers can maintain a good working posture and perform a variety of movements? Project Designs are reviewed to ensure accessibility in and around equipment. Safety training is used to teach and reinforce proper methods for bending, lifting and carrying. 2.07 Are all controls accessible? Yes, controls are designed and constructed for accessibility. 2.08 Is access adequate for routine operation and maintenance of all equipment? Yes. COMPONENT LABELING 3.01 Is all important equipment (vessels, pipes, valves, instruments, controls, etc.) clearly and unambiguously labeled? ABD00029858 3 During commissioning and start up the project has labeled equipment, instruments and piping. 3.02 Does the labeling program include components (e.g., small valves) that are mentioned in the procedures event if they are not assigned an equipment number? No, generally not. 3.03 Are plant instruments and controls clearly labeled? Field labels are put on each instrument. Additionally all instruments are provided with permanent metal tags. 3.04 Are the labels accurate? Yes 3.05 Who is responsible for maintaining and updating the labels? Labels are installed as part of projects. There is no system for maintaining labels. 3.06 Are emergency exit and response signs clearly visible and easily understood? N/A. These units are outdoors. FEEDBACK/DISPLAYS 4.01 Is adequate information about normal and upset process conditions displayed in control room? Yes, process reading and alarms are displayed on the distributive control system. 4.02 Are the controls and displays arranged logically to match the expectations of the operators? Operators review new displays and graphics for comments during a project. 4.03 Are the displays adequately visible from all relevant working positions? Control room layout was designed for optimum visibility for all operators. 4.05 Do separate displays present information in a consistent manner? Programming standards were developed as guidelines for consistency in developing displays. ABD00029859 4 4.06 Are related displays and controls grouped together? Yes 4.07 Is the information displayed in ways the operator can understand? Yes, operator training explains new controls and how they operate. Operator comments are used as feedback for making improvements on displays. 4.08 Are the operators provided with enough information to diagnose an upset when an alarm sounds? Yes, instrument alarms and program messages are used to help the operator understand how the unit is operating. 4.09 Are the alarms displayed by priority? Are critical safety alarms separate from control alarms? Yes. Alarms mainly indicate control alarms. Unsafe conditions are programmed to cause action by interlocking instruments and equipment to bring conditions back to a safe state. Interlocks happen automatically without being initiated by operators. 4.10 Is an alarm summary permanently on display? No, when an alarm occurs a sound is activated and a message flashes on the lower right hand corner of the screen. Selecting the flashing message brings up the alarm. 4.11 What kinds of calculations do the operators perform when reading displays, and how are these calculations checked? None 4.12 Do the displays provide an adequate view of the entire process as well as essential details of individual systems? Yes, there are overview graphics and detail graphics. 4.13 Do the displays give rapid feedback for all operational actions? Yes 4.14 Do all mimic displays (board or screen) match the actual equipment configuration? Yes, graphics are updated when systems are changed. ABD00029860 5 CONTROLS 5.01 Is the layout of the consoles logical, consistent, and effective? Yes, the layout was intended to maximize communication and effectiveness. 5.02 Are the controls distinguishable and easy to use? Yes, programming standards describe how controls are to be configured. 5.03 Do any controls violate strong expectations (color, direction of movements, etc.)? No, if there is any confusion a change order is written to correct the display. 5.04 Do the control panel layouts reflect the functional aspects of the process or equipment? Yes, control panels are flow diagrams of the process and include the main control loops. 5.05 Does the control arrangement logically follow the normal sequence of operation? Yes 5.06 What are the consequences of operator intervention in computer-controlled equipment? Operations can stop and start the automation sequences at any time. The programming brings equipment to a safe condition when stopped and start the equipment safely bringing it up to normal operating conditions. Interlocks prevent operators from opening valves or starting equipment at inappropriate times. 5.07 Are any process variables difficult to control with the existing equipment? No 5.08 Does the control logic seem adequate? Yes 5.09 Is there a dedicated emergency shutdown panel, and where is it located? Yes, it is located by the DCS consoles. PROCEDURES ABD00029861 6 6.01 Is a complete, current set of procedures for startup, shutdown, normal operation, and emergencies available for workers to use? Yes, they are kept in the vinyl control room. 6.02 Are procedures written for the workers, considering their education, background, experience, native language, etc.? Yes, operations helped write and review the procedures. 6.03 Is a step-by-step format used and are the steps in the correct order? Yes 6.04 Are diagrams, photographs, drawings, etc., used to clarify the written text? Diagrams, drawings and flow sheets are used in training but are not part of the written procedures. 6.05 Are cautions and warnings clearly stated in prominent locations before the potentially dangerous action? Yes, the format for writing procedures tells how warnings and cautions should be shown to attract readers attention. 6.06 Are checklists used for critical procedures with only one action specified per numbered step? Yes 6.07 Do steps requiring control actions also specify the correct system response? Yes WORKLOAD AND STRESS FACTORS 7.01 Are the operators only in the control room, or do they work in a variety of locations? Reactor panel operators stay in the control room. Dryer operators must do some field work throughout the day. Reactor operators must cover the dryer panel when dryer operators are out in the field. ABD00029862 7 7.02 How many manual adjustments must a worker perform during normal and emergency operations? Operators must monitor process and keep parameters within right ranges. During emergency power loss operators must manually open emergency cooling water valves and sometimes manually add stop agent to reactors. 7.03 What is the normal operating shift duration? Is this duration appropriate based on its impact on alertness/fatigue? 12 Hour shifts. Yes 7.04 How many extra hours must an operator work if his/her relief fails to show up? Maximum 4 extra hours. 7.05 How many hours to operators/maintenance personnel typically work on a shift during startup or turnarounds? 12 Hour shifts. The number of consecutive days worked is monitored so as not to cause problems. 7.06 Has the operator's mobility been considered in selecting the design ofprotective gear for certain tasks, including emergency response? Yes GENERAL Issues 8.01 Have the operators made any modifications to the displays, controls, or equipment to better suit their needs? Operators don't make the modifications, they make the formal request and a controls engineer executes the change. 8.02 Is there formal mechanism for correcting human factors deficiencies in the human/machine interface? Yes ABD00029863 8 8.03 What means are provided to allow personnel to compensate for errors? Can personnel detect an error they or someone else makes with sufficient time to correct the error? Different alarm levels allow operators to take corrective action before automatic shutdown. Also the system will check whether parameters are within correct range before accepting them. 8.04 Is the control room adequately located relative to the process? The control room is located in proximity of the unit and at a safe distance from equipment that contains volatile liquids or gases. ABD00029864 F. HAZOP TABLE ABD00029865 APPENDIX F HAZOP TABLE ABD00029866 NOTE: The following are the frequency and consequence categories shown in the HAZOP table: FC: FREQUENCY CATEGORY F : CONSEQUENCE - SAFETY X : CONSEQUENCE - BUSINESS LOSS ABD00029867 NOTE TO AVOID REPETITION IN THE HAZOP TABLE, THE WORDS "NONE" AND "NONE OTHER" ARE USED TO QUALIFY THE CAUSES AND CONSEQUENCES. THE MEANING OF THESE EXPRESSIONS IS PRESENTED BELOW. UNDER CAUSES WHERE IT SAYS: "NONE" IT MEANS: "NO CREDIBLE CAUSE WAS IDENTIFIED BY THE HAZOP TEAM FOR THIS DEVIATION" UNDER CONSEQUENCES WHERE IT SAYS: "NONE" IT MEANS: "NO CONSEQUENCE OF CONCERN (I.E., SAFETY RELATED) WAS IDENTIFIED BY THE HAZOP TEAM FOR THIS DEVIATION" WHERE IT SAYS: "NONE OTHER" IT MEANS: "NO SCENARIO OF CONCERN WAS IDENTIFIED BY THE HAZOP TEAM OTHER THAN THOSE CONSIDERED ELSEWHERE IN THIS STUDY" ABD00029868 eU<0 --fV 0> O 0) O 0H) ---- a3 3 SS nv ti- --o. 0. ' <1 >* i JII HitOO DESIGN IN T E N T IO N : STORAGE OF VCM 1 0 1 .1 0 HIGH INTERFACE E 4> s-i 2 u uj j u a 5 0. Tu t- X 3 g U 4 H X Q a XN CM3 o X .z X oM X m \t> r** <D H O H o rH h o H iH O r4 /1 0 1 .0 TANK VESSEL - VCM STORAGE SPHERE ( c o n tin u e d ) ABD00029869 1 0 2 .7 H IG H CONCENTRATION ABD00029870 ABD00029871 EVi I->3) CO 004OV111i oX 13 C"J -Co Co AJ <Or0t TCH> --. rH <N *coH u <0 oh TCH> coi s. vu> uaE H 0 n u c TcJ OxO 4j <a Voal X03) oX & CN c 3Eaa TcJ OV3l <n -iHcH4> *h>4J X</i) J 0H1 O* X-- c3Vi ae3 4V)l >L. 30011 4>0) aU41 U41 u UQa 0) Ua*J C>Q, DESIG N IN T E N T IO N : REMOVE L IQ U ID VCM FROM VAPOR STREAM s -Sh' j .3EcS 4u3> Co OE eH u U -4HJ r E 41 iZ-> Z3i HZ Xu oo LOW CONCENTRATION 1 0 4 .6 ABD00029872 oC3O a4Ua1t n uo --n SH V<NA <H "<CsNN. 1) d lx c0 o^ -UH OIl Sfc 4J 5 O' .mc -h T433J 4H1 O4S1 CHl X aC4UO1 a. . oQ. oa 0H1 OOi4 X-- <UV4H) Cd a JQ 4i m Hae41 Uc<Vol aQ97U>>>. 0O~* H 41 CyaO iaE4-ii n 4m1 4J r4t1 3O 4(4) f-H <4-1 1C) * o C an>> 4) 3eao 4ui a Cl -Xh n<N T3 1<Jd 0<n) Qe 4) m 4CouO1 QE0u. J&H svOl <<NN m DESIG N IN T E N T IO N : TRANSFER OF VCM VAPORS TO UNLOAD R A IL CAR T4J) 3C e 4i 21 oz r* CO 0> o o o Ci) o DESIGN IN T E N T IO N : TRANSPORT L IQ U ID VCM TO ABD00029873 ABD00029874 o X v c H u pH s j: >4 0} o >. E UH ci 41 <0 c 4-1 CD 41 01 01 >. l-i 01 c 41 -H 6 41 41 01 3 >H W H U <u <DD Q | a w & 1 CO o rH <T> oU a CO u >X 0. cn tn 3o o e- 5 to a0 CO X a co H < o <N Cu O O u iJ H 3 D> \ c 0 >H u Ifl u< H ro -a o C (N H ( CO 3 Cu 0 pH O Cl4 O u o aaU3 C Xtaa> fl3 > .* O 1) JT U 3 0 pH MH CQ CQ W U 0) X0 CO th 4J c 14 41 J X 41 in o r-4 41 TJ O C 41 41 ^*1 DESIGN IN T E N T IO N : TRANSPORT L IQ U ID VCM TO CD uCQ D c o "D 41 Uc o ci cn cH X a> 1) D) 0) 0 > 3 v > 41 Ol e4) -oC Ji X 0 4) <8 a co ^u ion 41 > <0 > vI- oion f3-i mH c o O! ,26 <8 41 o H O ci 14 Cl H T3 O C 41 c IoD A) O Cl -- a T3 1 01 41 *<H <kol o01 c 4) 41 -uC o 4cH) J 4a-1 4i WE C4/1l -X f01f4l 41 C zo oi <*n VoO voo voo M IS S IN G COMPONENT 1 0 6 .4 ABD00029875 1 0 8 .0 PROCESS L IN E - VCM STORAGE SPHERE RECIRCULATION (d w g : V S -0 9 3 1 0 5 -P ID -D ) ABD00029876 ABD00029877 DESIGN IN T E N T IO N : EVACUATE REACTOR IN PREPARATION FOR CHARGE 4J 3 03 -Ci 1 <-> SS S' V iOJ 40u) 4c1 C 2o -hc uo J4=) (N 41 C oC c 2 o J C"} <H3H O *H 41 <0 E 41 Si EXTRA WRONG/ COMPONENT 2 0 1 B .6 ABD00029878 None o th e r (see h ig h p re ssu re in node 2 1 1 ) 2 0 1 B .0 REACTOR LIN E - REACTOR, STEP 2 : CHARGE OF INGREDIENTS { c o n tin u e d ) > a> 41 01 ao ns u as 0 Ch J43) *cH 3 O <M 3 O 41 41 as kl 41 -- .C <r uo O IN OJ 41 c 3 O i*J C CHl A 1) --0to) s, * ua 0 IN a i> CO TO3 ZC i ai zo VM i--1 n H U <t\ 2 o3 as X oH a Cl 3 CO *o o H z oM as O H k<lt oH < *-i us as ZM 8c ft as a. O H US H <kl CO (k- *Z as o ti Q 41 kl U3S 01 4k1i a Cl c. 41 '--4a1s -- kl <-> 41 IN c. U 41 O T3 O 41 C i<J4 aOs 3 uCH ouc it a -UC ^<0 4) 41 X as z o u sk H H o z O z r- as as O as a as o IN OO in rj O os w B CO CO CO us aas. 5 to to XQJ US aas. x o z okl X rt <N u cj r-i H o (N (N US aas; p5 M5 2< 2, kt t- 2 uas Xus uas. X w t- Has OX co e3 s QJ M0 X o z n"i lA <J (j 6 H iH <-< OoO CN fN (N LONG TIME 201C.6 ABD00029879 UO & a Q IH TJ -CH --<N V <N aH <--7i DESIGN. IN T E N T IO N : HEATUP OF REACTOR TO REACTION TEMPERATURE 3e3 a . --on> o u t- oV i <0 O > U CV 0X2 U T3 i 9) C <N C O <r> -HO -- ABD00029880 Low amp in d ic a to r /tr a n s m itte r on a g ita to r m otor (92-IT -772) tVu3) a--SI ' *uV u41 q, u E *-* -<0 CJ Q. J3i <<mM ao O -H M- uc u41 V> 0 U 3 u0 (I D1C 3O -CH J V V 3UC U -H o UC ' 4Q1. 41 H> EO> U4) -UH H41 3 Dl 4) Dl -aH -CH -H 4) > c h b 41 3Ia vua uu3 >m. >w 1 aV.-4*) U E r-t -ZH u41 h41 %& *4 -H > H 0 5) ES a m <0 4) 4> O' 4) H e O' H (4 ^4 Q 4) IN O <0 Ol Ol 3 O .2 J <J\ V) -- X u 0 -H X O b. u cE U 4) 4) 3 OO O 41 a. x ffl EV Zi ABD00029881 DESIGN IN TE N TIO N : POLYMERIZATION REACTION a c auwi (3 <0 IHS UU Uc0O1 -u3OC am a wy C 0) -h a VV 0C TOJ zc uvav c-- J= E o Vc tn-H*j o -< cn z flj EV ui >-> 3 Z z oIH 5 t- J M Cd U> < w J U 3 oQ r~ ai U pH O o C4 fS J u >u j X ot-H X a} u--1 o (N a ^ be-l oz <2 CL X o M X o pH cu Cl] pH oo ts f\| a vi Po P> Zw h a oz rH (N pH pH u oi pH o pH o fN r* H gz Q3 H u pH o ABD00029882 u < 0} T3 <30 fl <*> Om 41 u3 01 01 41 ua JZ 01 -H s 41 40>1 W J 41 O "0O 41 41 C Zc0 c zo -cH c >H 3O <u o c 4a)i 01 ai 41 .uOc C 4) C C *4 zo zO -^H DESIGN IN T E N T IO N : NORMAL K IL L A T END OF REACTION ABD00029883 eH c 3 eH 0 s H0 w 0 *-H <U rH VH c. 3 #0H HH 0 c 0 c oH c 0 c n 4> V a 41 4) a 4> 4) a -- u ju: <on O (N u C41, -- U1 U rH O IN M 4) -- in *J r-l ON h 41 jU: in rH O CN 41 c V J C TJ 4) 41 c -o 4> C V4) 4> 4) c o o z O0 zc O0 zc O0 zc O0 zc o-g c c *0 -cH e S -i *H None NO SHORT TIM E/ 201H .5 ABD00029884 u < muD 3 MvJ co -so Jo -- On 41 3 O' < CO w X cl 49JJ CO cu o cu o u HCO < as 2 of-c oH c * 3 fH 2u __ - as 4> V --IQ M4) ~. .C r4J -H O <N 41 4) C T3 OO 2C u 0 CO QJ mco u a. 2 u HCO Mo >. cc o Z 01 H2 gM <2 c 30 V 0) 2cO f-cH* 4> 2co ABD00029885 <n c 3O Ck U A) 1) C T3 2O 0a .cHcn u Xo rj 4-i i 4J 4-1 -CH -H 4J -H ( 4 H *H fl *4 O -H U -rt 411 UOUU 4C1 hD 4J J D aJ jj * 41 > o g Z h oa e d a> C TJ 0o 2C ABD00029886 None o th e r (see low flo w in node 221) &sD C 4J v O 0) C0Q. zC0 uE0 tl -- 40J o(<NN 01 u zCO Tc0l 4) 22 xQ bKOl. a. bCml O XuH 2Q zX *--1 (N r*t X rH o X rH O *OpH <N CN fN z u o X sM f- V) f- XoM -S, o OzQ Xz V 1/) vo XX X rH rH rH Oo o M <N <N a s Q wi bl aa.. 2 ba<l y au. z a t- X z 5 H rs. X X o X C3 oo M Q rH z zX X H (N r*i l/> Jj a H pH rH OOo O o fN <N <N (N CN HIGH REACTION RATE 2 0 1 L .6 ABD00029887 DESIGN IN T E N T IO N : REACTION K IL L IN EMERGENCY S IT U A T IO N 4<-0> i>->. 5 4) V Ol U J3 -4HJ O <0J 031 .& 0 fN z4C01 T40c3J au -0h1 H4oC1J *-4-4H<>) x am ro X01 c o H <o 41 a u ou o rH jj 01 3 cUH a4) M <0 H 41 a 30 a c Uzu o X u tw- ao" < g z <u X z o oU Ho <u b zM Xz oM ow u rH a HM (I U *0 HcoHojJ 0 Vco z a 4E1 B3) v > n O 41 mc 4) -H u cn oi 4) C C Ol -H -H rH 5>0Oo00 o n o coo C 4) <0 u vu zo Hu Msjo a. < u 8" 2Ml CO V) H X O xw o z f- J H o {N o fN H M H U z QJ (J> -j r~i O <N J e> uJ x o M X o H j H o fN aU uH S3 j ABD00029888 -C --u 4> > 41 0< folj t-i c -i > <0, Xi (J IN 41 0\ X-- <OH0 4>O1 4) <Q V 5> -gH 4) fr 4) a &> 4) oO> W4) CD > 04) uuX u4) 4) <0M iJ -H <4 U cH <a 4) X> U <H 4) X> 4) 0 . *H cn -<Ut0 UH 0 X E 41 Hi -> 3 Z o o zo i| M CO CO Xp X uo w oz o (J z 3 u oz o o X C3 IH X LO (N n oo (S CN S0 r- <\l IN oo <N fN NO LOW PRESSURE/ 2 0 2 .0 ABD00029889 o < 05 T"U3J . 41 coa c o TJ 43) C H hi C oo DESIGN IN T E N T IO N : VCM RECOVERY FROM REACTOR TO RECOVERY SYSTEM A. a l aM CL 1*1 V ,--1 0O5 OZ * O HO 05 3 <id T--J a: a o H o PLl 0 2> co as a. O o H CO o CO zM 2 * co oz j? oM 2H z CO H GZ > lh co H Z CO H J a[-J CO CO 01 y o aas. o o <N E 41 U 01 >1 0) X CN 3< 0 CD TJ CD c m* r- a u hi o V 3 H Cl* J H ID 0 CM 0 r--1 *J /--1 rH a C-- 0 IN s 41 05 cd Ji u o> r c H Hi a 3u 4N5 41 > D c0 rH "H -H 4) rH id i* a 41 05 <d > l< s Li u } u H it 0 <M Cl. u jz o Hi 41 H 5 CL O CO CoO a H 0 -H CO 3 45 a H as -- ou 3 Li JZ 4) CO HI hi H -H H E H 05 3 C >d CO uu uQ 41 s Li 3 Li CO 0> 0 05 n) r* 41 i Li U a a TCJ i CM . CD 9s -- J= 4) Li U c 300 05 4J 05 0 c 45 U cl fts V M * o TJ CO N < <90 M* r- Ch CM flO W 0) k4 Of N *W r-i JJ o JJ * 0 rH IW <0 3 2 m CD 0 rH Hi U 3 TJ 0 Li CL % 4) a o 45 Ll U O 41 U U O O Me ro m T CL 3 a r> O r* 4) Li CM 3o rH rrl 1 U a> <H X rH V u 4-H H 41 0> id CD IS CM <U CD o 9s rH W 3 rH c 0a ID 1) tn JZ > o i--H 4) <13 > tn V 3c w H a* J V 05 05 E 0 rH 45 U CO HI >, U 01 3 O 0 Li a * Li u HOi *4H5 o i--1 id 41 - 41 Li 41 Li a SZ H <U CD Cl 0 3 41 O Li CD Li C hi H HI C5 H 45 U 45 m Li K4 id 0 U 41 U 4> iH C > 41 IH 6 Li n - Li 45 Hi 41 4) Li 3 -H LH c *H o id o Jj -H 0 ec id 3 n-i o 4) 3 E aa ae > H rH Hi a >c -H c 5 TJ oa TJ Hi a H5 rH 3a g ao u Hi rH Hi rH o 3c HI a 45 3 rH >0 rH a 10 a CD > 8 Ll H a HI JZ Uu 45 r (MA c u O rH i*i 45 CD Li 0 JZ V a u o cH H5 Ci id 41 D Li > JZ CD O3 rH 0 H Li JZ 4) Hi a ua 3 >O 4) rH tc IHI f*l a E 3 a 0 > V CD Li Li 3 H JZ H u IH CD c rH H Ll o3 H TJ c a OB JZ rH u 45 l* 'Ll s o iH <ON COM COM <M CM CM o 2 O (M o CM n mo <N ro> (N None M IS S IN G COMPONENT 2 0 3 .4 2 0 3 .0 PROCESS L IN E - VCM CHARGE L IN E TO REACTOR ( c o n t in u e d ) DCS tim e - o u t w i l l s h u t down i f charge ta k e s to o long ABD00029890 UU cVQ. S O ES Ul --HH XU 9* <(a<N<r\\ Cb --O m>JO- S N O* U. " OS ^H --ri C in J>V --co H<OSU U<<CNTI O1/I1- 0O T30> V <u C o o ABD00029891 DESIGN IN T E N T IO N : CHARGE OF G H -2 0 TO REACTOR O-' C0 cu a -a o c. V) O VuM 4o3J OO TO3 C m Ua t> -- -- c0 Vu cO c0 zo EU Z S QX S 3U. s o z o o Z o J CWO ac* *X oo 3 o z M x r~ a) * o IN o <N o CN ABD00029892 ............ 4 SOP, t r a i n i n g 3 Flow to sew er, o f f spec p ro d u c t DESIG N IN T E N T IO N : CHARGE OF ALCOTEX TO REACTOR : r o r r e n m a n u a l" v a lv e/ U-- U0-l 4O1 V 0) --0] COH MU 41 *0H1 4J > OV a 41 u2 O M in - 12 Cfa u fc! M-- 0 41 0 oc rj -nH 4a1 -uC o c > 4t a --n co u> 0 4) "O 41 C rH 0 >H 2 3 U >-< z >o MM JH o2 0. a -- >0u 'O41 4> n --m Co Uu J42) -iHQ u> O 4) a 4> C H Ow 2 <0 2z Mo JM V) C/i U3 wD a o o cc a 22 (H O O tH to CO a CO a o o a HH J H to CO a CO Q a Cl Cl Cl 4J 4) o> o rH iH a. 4> O Jj 0. > c O 4) H (X > 4) <u *to e4) a. Q, ao 41 21 a to r ope r lOepf te REVERSE M IS D IR E C T E D FLOW 2 0 0 .3 2 0 8 .0 PROCESS L IN E - BME CHARGE TO REACTOR ( c o n t in u e d ) ABD00029893 ABD00029894 None o th e r (see low flo w ) DESIGN IN T E N T IO N : CHARGE OF HOT WATER TO REACTOR 25 V-- XX <1 L0t O<N V 41 CO T0> zc U C 41 u41 t4) 4tt <0 TJ 4) * 3 -< 0) 4H1 01 * 35 ^ 19 > M M41 -uH 6 UiC 4J Tl ja > c u oc c o -H v U A E u ca 41 * -H 5.2 *g. > (D O *-/ u 3a t) Oo --m - 0u1 <s m o 4U2) V10 UO 'H U f~h) chi 4j) G3O n-HuTJ a -< 3 .H ao *a -h pi -H 41 4-1 c^ x<uxo 3 <- a ae, 41 ast 41 ** 3a <o0 22 HX Xu oo NO LOW PRESSURE/ 210. B ABD00029895 u < TJ C |Q at uuo A uH o BH n V ij u<U30 41 -4uHJ ue V CO aC e fV-- 4<uJo O' icH c H 4-1 - a, oCO cfol nu 40-1 IQ *Urt T3 c H CO UV Vc 41 43-1 4iJJ IH -pH U4ai B<cn E 41 |UQ H 4-> O' *cHCH *u U oa(/> A a DH ai ^4 4J 3 <a u u co flj * c CH -0H u IQ cO' cHH U -r NH OH ^H <Q U*> *OW TCJ pH <a 4J < c u14 0H UO -0H - U5< 4rtj ao. CO 0 fN < 0\ Cl- ~ a a0* CO 41 3 DESIGN IN T E N T IO N : CHARGE OF HOT WATER TO REACTOR c uo O a 3 4J <0 41 -C U 4) OB ' JQ pH 41 pH Ol H IQ > >H OBl 4411 -pH Q 41 IQ B U S 41 3 aT3 41 at 0 O 3 Ih xa o 2 x ato 2 a xQ 0 h< M H M zo1-4 H zM ZU 3o O44 a o 41 a 4) 14444 o 1 HZ PH * U3u -p3h<Ho ft4) *4 e poH ih eo o3 14 4J TJ C pH u0 oo *4f41l 43) * TJ *J 00 X pH U3 5-0 pH 'O OC 14 IQ 4-1 C 4J U0 0 3 --m < Vj (7. p3H rpHH I <0 > >M XCO pH IQ CN 3 C0XO. _ OZ CO UIQ 4>1 41 pH c<o 41 > 8 5 3 3 O o rH ABD00029896 None O 3 Etn 3 c 41 *a. >q 2 1 1 .0 PROCESS L IN E - IN IT IA T O R CHARGE TO REACTOR ( c o n tin u e d ) flj -M Q, O <"M1 0 ->rhBHM M>X<NI WX0X, aUj <--T1 C) -ci n a JZ v> c 41 EV 2i M3 2 s B aM q; 22 Z C*. Sfc B> a414,) --f<NT -Co4 t3n -4HJ O14 B O 4J 9E* <u OU0 -H-t -- T3 4) * Vi B Vi V u UH H * T5 4V)i 4) o 4) 3 Vi 4) U B3 BU c o 0 X 4V1i 03. 2 Cl] a M 2 1 1 . 1 0 LOW TEMPERATURE ABD00029897 2 1 1 .0 PROCESS LIN E - IN IT IA T O R CHARGE TO REACTOR (c o n tin u e d ) 4J 4) 0} * Co r4 u u0 n 0 aa 73 E IIt UO -- H II II -- 73 ^ 3 Ci u m Xun EC tcoui o A4i a Vc iolXcn ox Z o P 2 eox XH C01i) < M 01 H Ci] M 5z M 01 o Cb o H iH IN Cd Q zO JC P M X e ii H 3 Z kl OJ Iat ToJ 1) 41 co no zc o u o. c 3 a 0 nU 4>1 4> <H 4J a v u r3* > cH H u UI-tl 0u co U -H iH t) 1-1 IoHt d Cl r<-0t uO o3 A(0 <Ctl -CHl O 4) U 4) X OCU 4C)i U 41 UO X0) flj *H Cl X V 8o ? 2 1 2 B .0 PROCESS L IN E - MANUAL K IL L L IN E ( c o n tin u e d ) ABD00029898 2 1 3 .4 M IS S IN G COMPONENT 2 1 3 .0 PROCESS L IN E - IN ER T VENT L IN E ( c o n tin u e d ) ABD00029899 ABD00029900 0) *Ui0t g. o aM Oh f+i nH o Off. DESIGN INTENTIO N: AUTOMATIC SUPPLY TO K IL L REACTION X oz Xo oz CMO o CMO ocHi Xc X c a c o a jj H <d --. em H aU o rH --a a a E o co 0 J A x 0 jj <30 JJ E 3 o a cX 3o o au B 4= 3 a *H u-- o jj a> c 43 H rH -h*a rur*-i rt -- ax si o-- o: au v<. 0.45 3 JJ XU -H E u a rHH X ss.* u rH fl V Jj > V >. rH rH a *a J6 a3 jVj tro- V <J\ Ei rH ftt. an 3Q -- a -- 43 < rH <N a rH 3 CH Ba o jj >ai MH arj rH a K >1 Uca 0u1 a ue nt* ro H>4 rH o aa 3 a am 3 HH , UH B0 0 H o JJ B Oa aa a uE -H aa 3 JJ <U JJ B H 0 u 3 JJ a o Ba0 0 0 SJ o rH a a 4 01 H j3j ab a M Q. 3 rH Ea H jj it *J 4= 9> >H H a jz * 0 o. * aM a 01 B H 3 a a a a a H a rH 3u a 6 Q. U aB -H -H a Ol a a u3 a a B Vj 43 O JHj B TJ O 3a a a raH o a rH c H X 0H JJ sz 0i H H>.U 0 0) jj 4 Vj a Xc a oE.taj jj a a a 0 o B o. o. a E 3 E rH 3a M o o u rv r-1 r> > b a3 a a r>H a a IH a a > B 8, a S' uU 3 rH H CD ax < JJ H B jj rrH <N Sa r* H 0i o i u B *H H > Bw *H HH N a a b. a SC a 0a a <j\ xw *4 3a Mc UO3 ov< a v V aa. o a3. C EV ti (N LOW CONCENTRATION 2 1 4 .6 ABD00029901 Flow in d ic a tio n and tra n s m itte r on steam lin e (62-F T -083) 2 1 4 .0 PROCESS L IN E - ISONOX A U T O -K IL L L IN E TO REACTOR ( c o n tin u e d ) <XJ xj 41 <0 4) <a O c a o c1 a (X E 41 > >> H co > 4) > co o ou 41 TJ c 1 c CM 09 H *" H Ij Ol c 01 XJ 3co r~* H 3 n c 0 H o3 <Q Xj (0 M 4> rH rl JU XJ V "3 01 u ua XJ 41 O T3 H *0 0 H Ji e( U 03 co (Q 4) Xj Xj 3 <0 T3 C uu 0 4) co 3 ^m. -o O U H rH T3 Ol 43 a l 4) E 09 41 4) a c u 41 41 41 c <XJ a M M 3 41 t EO H o H XcJ o H na CL i XJ a CO Cl XJ pH 4) XJ -H E 4) 41 M r> of Hu 4) 4 U cM a o 40 C y a a n 0 a 41 o XJ Q CD n a0. 0> COH r3l T> U 3 01 . miJ e -cO1 -3 fut uV U 0 -VnH 01 ^ -cH a oi aH *h U a aet xj *h XJ -H "J c xj u M % XJ 41 2H 41 > 4) Q\ U u CO H Ol 4J 41 H oc 4J XJ *"4 3 U CO a ^1 *H 0 O C 3 Ol O <*j a XJ CD 3 o <m a 4) 41 41 CD O z > 3 -H c zo C zO C o z c c 0 41 M U u u a XJ M CL a Q. a CD u E C XJ o IH > i--t o CO cn z o CN W <N a o 41 a <XJ <XJ o T <u13 u 4> a a-- E 41 o> -- xj C U -OH 4E) V H 3 Z Broken no2 2 le 3 ABD00029902 o <s II ao T>v> -h * V 4> 41 41oc3O aU01 a <g 4) j -0h -hc ua i-H cn 3 <fl U d 41 Ua 2T 30 30 3O 4) 4m) U 4) uC o 4Co1 z 2 1 5 .0 PROCESS L IN E - S TR IP P IN G STEAM SUPPLY TO REACTOR ( c o n t in u e d ) 4) C o z 41 c0 z 4J zco 4) c0 z o 43) C -OH Coo M3 z in <HN ABD00029903 u < O> c c3 T5 rH V rH CL XH 41 kJ M-HH my o4 U 11 a i- c OI C(JO c a0 E 4) M0 c 0 aro 6uOl aH flj a 01 u 3 udj > m J4S> D a 4 Q 4) k4 H c u<UQ * 0* o CO u3 Tf n tn o 41 i tj 0} a o- *N O co J-- fci C 0 H Jj *H CQ a0, o E m nj d B U> 41 3, 0 *j 01 4> >, > 01 H 41 O' c 41 3> H 41 U a 0. 0 4) rH hi v- a 4) U J= C O' H -H w ya co C H H U H3 y 0D) >0 > CD 41 4) C ao o E 41 > 01 H 0 Jj O' c 1> 4) >o < aV4. O 41 rH hi U Q. 41 4-1 JZ C O' -H *H ya co 0 y3 CO -0D V <toi 0oai -4o) t<oo IQ 4J 2 1 6 .0 PROCESS L IN E - EVACUATION L IN E FROM REACTOR (d w g : N M -0 9 3 1 4 3 -P ID -D ) EXTRA WRONG/ <o r- -hy >i a<0 tXn uC ' in 4) O' Z" ev H 3 Z oa 41 IN Z O' UQ euoMi os MS z u. 2 1 6 .S ABD00029904 O3 TJ 0c >V oV U XI 2 1 6 .0 PROCESS L IN E - EVACUATION L IN E FROM REACTOR ( c o n t in u e d ) E m p ty a G0 E3 UH T! IQ TJ 3o 4n> iq O > MO 1 z oM uH zM ZH H cn Zi-i CO W a z o o at w CL u a o r* Oi <N a Q 4) J3 aa E6 33 a. a 4u) 4) 41 u> *3-* 3 -H IQ H > |Q IQ 4) ixi H rH CH --H 0 r-1 H IQ <a x) ca oc 41 IQ Z XI ABD00029905 DESIGN IN T E N T IO N : ATMOSPHERIC DUMP OP POLYMER FROM THE REACTOR % % k t2<0 HM jj* co -- K ci to 'C t- O H H 'a Ok V Va h a\ co ~ H M 0 uV u o 3n <4u0i u c Ok o u 3 Q rH fH H 1 3 3 Ji m oa O 4) r-< U ua 4) U C 01 M *H v c SO oc> cH uW u a. O w % % Vu V> .H3 * H > <0 oH JeOJ ev j> * <0 CV CV 3 IUk rnH y wo iVHt4 3 0u C 3o o<<0 u Ucn E zi ABD00029906 V cH -- PI 9> * 0U> CM Q. a: (ob O H o W zM wz t u> W> zoM 'g u zM J --1 to CwO uo zotMo u as Q a e 3 "O in c 3 rn Ho><13 > 8 teuaH 85 8 ABD00029907 4O-> <4 None o th e r (see no flo w ) DESIGN IN T E N T IO N : CLOSED DUMP OF POLYMER FROM THE REACTOR oi TuJ (0 a a 0upo)i 0411 n -uucH Ua. uiud *h n rt T3 UC H a rc pp Qa Ol i oi 4J Cb i Ol IN H <T\ oi -- Vl 3w a a 0) 1 4) CN U Ol a. -- 41 ^ (0 4> a tj o o q <a 41 e 0 0QO1 c 3 co <*i ni Vc zo ei O fS tH <n u-- Ol u u 3 4J a .s C a u 01 w a H U -H wa Eo M u 01 cV o ID aa n 0<1a e Ol T3 Ca ma oH ox 0] rH -zoH> ^*o n c *0H JJ Id u C oo U jC= r- > oz <s <N M s s GuOi M a* 2S X Cl. oi oi 0 CD 0rH1 <rnH 4) U O 4t) M VO C** 0<HN0 CrHD Oi NO LOW PRESSURE/ 2 1 8 .8 ABD00029908 None o th e r (see low flo w ) u y < DESIGN IN T E N T IO N : CLOSED DUMP OF POLYMER FROM THE REACTOR a 4 a M a. n v rH n o91 os 4 o P 2u < 01 m as 3 2O H OS o to GH f< <3 u OS. u CO Oz p H as >* a ti. 0. O a D CO > a Q. a a. w P D CO < 3 z Uo 10 M z M Eh 52 OS U , Ch M w zz H o JM CO CO u CO Q u u o OS a* rH <N o Cu IN C--O C 0 rl Cl Li 41 18 uy 41 H E co 3 hH c0 rH UH c 0 B1 <a H C C4 rH 4J H c4> a *H a4J iH <8 3 0 18 30 rH ak Li 41 UH CD ti > ft C 3 rH a. iH Q 8 o OS J > CO mn ccn rH H (8 c01 rt Cl H 4) Cl 4J 8 4> E 4-1 Vo rH 41 aB Q. 01 o co UH UH t-H o fl n is 4) IQ > Cl H Q. ns 01 > C4 m Cl 41 Li <8 3 4) CD C hH k 41 1*4 "-ft Li UH C *H KO rH 1*1 rH -rl rH rH o 4) 41 18 C- on 1 > C CO *4 o 4) 8 UH c 041 C z 01 rH Ol N 3N rH O ac s<8 S> OM 41 91 x-- m Pi 41 3C rH hH a rH a5 y V X 41 c o z V3o C o UH c <o o Cl r<HN (N Q3 22 X b. a rn m ko r* a\ (?\ o> H H r<HN CN <N fN NO LOW PRESSURE/ 2 1 9 .8 ABD00029909 o CN CN m r- u. Vco D Ma a. UUl4i) -.4 V Em -- -Cu CIfl rcno u U oO a. IaN U14 V e *o <go a. 44J> CCON CO -- ugav to DESIGN IN T E N T IO N : SUPPLY OF R IN SE WATER TO REACTOR O O' IN v c o z fr J u >ee Cl. l-l o H l-H >* Q D J a. 3 a. D J CO 3 3z o <y M < Ju U M uz za hH M J CO Ci] 0 Tl a CTl 3 cn | 3 o rH a H u .0 4> m e 4) 0) E "O Rrt Co rH 0 <0 o a* r-H H M t) 4J d V 0) a to t S-4 *4-1 o <N * U CJ 4J 4) r--. <--I V e k. 1N Vi O 3 C N 3 -- 4) r4 -H O --1 V H O -H c h n y <N (N <0 <U h 4> >. r<M N c c* CN H 4* O' n r-t a * f H um -H o c V Cl O1 H > c 4> > V o 0 wo <C X H .a y en-v 3 *D A1 U IN a X H C a 41 O' X-- Q -3 V c 4) c m 3o o zz t3o) C >-> 3 Z as o 2S z S Cu <N m o IN IN o(<NN oc<Ns o<<NN None EXTRA WRONG/ COMPONENT 2 2 0 .5 2 2 0 .0 PROCESS L IN E - CLEAN WALL A D D IT IV E TO REACTOR ( c o n t in u e d ) S econdary b a ck-u p system <u mo 4 3. c H u 4c U <J _iJ ea, H O. P o& CO bl ABD00029910 4 uO a 1 a M 0. > 1u m2 3 in 4> m r- r"* a> i H 4) e M 4J vJ U CO Q.O. o> > 4J f--41i a 3 -ri <-( 4) S <N 6 o' A O' H * 5 .* u 4 K J -- <0 j a --nV --c0 U C. u4h 24Oc> Uc0U --u><. -c0H H 4J O O 44 CV 4mJ u4) 41 e. u 4M) 4a $s >-8 ss h. 2 s (fNS ABD00029911 2 2 1 .0 PROCESS L IN E - AUTO EMERGENCY K IL L TO REACTOR ( c o n t in u e d ) 2 2 1 .1 1 HIG H TEMPERATURE 41 -- > CD r-t O > f* > 4) co b3 B C -(H0 *OH VU H O II O pH 4> <g ev SH 3i Z 03 CMO QO Cla CO CMO n (N > O C (oN -o > CO 4i a. b-- ii B3 J<J0 4) <S b -H a. yc cHn i-4o>) xa tn -- 41 bo o 4) pH b in St V& b-- &C C 4) 41 0. K b TJ z* ABD00029912 2 2 2 .0 TANK VESSEL - EMERGENCY K IL L (AMS) POT (d w g : N M -0 9 3 1 2 0 -P ID -D )/ Ou > os Cd us> pi z au u t- o wp u> QJ a Id a OD O V) z a Cd ftd J Cd Cd a o z <N <V CO a Zo ao z *H<h ss WQ ABD00029913 S' a o *H > H2 2 aii n 2 j o c 41 uJ CD Dou O 01 1) a c H (Ddu ft. V) 0y lu > 2 5j Zo HH cn l o gM V c zo . r~ Tf [" SC {- u0) -oH* iu3J <44 *0 o Ou u Q. oo 1> 1) Vi Q. -h O a -a4 <<4u4 O u 4> Cb 0) 4-J 0 c 0 H JJ -H U E Oft ij 6 C0 0 Vi U Q. n <o 8. a B g MD * 523 ft. ev M3 Z DESIGN IN T E N T IO N : STORAGE OF SLURRY ABD00029914 ABD00029915 , a6D DESIGN IN T E N T IO N : TRANSFER OF SLURRY FROM BLEND TANK TO CENTRIFUGE Hc -u3H $ 1 cQCU OO O Cl Xo M X 111 aQH. 3 VM> QJ r n. a zH <M0 <H os. XU PO ZOO XQJ (N * m or> m o om onm rono OX 23 Z b. s -4i) DESIG N IN T E N T IO N : M A IN T A IN CONTINUOUS FLOW TO PREVENT S E TTLIN G 41 4) zC0 T0aJ ABD00029916 zMo H M H u B 001] ABD00029917 DESIG N IN T E N T IO N : DEWATERING PRODUCT D u3 m u >-> 41 H <; H4) t--f\ m - u4h3)i -4Cnr)i hi B 3 4 hi .Q fcS, - i D4b<0T4aIi C<oa 4> V hi UU hUi 4>1 e h -hc -hai <0 01 c -2 -oH sB: U|Q ^3 Ihji <w CB 4) 4) UG *hHi 8& S U 4) C0o B0 u a-- h0i *oH hi u hi HB H-H M n 8 a E & c 0 aH *4 mi S.& 2> O4) fIBt m<?\ X >-- 4) C o 2 41 C 0 2 8 u 4> -- --B C0 G -OH -UOH it 6 st Si ABD00029918 4* uU3 ~<N <o Sh 8tf1 AON H-- & a va uE c H JJ a3 -peH> M. 001) O3 m<8 *oH. DESIG N IN T E N T IO N : TRANSFER PRODUCT FROM CENTRIFUGE TO DRYER OX wW JQ Zb. V) V*->t S ABD00029919 3. 2 Q m Cd Cl, D CO 2 2 2 cu 1 cc o ca u Ci] (X H oz co M C3 M u CO Qu Ci3 Q u Cl, /-H Q.XI U U 1C JJ o JJ eg T3 ci m 4) n ao O rH C*1 M 3O 3O 0011 tn co 03o> '4HcJ c oo M3 z CU A<u0 x<U>Q S001i T443>) Z ** 0) c o z 01 c0 0) co ic> o zzz X Q N^ z oa, C3 Z j u > o w w J a o CO Oo u> up J CO Q rn tJ2 x 0 J 2O u o a. z 3 5U Q J w J Q J 0- CO - <j z Q3 CO p2 a* z\X 0 z o M X CM0 QJ Z Cl. CO 1-1 z Pr xfcJ ou o z o M s O z O H X OJ m U1 VO f- CO to fd m V <0 >0 ifl * S V| VO VO \0 vo o r* oooo Oa o f** n ro n r"l ro n*i m a <O 0) u Q QM CL ABD00029920 C M 0 z4cO) 4) 0c z4co) DESIGN IN T E N T IO N : TRANSFER HATER FROM CENTRIFUGE TO CENTRATE TREATMENT ro** M3 Z V C zo u CO S Q 3 (0 (mS0O.QJ W mS O Z <N rO in VO r* 0> oiH ro* r> r-* r- C- e- f- r* f' o m o r> o co o r*i o co oco oco oCO oCO ABD00029921 a <V DESIGN IN T E N T IO N : SUPPLY OF HPSW TO CENTRIFUGE 3 0 8 .1 0 LOW TEMPERATURE u CTl 4HJ 13 01 C<o c 4) . 0} Q, 4) ii e c U 3 0,0,0, Om 1-4 -uH 'HCO 3 X T3 C 4> O3 o 40 a itt 3 UV 41 4a1 U0 40(4j -UH M 4J 41 44 Oi 41 O i--4 "O5 -H 41 em <a s i-l O -H 41 4i4fl u c -4H) -fl e10 * Q J 0 01.2 C 41 14 "O a .--i m Co <C0J 41 -H > u -H 11 og c^ 0 <0 U 3 rH -rf 41 4<40 r-4 M v> 0 *-< y2 -cH 41 c 0 z 41 C o z 41 c o z 4a1 3 --uCH E 1) c oo o z o az 23 Z Ck cv r) CO o oo n r* u o z ^ ^ r* A <o om om CO o CO o Oro o r> ABD00029922 . <o m 0 . o> 0 cu 0 uE H H u 4 u IM f" IT) n r~ Ol U a a\ it -- 0 at <n uo U a oa o lH On 3 CO a os > a 41 V O Ot v a o c <d '--- u c *5 \C Q.<1 (0 > O. <- at c 0 at --t C Mi 2 u o a a i H X u3 c w 31 V <1 c U 0\ H 3 C *H i a M -- 4 e c X v 4> Q H n< >M g > m t> a <H U Q u h4 -- -H <Q 4J M ua 0 -1 c 04 1 S3 et 4 X tl > 0VO a cn <a )c 11 o 'H #H H a n arH X <a X <U a aU c IM 0X u X Ci] o 3o ul H M 0C6 3 a 2J a WX O a oo H >< z2 CO a Cb a tX D a Mz zo MM JH a CO a ct z Cb a M a Oa o 9 o r> }H W a a z --o H X a 0) t3 XM a< Sm - 1-1 0 Xo XQ aa u >. aX x ua o aX >* a X DX a 2 fQ2 2M pa ? S3 a 3 0 a z o Q2 H P otoX f- S3 un m oX >- a uH o a a o 2 no 4O-J1 o < 3 f. (- aa a >- a D 2a iMn co rt X ao a a a 5 O 4J 11 u M Xa O3 Hx <a 3a ft a oQ z (H <z o 13 5 1) u xa Mz 2o tH a a Hz aa o o 55 XM u c zo 0 44J 7u3 c<e u3 Sa3 --h> c o z td cV o z s 3h. X 3 oz <9 o r*i ori oH g i (N <n oo H lO VO r ooo m n*i ABD00029923 3 1 0 .0 PROCESS L IN E - DRYING A IR SUPPLY TO CYCLONE DRYER ( c o n t in u e d ) COL TG5 CO o> j: 4cJ -OH' M SZ Uto CO H 0U E U3 JS 0H1 TJ oU xa .a 4J O 3 T3 O U a o 0a) a to O*' t- --o > X Q os w >* u. Zo QM X2 c0 W *3 55 u. M 3 0 pH a; --<8 D <0 <4 J O 0m 41 41 va >. u O T5 N 3O aU jb. UM a. co MK 82 None H IG H PRESSURE ABD00029924 3 1 1 .0 DRYER - FLASH DRYER ( c o n tin u e d ) O > 4) >0H *00 4> c a> c or4 rl 01 4J H T3 i: o 4> c 4) C Zcov UaBv cv aE ov zu >* so u S1 tj r* o S 4) O 13 -I 0 c 4411 C O 4oJ on n ao . an En c -H 0) A3 H iJ o 3 c " z -H t c H u 4> X T3 * QJtu M uu as u as H os 3 u 3 -.--H< n <a V3 >u. a n u cu 03 h a, uc f<cfnl aui> n-ho 4ai n uo U0c ^00uo uo<d Uv MV Cl 8*2 3 81' az 22 b. M IS S IN G COMPONENT 312.4 3 1 2 .0 PROCESS L IN E - CYCLONE DRYER WATER RECIRCULATION ( c o n t in u e d ) ABD00029925 P3oi to p 2 * ZO u oX M 5 Q s o XzX2 u aa:. oX M <u a ee O 4) Zu auz. H XQ 3 1 3 .6 HIGH TEMPERATURE ABD00029926 O < C4 OLf> <r> S o T3 !V- O[-' > O' 4) <-t X cn D > V A OI x V c0 <CHj Tv3 O rH V c0 z ou o. av n j32 a QMa (*NT rH m o\ o >Q T TJ C * 0 o 41 4) U-- 41 (Q U> JJ OM 41 4) OC T03 4) c 0 1) c o zc z z 3 1 3 .0 TANK VESSEL - CYCLONE SEPARATOR AND PRODUCT RECEIVERS ( c o n t in u e d )/ HIGH CONCENTRATION c 0H o 41 3 C u C o *H 3 uz o <>0 O 4J 41 O u <0 41 C o z o z s O a> pH r*1 ro 41 41 ec 0o zz 4) C o z 3 3 Q3 WM OM X U* (0 CMO X pH (N <n m f*i tft mm 3 1 4 .7 3 1 4 .0 PROCESS L IN E - OFF A IR FROM PRODUCT SEPARATOR TO ID FAN ( c o n t in u e d ) ABD00029927 3 1 5 .e /NO LOW PRESSURE None ABD00029928 co fz CO 3 ZQ CO O 0n c ao CO a, H eOc 0. O u 0U CO CO j u O 4) W-<H-t CO O >< C u <w O 0 O U *H U. CO cc *va CO 0 N a *3 U zoM H-rf (1 41 'MMMac-H C 4i 4) a uH CO Z z0 j6> >o x3i CO H b ZM a Qz CN M HIGH PRESSURE 3 1 6 .9 ABD00029929 > irit u o 01 41 iJ U IQ E *OJ >u 3oD 0 a u3 a. o> cH *cH ^ h 0 *ai* io<nN "S3 apHi "4000J)) mI O--' e2 OQa ,0. ODQaa au zu cKo zuu uaw UM zo-l > 0 w0e *H ^CaoO *a Oa Hu 0c1 14 -H t> CO >3 6 J3 a 3 0) ao O rH <5 J3 C O H -uH H o U3 4) -a 4J o <o na. 01 r<Qt U -H H M 4<J0 44J] JJ <Q V) E <WB 0(4) 3 Is O iJ E o> Zi *h 3 Z None HIGH SPEED 3 1 7 .9 ABD00029930 ABD00029931 o c<q c h C *-- o (n *0 -r* V & o\ Vi Q uv ca c a CH uU Uh nu 3 ,,M. o> c rt cn w 5 rH a c -H J IN r> 0 <M ^0 aa C0 0> * cu H t) 4J 4J a r-4 3 *H Q <n n '63 5 Vi a -l O u 01 O C3 -H T5 X0 -1 Vi za a <0 01 01 cc H *fI a 3 4) 0 <1 fH <H W Vi U pV 6o on <9 ih h 3 fH f-I 0 -l*1 H <M e 55 3 0 01 H C H U -- IQ V <B a0 o 4) -t Vi U tfi 3 8i H Q. n<Q V>H m9i\ U 0. C0 O<j Vai IS Vi c v 8' ao 8- as 23 Z fa. t) 41 V 41 Qa Vl Vi 0) 4) A Si uu oo V 4) cc oo 22 None 3 1 9 .1 0 LOW TEMPERATURE ABD00029932 Hs 52 W0> js JV5 --O' Uo <r*> z4c01 -V0eo j U -oH* 0 c.. co uo o l B M k* OV l> JUS U0 * o 3 o ka< % oua ba S5 EV 3 2 0 .1 0 HIGH INTERFACE ABD00029933 u < a ABD00029934 D -- ha aE hH 4> JJ M H j: -H I-- a 4J cH H Mc w <n 4) u*i >4i oi M ai )o J0 --^ 3 a> uo <0 (S t) H a Et) mtf\ H-- w <U T5 UC o3> X V au. roH h. > O <H u 4) > 6 ft) CO c o T435) C Co u 1H z3 m m ^ iT> ^ <<mNN (<mNN dCl ri <<NN o d d <-n d d rn S 'o u ft) 4> O 8* <H 4>) --0> u Hfl Uo1 * >> 43 i U4) 4*J ci r >- Oz r* s ccmii ci dCl LOW INTERFACE 3 2 2 .9 ABD00029935 DESIGN IN T E N T IO N : SCRUBBING OF A IR USED IN DRYER 3 2 3 .1 1 HIGH TEMPERATURE Vo) 3Cl U4> (B CO Q a a m ar\) o o c 41 4) zC0 "0cO zc401 u 41 -- UC <(MN pVc -oal zc (i-Nl 0V0>> 3 ro <N c4) zo o fH <N ro 41 zC0 c4) o z 4) c zo Vc zo OW>ui .--I 2 a QU1 h OU 3Cn olXX-t u aH, Cl-HO aQJb ozM CCtHOO u g a 3 <N 1*0 ^ in vo r* oo o> o <N m nri nm (pN"i CmN m(N m<s (mN mcs <<Nn <fON uU < c o <u0 .-4 o c <4 uM 41 c cVkIIl c01. 3 ABD00029936 3 2 4 .0 PROCESS L IN E - OFF A IR FROM CYCLONE SCRUBBER THROUGH STACK TO ATMOSPHERE (d w g ; D Y -0 9 3 1 4 3 -P ID -D ) o 3 C E11 ^41 C ou <0 M >. U TJ C 41 41 U UH T34Ji u-i U 4) C o z lJ u0<u0 a 0411 41 a o o * T3 T5 41 C0O t03n1 41 rH co a 41 4) 41 c o c0 c o zzz 41 41 c c o z 41 c o z 41 c o z 3 Cl. X 3 V Q3 o m3 z Ci. <M 1*1 ^ i/> SO (N *<N (N M m rn (N <N 4? ^ (N <N <N C* r"> <*! m rO <f+N1 ABD00029937 4o-> < ---- 0 V 0 -Ch mo Is DESIGN IN T E N T IO N : STORAGE OF CENTRATE WATER 3 2 5 .1 0 HIGH INTERFACE ev 2 <-> 3 um 12 C >4 C H k-< <U UO O g-a o H 41 CU OV -fHl X 3 2 6 .0 PROCESS L IN E - CENTRATE FROM TANK TO HEAT RECOVERY COLLECTION TANK (d w g : D Y -0 9 3 1 3 1 -P ID -D ) ABD00029938 ABD00029939 DESIGN IN T E N T IO N : STORAGE OF COAGULANT FOR CENTRATE TREATMENT 3 2 7 .1 0 HIGH INTERFACE fti -- --a co uO uQ JZ u IuH a4> >M c ou Va-H41 *4a rQaH,. x-> 3 Oa 2M g JVS 4> J! E 0 aQ3. Z * ABD00029940 DESIGN IN T E N T IO N : SUPPLY OF COAGULANT FOR CENTRATE TREATMENT P ressure in d ic a to r {84-P I-51059) u V --. Aij Pn" 0m 41 4) CO V0 zc T40J) oc U *o 0c 41 U c0 co ZU o c -H V 4) (B 3 -h 4) A* u wo C 0 TcJ * MoxQJ SO. w(H0H X g s-i c -wH3 25 25 S *o V g" ABD00029941 3 2 8 .0 PROCESS L IN E - COAGULANT FROM TANK TO RECIRCULATION L IN E ( c o n t in u e d ) SOP <U Q. CE O 4> 2 4J coW Hno 4J 0) U 9] 4J 41 cc 4) -H U IB C0O 3 ^4) Cl 630^1 a> 3 a0 U 1 C3 M J2 >. 01 <aQ-*-, HCU E 4> >-> 3 /3 2 9 .0 TANK VESSEL - HYPOCHLORITE STORAGE TANK ( c o n t in u e d ) ABD00029942 3 3 0 .6 /NO LOW PRESSURE None o th e r (see low le v e l in node 329) ABD00029943 3 3 0 .0 PROCESS LTNE - HYPOCHLORITE FROM TANK TO PUMP SUCTION ( c o n t in u e d ) 3 3 1 .1 0 HIGH INTERFACE O Q ABD00029944 o ln at-< n <T H CO -J tr CO 4J (OT3 oc TH5 C H OIB H a c 41 > J41 DESIGN IN T E N T IO N : TRANSFER OF COLLECTED CENTRATE TO TREATMENT PACKAGE oc 2 V zoc 2o4c) M hi 4i hi C, 3 HI C<Bj H> 41 2C0 HX EO UU T3 4) 3 C --( <n p* oC <N N (N <N ro h*i <*"> f*"> hi h*> a3. 41 3 H <B 4-1 g o2 CO CN r-\ m Vc 2o *T 4) > IB > 130 C B I0I*j 4) 0 4(fJl TC3J zco4J 2Vco u a. a. x W a. u H H a2 3o M XU M X2 oH o> rH rH (N <N CN P> n HI <n ABD00029945 c 3 as -- g H -rl <w 4J c D H 0 H <44 <w 4> c M it c 0 z zaH Vu) a Q. E3 a. 4 > J .* y j: u 3C o -H CH j<0:0 3 -H 1v M 2 TJ It ma Vo % *3 4O u <sHU c 5? O l-H *2 n Va 0> 0 VV V V ac --o V 9 Va uu V <Q U Ln> 0c M V* ro t) m 4J 41 O TJ n kl r* UV n V O *0 4) c 0 z *1 u ce 0o zo v 0e co e Z *H 0 41 C co c_ Z -H 3 3 2 a .11 HIGH TEMPERATURE ABD00029946 DESIGN IN T E N T IO N : STORAGE OF FLOCCULANT FOR CENTRATE TREATMENT V-- --B *C0H uu V IUfl VU cc x0 o u a4) a. u Oa uV a. to E3 Oa ua 4c<0j 41 ft a3 <oj o0 fall i1--41 4-1 * O' MCOH' -cfMH) 41 W 41 -I UO r-Ht 44 a V Si ABD00029947 DESIGN IN T E N T IO N : SUPPLY FLOCCULANT FOR CENTRATE TREATMENT 3 3 4 .1 1 HIG H TEMPERATURE UU V <0 AU U c0 c0 zu 0) AU OH' c0 *c V4) -H H4> A LHi Li 4J o a vu c0 ao Zu uM V c<0 u3 AO r-HH V >Au) 3H U go Z o Z O U 3 5 A b.ax CHO JQ cn CIHO O kH a Xu ou u 3 QJ X oM X o z vO VO c- CO rv nV m r*i ABD00029948 u < TfU<f50l O3' +41J 4J V) D QM a <M rn H o l/l m m 4) zC0 DESIGN IN T E N T IO N : F IL T E R CENTRATE WATER O -TH5 C 1) u 3<n C -OM ' 9au)i a <n 41 o a j= a s. 4 * H o-- <wu * 9U) V U r*> z D > Wa to> jj c o 0) > flj > 0) 0> a c aH* 41 c 3 O 4) U3 u41 C T) *H o z m 41 Co z u 41 a 4) O' O' 3 --l a. c4o) z 4c01 z 4c) o z 4c) zo 41 c0 z ABD00029949 o < 4h1 uV 301 -unro- H 10 E ' JJ II 111 M (0 1< CD o H Q. >0 fa Ui *0 H U c <0 H H c -- c 4-> O C H 4) 0 cu u ^ >0 C aE 3 a 4u1 <0 a01 41 m -O qh c h tvar -cH % 01 CH 0} cH flj JUJ 01 aoco.- j-oha:> ti 3U 4UvJ -- <n -h o b 6 r- 11 B 1 u c *- a i-i ofa H U 1 -(H0 "VC. C<D UC -0H - II U D u <0 V* U4U) <^uH OvH -- c 0H 4-1 n> u H o c *H a Q* 2 -- H JJ c >0 -0H 4J U U yH o -cH oc H c H H TJ CH V14 a u>140 3 3 S .0 TANK VESSEL - CENTRATE F IL T E R ( c o n tin u e d )/ C 0**1 o x XI 4U) 4114 3C 3 -H 4) -h a 4-1 o * a 4J 'HOB u u4) H H Ma r--* -uH<0 uB3 fIQi Cffl 4) <i0 o > -h Xy <0 u T3 H 41 4> c w 01 01 <0 3 rH p O -H Z41 <0 > X>0I r-H cu 41 <0 Z <4H CD c H u 1) W4J M M o Q 0) JQ 2 Q. o V0 m 2 <" - QX 23 Z fa V 21 H IS S IN G COMPONENT 3 3 6 .4 ABD00029950 DESIG N IN T E N T IO N : TRANSFER OF T R E A T E D /F ILT E R E D CENTRATE TO OM NEW TANK M echanical fa ilu r e : fa ilu re 0 < -o 3tJi s4-1i <d c o T5 U D C C 0 V cH c su o. ow r O X o t> 41 m * co 41 uo 41 Co z Q Q a. r*> <Ti O >* O 11 u <d >M 4) 4) Co z 4> c o z <0 --I O -o r4) 4) e 4) 41 Co c 0 zz o rn m *tMn o a o c * cu 4-1 c t 1) > >II u a <o c QJ E 0 CO CO 3 V 4J c *-->I d ii >> un 4) *3 > u C3 3 0 i u ffl O MU4 U 41 U 3 aj n vu Q. * 3 MC 41 4) m \0 r* rn r> m 0"* m r> n <--> 3 a X 3 oz (N r** cn m r^i m ABD00029951 O! -ua 43 O031' coJ 13 11 3 On C *H u hH XHCO C00 a. CO T fl H -0o1 z 30 e--i z01 H S3 00n1) u Su031 0 01 c zo DESIGN IN T E N T IO N : F IL T E R BACKWASHING c o u 7U33 CH JJ c oy M3 Z 41 01 cc zo o z 01 c0 01 c0 01 c0 zzz 01 01 c0 c0 zz "3 Z 0. XH --S ZW z CO u z o U z uo W Xu 5 cc o & uEL Zu & 3l p c<2 oa. u z XHX XH oZ CO o X o J o X o z *o-* X QX J o f--t X oH Ul 43 r~ CO cn H fco rcl n rn i-i tn r- r* m r* ABD00029952 iJ O < T<3n u 3t7> 4> U-4 T3 CO a- u o 4) 3c c0 H 3 z c 0 u 4) jJ 0Q0). o uflj 'uHoo vav > -H u HT) O >it -Ch Ua 'T r 4>) > 41 *H t-< r- 3I V --I CD A-- o H 4> cA u3 -C rH U -H z41 A cH u II iJ rH H iJ c1) H u *rl U-l U-l 4) C *r 4>1 m> il-Hi r- c Aa C. -* a -~i 41 l z^ 4> C o z V c o z 4) c o z 4J 4) cc 0o zz C o z sX b. X 3 o z OX Mr 3^ HX Xo uo o z <N D * lO ^ co ^ CO m a) h*i m r> r* CO r> m CD m co <X3 r> r*i <n r> ABD00029953 uo C\ n < DESIGN IN T E N T IO N : SUPPLY A IR FOR F IL T E R BED SCOURING 3 3 9 .1 1 HIG H TEMPERATURE uc n -h >ow m n<*o m no & t uo t} u tmt O0 -rt U e *<4 S XV VM ii * o *o 01 JS VVa sE V "3 Q3 22 X &. o ir> \ r* A H ai o> * C\ &S r> n *> ro m fo rn> <*\ <n <n n r> ABD00029954 G. DRAWINGS ABD00029955 APPENDIX 6 DRAWINGS ABD00029956 I Ui ..-. XG_ </) OItUoJ* l< >0-|Q! oC (/> s a > x ABD00029957 1 I-. .~c -tv' ".i. y ABD00029958 8 1 Hl * |o 8gi O 1 -- i 1 9UI| O CL 1 r-v a* i li ^o . sc *> 14 Oi O 1 00 > i B I1 _i_ - VCK.jrAMS._CAR J5.PQT.J_7 YCMJAHK .CAR SE0LJ8 vcm._TAHK.C4R 5eQJ_.l5 yCM._TAHK.CAR 5EPIJJ5 VCM.JMiHK._CAR VCM TANK CAR SPOT 13 spot m ABD00029959 /\ K 1A z. \ I * i s i 8: *1 V h* N* ABD00029960 ABD00029961 w ABD00029962 ABD00029963 ABD00029964 ABD00029965 ABD00029966 ABD00029967 ABD00029968 ABD00029969 ABD00029970 ABD00029971 ABD00029972 ABD00029973 ABD00029974 ABD00029975 ABD00029976 ABD00029977 ABD00029978 MAAA A 9gS53S5S 8 5 g | 2 V ! !*S s A ? * I V o * ? /\ c* t! iI 888 A AA oC s1 1 i i S ! fi I 1 i&< ii i i ii f & i5 1 y CO OMMDIW * TV CM 333 l? JI ez ill I --CBS'- vfif &v A <- >-<> n coa-.ui V*. iVt | 4M V* > - Vi " y> fifV V>* r--mQh 0 i|>--------4 4& o9 CO e i______ 1 K si1 / / t, T ilT-bVi t S *i iY,-i r 'v* //T an iV firTr ?. -ri . v> v_J. te-~ttiv 5JL t. -CMh <D* {/> S-flV-*-KKJU>-S*- ui 1/1 oa t AA oe 5 ss if s 1& AA | A (\k ft A III5 01 si i e !i 1 I !M i 8A \)fi V 3A ac A *? ? 1& ii 5 A ABD00029979 ABD00029980 it fit ill I |I|||I*- ` Itfi s s ijM Hiiii;85|- 8 is iiili iiiinii in8 fill it M p\...L II__ U fS sj a H lill 8 I s 1 CD 2 se < < 5 0. E 12 ss oo I $S Xg 1s BUJ a u ftnmitic wru O I Q a i <> d> rO ao> i >o t* lit IS H!4:l J* *2is I uo 5: s Ci CO X sX 2 z UJ 3 3a--: tzo *s oz 0_ s a. 2 =J < u ABD00029981 ABD00029982 ABD00029983 D Y -0 9 J 1 2 9 -P ID -D ABD00029984 ABD00029985 D M -0 0 1 centrate flocculating tank ABD00029986 96611CD LV-6Z-01IX &S Pd Wd@*Id (t^isd CL 2 3 CL oc Lttd S x > uO x UJ ee ABD00029987 96611CD IV'LV6Q LI dS Pd >lsdV>id (frlsd-iioe)JI<M8H*V TO v~> I Issi Q I o si a i oo ri $11 Cl o ro a> 0 1 >o os mr*mpi mm I I----------------li tMC,W,>W>'K X I 2 a UJ & O< T" u Of S z a a. 2 tI 2 3 I <J a tt oi vi <N o^ 78 &H o 8 V) A $ UJ 2 IS till! l!i!I * s* i| 2 ABD00029988 ABD00029989 9661 ICO 6S:8fr:60 LZ d3S Pd (ttsd*ZSI0)Hd,Jd6frI^ ABD00029990 ABD00029991 / C T -0 0 6 EAST COOLING TOWER ABD00029992 A n Ow d? --\ 8 3 --- A I 3o!t m A ?j En ABD00029993 9661 iCD 81 -ldV nm'|S|@]0|d (|Si^oU !U -A 2 S' I' A i s VM y*-t- |X I Hae x&a />> _ OoQ W 1 1~ u ?*<* oao nr>pi ??? auoa. ua. --njrt IBX Iti o l\ s J <t x g > 0 as g l |i 1 t 0 It 1 Q g Su M < i u J g u ts s: UJ {>/--> UO O O C= --> a. Q UJ <c > UJ C u_ g.u Cl 1 Ci a_ uj 1. 1 G' O 1-- < S t aA Aiutocm wn< & S3 "B kN v> 8I--{Bffl r s 3 r 1 J!p s|*g|8*l FIRE PUMP HOUSE i i I w e K 8 i| ?x u 4/ V uv 2 V V VV ABD00029994