Document 5b08a0kv1apB4aveLQN7LZov8

PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XI APPENDIX A - OSHA PSM EVALUATION AND DOCUMENTATION OSHA Process Safety Management of Highly Hazardous Chemicals These questions are to ascertain if OSHA 1910.119, Process Safety Management, applies to this facility. 1. Yes [X] No [] Does any process or storage area of this facility have any materials on the attached list in excess of the threshold quantity. 2. Yes [X] No [] Does any process or storage area of this facility have any flammable liquids or gases (flashpoint less than 100F) in quantities greater than 10,000 pounds, except for: * Hydrocarbon fuels used solely as a fuel if not part of a process containing another highly hazardous chemical Flammable liquids stored in atmospheric tanks or transferred which are kept below their normal boiling point without benefit of chilling or refrigeration. If the answer to either question is Yes, then this facility is covered by the OSHA PSM Standard and all plant action items in the following summary need to be evaluated and specific plant needs determined. The OSHA Process Safety Management regulations are consistent with Dow requirements. Compliance with Dow requirements will comply with OSHA PSM. Those that have the listed chemicals in the quantities listed by OSHA need to assure that documentation is in order. (Revised 02/18/94; cmk) : LAD:bwb DO A O 4 7 3 ? 8 C'.ONF TOFNTT At PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XII Appendix A to 1910.119 -- List of Highly Hazardous Chemicals. Toxics and Reactives (Mandatory) This Appendix contains a listing of toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantity. CHEMICAL NAME Acetaldehyde Acrolein (2-Propenal) Acrylyl Chloride Allyl Chloride Allylamine Alkylaluminums Ammonia, Anhydrous Ammonia Solutions (>44% Ammonia By Weight) Ammonium Perchlorate Ammonium Permanganate Arsine (also called Arsenic Hydride) Bis (Chloromethyl) Ether Boron Trichloride Boron Trifluoride Bromine Bromine Chloride Bromine Pentafluoride Bromine Trifluoride 3-Bromopropyne (also called Propargyl Bromide) Butyl Hydroperoxide (Tertiary) Butyl Perbenzoate (Tertiary) Carbonyl Chloride (see Phosgene) Carbonyl Fluoride Cellulose Nitrate (Concentration >12.6% Nitrogen) Chlorine Chlorine Dioxide CAS* 75-07-0 107-02-8 814-68-6 107-05-1 107-11-9 Varies 7664-41-7 7664-41-7 7790-98-9 7787-36-2 7784-42-1 542-88-1 10294-34-5 7637-07-2 7726-95-6 13863-41-7 7789-30-2 7787-71-5' 106-96-7 75-91-2 614-45-9 75-44-5 353-50-4 9004-70-0 7782-50-5 10049-04-4 'J'Q** 2500 150 250 1000 1000 5000 10000 15000 7500 7500 100 100 2500 250 1500 1500 2500 15000 100 5000 7500 100 2500 2500 1500 1000 (Revised 02/18/94; cmk) ; LAD:bwb 0 A 047379 CONF JDFNTIAI PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XIII CHEMICAL NAME Chlorine Pentrafluoride Chlorine Trifluoride Chlorodiethylaluminum (also called Diethylaluminum Chloride) 1 -Chloro-2,4-Dinitrobenzene Chloromethyl Methyl Ether Chloropicrin Chloropicrin and Methyl Bromide Mixture Chloropicrin and Methyl Chloride Mixture Cumene Hydroperoxide Cyanogen Cyanogen Chloride Cyanuric Fluoride Diacetyl Peroxide (Concentration >70%) Diazomethane Dibenzoyl Peroxide Diborane Dibutyl Peroxide (Tertiary) Dichloro Acetylene Dichlorosilane Diethylzinc Diisopropyl Peroxydicarbonate Dilauroyl Peroxide Dimethyldichlorosilane Dimethylhydrazine, 1,1Dimethylamine, Anhydrous 2,4-Dinitroaniline Ethyl Methyl Ketone Peroxide (also Methyl Ethyl Ketone Peroxide; Concentration >60%) Ethyl Nitrite Ethylamine Ethylene Fluorohydrin CAS* 13637-63-3 7790-91-2 96-10-6 TQ** 1000. 1000 5000 97-00-7 107-30-2 76-06-2 None None 80-15-9 460-19-5 506-77-4 675-14-9 110-22-5 334-88-3 94-36-0 19287-45-7 110-05-4 7572-29-4 4109-96-0 557-20-0 105-64-6 105-74-8 75-78-5 57-14-7 124-40-3 97-02-9 1338-23-4 5000 500 500 1500 1500 5000 2500 500 100 5000 500 7500 100 5000 250 2500 10000 7500 7500 1000 1000 2500 5000 5000 109-95-5 75-04-7 371-62-0 5000 7500 100 (Revised 02/18/94; cmk) ; LAD:bwb 00 A 047330 CONF 1 DTNT T A! PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XIV CHEMICAL NAME Ethylene Oxide Ethyleneimine Fluorine Formaldehyde (Formalin) Furan Hexafluoroacetone Hydrochloric Acid, Anhydrous Hydrofluoric Acid, Anhydrous Hydrogen Bromide Hydrogen Chloride Hydrogen Cyanide, Anhydrous Hydrogen Fluoride Hydrogen Peroxide (52% by Weight or Greater) Hydrogen Selenide Hydrogen Sulfide Hydroxylamine Iron, Pentacarbonyl Isopropylamine Ketene Methacrylaldehyde Methacryloyl Chloride Methacryloyloxyethyl Isocyanate Methyl Acrylonitrile Methylamine, Anhydrous Methyl Bromide Methyl Chloride Methyl Chloroformate Methyl Ethyl Ketone Peroxide (Concentration >60%) Methyl Fluoroacetate Methyl Fluorosulfate Methyl Hydrazine Methyl Iodide CAS* 75-21-8 151-56-4 7782-41-4 50-00-0 110-00-9 684-16-2 7647-01-0 7664-39-3 10035-10-6 7647-01-0 74-90-8 7664-39-3 7722-84-1 7783-07-5 7783-06-4 780349-8 1346340-6 75-31-0 463-514 78-85-3 92046-7 30674-80-7 126-98-7 74-89-5 74-83-9 74-87-3 79-22-1 1338-234 453-18-9 421-20-5 60-344 74-884 'J'Q** 5000 1000 1000 1000 500 5000 5000 1000 5000 5000 1000 1000 7500 150 1500 2500 250 5000 100 1000 150 100 250 1000 2500 15000 500 5000 100 100 100 7500 (Revised 02/18/94; cmk) ; LADrbwb DO A 047331 CONFTDFNTTAl PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XV CHEMICAL NAME Methyl Isocyanate Methyl Mercaptan Methyl Vinyl Ketone Methyltrichlorosilane Nickel Carbonly (Nickel Tetracarbonyl) Nitric Acid (94.5% by Weight or Greater) Nitric Oxide Nitroaniline (para Nitroaniline) Nitromethane Nitrogen Dioxide Nitrogen Oxides (NO; NO2; N2O4; N2O3) Nitrogen Tetroxide (also called Nitrogen Peroxide) Nitrogen Trifluoride Nitrogen Trioxide Oleum (65% to 80% by weight; also called Fuming Sulfuric Acid) Osmium Tetroxide Oxygen Difluoride (Fluorine Monoxide) Ozone Pentaborane Peracetic Acid (Concentration >60% Acetic Acid; also called Peroxyacetic Acid) Perchloric Acid (Concentration >60% by weight) Perchloromethyl Mercaptan Perchloryl Fluoride Peroxyacetic Acid (Concentration >60% Acetic Acid; also called Peracetic Acid) Phosgene (also called Carbonyl Chloride) Phosphine (Hydrogen Phosphide) Phosphorus Oxychloride (also called Phosphoryl Chloride) CAS* 624-83-9 74-93-1 79-84-4 75-79-6 13463-39-3 7697-37-2 10102-43-9 100-01-6 75-52-5 10102-44-0 10102-44-0 10544-72-6 7783-54-2 10544-73-7 8014-94-7 'J'Q** 250 5000 100 500 150 500 250 5000 2500 250 250 250 5000 250 1000 20816-12-0 7783-41-7 10028-15-6 19624-22-7 79-21-0 100 100 100 100 1000 7601-90-3 594-42-3 7616-94-6 79-21-0 5000 150 5000 1000 75-44-5 7803-51-2 10025-87-3 100 100 1000 (Revised 02/18/94; cmk) ; LAD:bwb DO A 04733? OONFTDFNTTA'. PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XVI CHEMICAL NAME Phosphorus Trichloride Phosphoryl Chloride (also called Phosphorus Oxychloride) Propargyl Bromide Propyl Nitrate Sarin Selenium Hexafluoride Stibine (Antimony Hydride) Sulfur Dioxide (liquid) Sulfur Pentafluoride Sulfur Tetrafluoride Sulfur Trioxide (also called Sulfuric Anhydride) Sulfuric Anhydride (also called Sulfuric Trioxide) Tellurium Hexafluoride Tetrafluoroethylene Tetrafluorohydrazine Tetramethyl Lead Thionyl Chloride Trichloro (Chloromethyl) Silane Trichloro (Diehlorophenyl) Silane Trichlorosilane Trifluorochloroethylene Trimethyoxysilane CAS* 7719-12-2 10025-87-3 106-96-7 627-3-4 107-44-8 7783-79-1 7803-52-3 7446-09-5 5714-22-7 7783-60-0 7446-11-9 7446-11-9 7783-80-4 116-14-3 10036-47-2 75-74-1 7719-09-7 1558-25-4 27137-85-5 10025-78-2 79-38-9 2487-90-3 TQ** 1000 1000 100 2500 100 1000 500 1000 250 250 1000 1000 250 5000 5000 1000 250 100 2500 5000 10000 1500 * Chemical Abstract Service Number ** Threshold Quantity in Pounds (Amount necessary to be covered by this standard.) Appendix B to 1910.119 - Block Flow Diagram and Simplified Process Flow Diagram fNonmandatorv) (Revised 02/18/94; cmk) ; LAD:bwb DO A 047333 OONFTDFNTTAl PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XVII DEPARTMENT VPP/OSHA PROCESS SAFETY MANAGEMENT PROTOCOL (Refer to the OSHA PSM Communication) Compliance to OSHA regulation requirements is a basic tenant for participation in OSHA's Voluntary Protection Program. All elements of the OSHA Process Safety Management regulation must be in compliance as a prerequisite for VPP participation. I. EMPLOYEE PARTICIPATION A. Develop a written list of those safety activities that involve employees (examples in the OSHA PSM communication). Be sure employees participate in appropriate Process Hazard Analysis activities. B. Document the employee's participation in those programs. C. Provide access to Process Hazard Analyses. II. PROCESS SAFETY INFORMATION A. Review plant status on the following Operating Discipline sections. Process Technology Process Risk Management Industrial Hygiene B. Review the OSHA PSM communication and document the minimum process safety information that is required. III. PROCESS HAZARD ANALYSIS (Refer to OSHA PSM Communication) A. Retain the documentation of each Process Hazard Analysis. B. Assure that recommendations from the process hazard analysis are resolved in a timely manner and the resolution is documented. C. Communicate the results of the Process Hazard Analysis to affected employees. (Revised 02/18/94; cmk) ; LAD:bwb 04733A 00 A r ONF1 PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XVIII IV. OPERATING PROCEDURES A. Assure that operating procedures are reviewed at least annually and certified. (See Texas Operations Safety Standard T-13; III. E, F, G.) B. Assure that operating procedures include the elements listed in the U.S. Area Operating Discipline Standard and the OSHA PSM communication. V. TRAINING A. Assure that all operating employees in their job as of May 26, 1992, have been certified. B. Assure that new employees are trained as per the U.S. Area Operating Training Standard and the training is documented. VI. CONTRACTORS Assure that plant contractor orientation and safety communication is documented. VII. PRE-START UP SAFETY REVIEW A. Assure that projects have pre-start up reviews. B. Assure that resolution of the finding of these reviews are documented. (Revised 02/18/94; cmk) ; LAD:bwb OO A 047335 OONFTDFNTT Al