Document reQMdw8b44dJDQxGkvNaJVee

ABD00031700 COPY No. 3 CONDEA VISTA COMPANY ABERDEEN EXPRESS, PHASE 3 ABERDEEN, MS PROCESS HAZARD ANALYSIS REPORT RAYTHEON ENGINEERS & CONSTRUCTORS RUST DIVISION PROCESS TECHNOLOGY DEPARTMENT September/October, 1996 ABD00031701 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: ABD00031702 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. ABD00031703 CONTENTS ABD00031704 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. ANALYSIS 5.1. Hazards o the Process 5.2. Potential Safety and Health Effects 5.3. Background 5.4. Engineering and Administrative Controls 5.5. Consequence of Failure of Controls 5.6. Reactor Operation 5.7. Previous Relevant Incidents 5.8. Siting and Layout 5.9. Human Factors 5.10. General Deviations 5.11. Formal Analysis 5.12. Action Items 6.0. SUMMARY AND CONCLUSIONS APPENDIX A APPENDIX B APFENDIX 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 ABD00031705 1. INTRODUCTION ABD00031706 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 ABD00031707 2. PROCESS DESCRIPTION ABD00031708 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 1.2 Permissible exposure limits 11 11 1.3 Physical data 11 11 1.4 Reactivity data II 1.5 Corrosivity data 11 11 1.6 Thermal and chemical stability data 11 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 It J.Minga ABD00031709 PROCESS SAFETY INFORMATION # INFORMATION LOCATION 2.2 Process chemistry 2.3 Maximum intended inventory rt DATE RESPONSIB LE 11 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 ll 3.4 3.5 Relief system design and design basis Ventilation system design Equipment files, PSM room N/A (*) J.Heywood " 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-09312 9-PID-D D 05-06-96 Product Storage - 600 Series Silos DY-093130-PID-D D 05-06-96 Product Storage - 600 Series Silos 2-2 ABD00031710 LIST OF DRAWINGS NUMBER REV DATE TITLE DY-093134-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-0 93141-PID-D F 09-20-96 Centrifuges and Centrate DY-093142-PID-D E 09-20-96 Dryer and Separator DY-093143-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-093147-PID-D B 05-06-96 Product Storage - 600 Series Silos DY-093148-PID-D C NO DATE Recycled Centrate Processing DY-093149-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-093119-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 08-02-96 Steam & Reactor Evac. Systems NM-0 93122 -PID-D E 08-02-96 NM Steam & Reactor Evac. Systems NM-0 93126 -PID-D E 08-02-96 NM Seal Oil System NM-0 9312 7 -PID-D E 08-02-96 NM Normal Kill Systems NM-0 9312 8 -PID-D E 08-02-96 NM Clean Wall Supply Systems NM-09313 3 -PID-D D 08-02-96 Stripper Rinse and Flush System NM-093136-PID-D D 06-06-96 NM Emergency Kill Systems NM-09313 9-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 9314 7 -PID-D E 08-02-96 Catalyst Injection Pots NM-093149-PID-D B 08-02-96 Hot Water Charge and Rinse Systems 0*M - 0 93101 - PID-D E 08-02-96 OM Hot Water Charge and Rinse Systems 2-3 ABD00031711 LIST OF DRAWINGS NUMBER REV DATE TITLE OM-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-0 93110-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 ABD00031712 3. MElUUULUGY ABD00031713 3.0. METHODOLOGY 3.1. Technicrues 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 mere 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 ABD00031714 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 ABD00031715 ABD00031716 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 ABD00031717 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 2 3456 34567 45678 3-5 ABD00031718 4. REVIEWS ABD00031719 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. H Process Technology Process Technology Houston Smith Ken Campbell Deevie Rambus Luke Threadgill Steve Wilkes Rodney Strickland Dean Honeycutt Janice Minga Condea Vista Co. 11 ft 11 11 11 II n 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 ABD00031720 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 ABD00031721 5; ANALYSTS ABD00031722 5.0. ANALYSIS 5.1. Hazards of the Process The hazards associated with the process are the usual ones, i.e., * 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 ABD00031723 * 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: 2 01A, 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 ABD00031724 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, and to reduce residual VCM to an acceptable level. 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 ABD00031725 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: Notes: 201L, 221, 223 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, internal leak/rupture Nodes: 201M 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 ABD00031726 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 ABD00031727 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 ABD00031728 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 ABD00031729 S ta tu s | j R e s p o n s ib ility j j A c tio n oU >, >r 5n u U nj 41 01 it CM o <4 OS >4 CO co U 4-1 a c c 01 HI <4 01 rH H os Or Dr >r N (4 It It Cl U 10 m XX T3 a 41 01 41 01 DC a >< to >4 it It uU C4 <4 XX a C 01 41 01 41 as 03 U >. u >, 41 14 <H X <4 O CD 14 X L> C T3 14 41 H 41 aa 00 <u 4J a an 3V JO c U 01 0) >, o c <0 41 o 0> Co V0)i oe 4) 41 <0 C Ho 41 -I <0 -H J a v o u <4 H c H tr\ c - H >r a rH p Or Or u3 ti O *0 (N rH a Ud 41 c 4J rH O <4 o CJ 3 (N 01 0) X 4) U U <4 3W o O 41 ou ou Vl 41 au 41 41 T3 O H uc c0 41 H > 4J 01 u u 41 a Or a 3c 4) C H -- Ir 41 0 o u in -H <4 tl d c H rH o 01 O u <4 OI u01 0 4J Oi a <o c -H 0 0V< iJ 01 imJ -0h1 <4 H CJ c u 01 c 01 Vi *H u 0 c >M 0 41 01 u 3 0 41 41 u > HH 4J <4 01 > CO C rH rH a. -h q X N 30 41 C OI 01 41 <0 rH C U M -H -> 41 41 u > 41 M 41 m H o o OrrH 01 u U hO 0 U >T a H OM u H-l 41 0 Jj H 4J Or c 0 rt3 O -H 4J H W 3 >4 JJ O H 3 41 41 c 41 Or H -H u O > 41 C c r a H jj o-- rH rH a <4 3 3 C T> <0 H 01 <rf rH 3 o H 4J oc ^*mEH 2T4'3i o <4 IJ Ol 41 Cc *H rH ^H a i-i ac <4 41 > Vr 41 lH *0 o H u H CO o c (4 m o 41 H o 1h (N OlJt m c H 01 j: U (4 u TJ M -rl 4J O O m> 4J rH a H <4 C 01 O X) H 0) rs 4) e 0 U *H c (4 N H 'IOOI' Wh41 h<U0H4-J' a rH rH rH d 4) cU H *H c rH rH 41 CO rH >cm rH 01 w u rH jj a H Or 4-1 >. V 41 0u XU o 41 01 z cUH o o 33 w Uu H iJ <4 <4 U rH 41 41 U P a Or 41 Q E E C 41 01 U 4J 4-1 o -H 4-1 T> C 41 g g 0 O 41 ce n <4 4) E CO o Ou sH:IMu >r 'H *--* u 41 e 41 41 41 u rH 4-1 <4 O 0 u Vl Vl a 41 O iJ Ol <4 <4 3 rH 01 rH m ca OE O3 o rH 41 U > -H 4) V4 rH 01 j: t> a cm <4 0 g 0) 4> w' 4) c H rH iJ H C* h-rt 0h01 H-H *e0 Uu -3H (0 (4 01 m Vl u -H 41 xJ 3 u (4 41 3 C **H H u0 0) 3 41 01 4J C u H o 01 E u c o u 4) U 1-1 41 0O Vr <u O u 44 d A H u no <0 <4 u f* 41 rH s Ct x> CO fS X c 01 m *H 4J Ti Oi to c H 01 0--, o fN o U 4 0 rOH i--i Vr (N 41 CO c O Q m a> c 01 jj o M u 4J 3 -h E m oi <s rH 1t CO D ro ca rH CN Oi cc H 0 o H o JJ <4 f6 T5 Vr C 41 4) TJ g H 0) 0 cu o u f*i vr r- -o' r- VO r- 1-4 H H q a CD H h rs O rH <S fM <N (N <N <N r- H rH (S <N <N *H r- o t--( rs OH rs | | P rio rity ] j R eference Number ABD00031730 m 3 JJ u CO -- >. H 0) cn cc c JJ < >, JJ Vi 0 Vi tx 4> o 0) 41 a: >. >. >. s* u; o Cl u ft <0 -c a a T3 4> U as 41 cc c4c) cVc 4) K a cd JJ (N X Cn TJ > W T5 41 ii n u >H JUS JoJ uu H g D> C Vi 1-1 JJ m * ii H 4) u c U Vi -H Vi Vi u tn 41 C Vi #T1 U b. 0 0 <7> Ol o 41 U Vi oo 5. a. <0 n 0} 3 <u O Li Oi cc 41 01 Vi N <4H 4) -H Vi u > E Vi u > T> V H P M i4J1 41 JJ ~ tn (8 r*i UH n*> 41 F M 4) -- tl - Vi "O 4) Vi u JJ Vi > rH C/1 Tl CO 4) VUi H G11 Vi CC. Q. u n U jJ CD m H 41 3 jj "0 H Vi Vl -H H Vl "O o ii 0) 01 O Jj V4 Vi 0 -- Vi 41 ' Cl C\ COn Vi O -H g 4) "i -- .uc u<0 Ol 41 41 HOW TJ -H 4) C O 5 O 01 CO a> f- t 1 rH l H* <N m ri <+l r*l ABD00031731 5. SUMMAKY^NU CONCLUSIONS ABD00031732 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 ABD00031733 A. PREVIOUS RELEVANT INCIDENTS ABD00031734 APPENDIX A PREVIOUS RELEVANT INCIDENTS ABD00031735 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 ABD00031736 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. l) 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. ABD00031737 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 ABD00031738 B. MATERIAL SAFETY DATA SHEETS ABD00031739 APPENDIX B MATERIAL SAFETY DATA SHEETS ABD00031740 U.S. DEPARTMENT Occupations!. Safety and Health Administration MATERIAL SAFETY DATA SHEET qmi n*. 4auir Required under USDL Safety and Health Regulations for Ship Repair**, Shipbuilding, end ShipbreaUng (29 CFR 1915. 1916/1917) SECTION I The Nippon Synthetic Chemical -Industry Co.. Ltd aOuaCSS SittrrU i'itr.Stste. 0m/ 7JF CodtJ NozalUrgho. fifra ~ku Oaalrn- 530 .Tap; CMCMICAI K&^ni?ohoi 4hIM IcrC'lAMllt Pooilyymi er TSKBOCa --06-314-1962 j2JThv~- SECTION II HAZARDOUS INGREDIENTS ^ ruKTs.rMKevsttvu, e mivtNTS %. TLV (UmImI ---- AVS-OYSAMDMCTMJJCCOATINGS eiGMCNTS N/ k ' IASI MCTAC ,, CATALYST R * AUL0VS. VCH1CIX SOLVtMT* n MCTAUJC COATING* n TrutUn-teeoMACTTmAoi. oe eoec flux AOOtTlVCS OTHCea it othchs N. a KAZAROOUS MtXTUftCS OP OTM1H UQUfOS. SOUOS. Oft GASR None \%) i/kf "1- . m ft n it % ItTMLeVl' . 4 uaim* PO*t<T |*fj V**0 MCStURC FM MM varoa OCMfitv |Atai) tOLueiurviNwAtce AMtAIANCt AMOOOOe SECTION III PHYSICAL DATA m eaeotete etAvirv ase*u VtAVtOtNUTA.VKeAUtLtM CVAtOHATtO*! AAVt f *11 No Llaifc Vhite* powder with no odor b4 i.z-i.fc at 201 ltsa than 3* H \ ? 1 SECTION IV FIRE AND EXPLOSION HAZARD OATA % 1 LAI 1 ** 1 I \ f --1---L--4 cumeuiSMiNc MtoiA We Tan alnohnl fnan. Hmv social riee fighting faoccouacs ... None especially --------------------- -- unusual ec ano cxfcosion mazahos None especially PAGE 111 (Continued on reverse side) * - : Form CSHAn err. er ft C lfS tt' 1 ft' ABD00031741 y v: - . . SECTION V - HEALTH HAZARD DATA THR6VOlOI.i-) VAi.ut .. .4, . Va-; * 1 None determined ---------------- ------- * ferptCr or *vi nlkpo>uA( It may happen to effect the resoiratorvoreans as sai" - as dust in case of inhaling fine powder for a long time. It is not considered a toxic hazard. Eyes: to wash out without rubbing Skin: to. eliminate after handline 4 hlAtlblTV UNItAlbC SECTION VI - REACTIVITY DATA CONDITIONS TO AVOID STARVE iNCOMAArAtiUTV fXtsitrmt itt artmdj X HA2AAOO{V.S OICOmOSiT<On AnUOUCTS PMOAL/.YAMREOROIUZAt TION MAY OCCUR hll NOT OCCUR ........ ; ' ^' CONDITIONS TO AVOID X . ... ... .. . T f SECTION VIISPILL OR LEAK PROCEDURES ntrj MTO 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 uo ( not .be washed out with water ).; wKSTE Ol**OSAL METHOD to burn uo * - \ . SECTION V!ll SPECIAL PROTECTION INFORMATION RCSRIRAIORV PROTECT ION (Spmfr type} ^ ^ desireble to wear filter mask, when VLN1 ILAflON local exhaust cue very dusty grade is SPECIAL MECHANICAL {(fmcral) 1 ,V t OTHER PMOTEClIVt CLOVES None especially I EVE PROTECTION None OTMfcM.HOriXTIVl tQUVMCMT None esp(.cially -* esoeeiaiiv SECTION IX ' SPECIAL PRECAUTIONS /nccAvriONS ro tc takcn if hamommc ano itoiunq . None 11 y ; DnaUfy does nnt. . ghgny*. at_ room * temperature and humidity.________ ________________ OTMCR RRCCAUTIONS .N.o_n_e_ genera- l-ly *. _______ _______ ___________ PAGE (2) ec 0B.ua IH NIPPON SYNTHETIC CHEMICAL INDUSTRY CU..L1 U. no.s-e*nozak;-cko. kita-ku OSAKA, JAPAN Form OSHA*2 72 ABD00031742 US, DEPARTMENT ________ Occupational- Salary and Health Admmtstratton material safety data sheet Required unda USOL Sifityind Haalth Regulations for Ship A(pairing. Sheading, and Shipbcsakfaq (29 CFA 191S. t916. t917) _________________ ._______________SECTION I________ * The Nippon Synthetic Chemical Industry Co.# Ltd. I ***** f\"~*+T. Xu*ru I ttT. Suit, mmjztrcodtj 2-S, N98akl-CtlO. Klta-tfll. n*V c,,` m'c, ?>iyvToyrtrAboi nr> .Tanan ChCmiCAl^U^V.LyVmer TOESCuX- 06-314-OOfizT"* SECTION II - HAZARDOUS INGREDIENTS '. punts. amavATfvts. a soivnm RIQMCKTS X I tlv ftMInf N/ 1 ALLOYS AND METALUC COATINGS EASE METAL CATAUVST n ALLOTS. VCHtCUK n METALLIC COATINGS SOLVENTS AOOITIVCS others 0 TILLER METAL M RUTS COATING OR CORE FLUX If others t . a MAZAROOU1 MIXTURES OP OTHER UOUIOS. SOUDS. OR GASES None \ \ TLV f * 1 lUMtt} m-- i. -i i it 1* w TLV % ! OJutwt _L_J1 VUM* wONt |**4 VA*0 N(tWC *-- NJ vanoa OCNSTIV |A*fll| soLuaiLirrm NAicR AMtARANCt ANO OOOR SECTION III PHYSICAL DATA m inrfe aaavrrv RVfaVeOsLvUrrM. vEoMunu Ct VAAORATtOiy RATS No Llmi L-______________________ White powder with no odor * M 1.2-1. 1 at 20Mj less t tan St IJ l.-J i rtASH RQlNf SECTION IV FIRE AND EXPLOSION HAZARD OATA WMdl FLAMMASLC LIMITS '* 1- CVtlNeUtSHIMC MtOlA Water alcohol fnaw. dnv sricial nee sighting rroccouecs None especially u" r uhusuac net and cxrlosion hazaros $one especially (Continued on mini aide) Pom CSHA* Art. MtT It ABD00031743 . . SECVION y . HEALTH HAZARD DATA THRESHOLD L`Wll VALUE N,, one d, etermined, -------- * -fcFFCCr> O* "VI NLIPOiUHfc It may happen to effect the resoiratorvoreans as sar as dust in case of inhaling fine powder for a long time. 1 Ml MIIINCV ANO 1 INST ASO PROCEDURES It is not considered a toxic hazard. # Eyes: to wash out without rubbing Skin: to. eliminate after handling . si ARIUTY unstable stable imcompatability (Xittcrmt ut SECTION VI - REACTIVITY DATA conditions to avoio X- HAZARDOUS OCCQmOHT<Ow PwOOUCTS HAZARDOUS POLYMERIZATION MAY OCCUR WILL NOT OCCUR CONDITIONS TO AVOIO X . . SECTION VII - SPILL OR LEAK PROCEDURES STEPS TO BC TAKEN IN CASE MATERIAL IS RCLEASCO OR SPILLED *PVA is water soluble and makes a sticky solution, so scattered or spilled PVA powder should be sweot uo ( not be washed out WASTE DISPOSAL metMOO to burn with nn water 1.________ . SECTION Vitt SFECIAL PROTECTION INFORMATION ArCSPiraiorv protection fSpm/r type! It is desirable ^to wear fil_te, r, mask, when VLNT ILAftON local cxmausT ' &nt!' Vbry ousuy graae is SPECIAL mechanical ((rmcrtty , OTHER AMOICCllVt CLOVES None especially CYC PROTECTION None OTMkR PROTECTIVE EQUIPMENT None especially especially SECTION IX - SPECIAL PRECAUTIONS PRECAUTIONS TO BC TAKEN IN HANDLING ANO STORING Hphp fitta T 4 , nof * temperature and humidity. othlr pr{Cautions None generally rh 9T\fr at room PAG (2) ce IB.IB Form GSHA-2 IH NIPPON SYNTHETIC CHEMICAL INOUSTRY CU-.L1U. NO.S-ENOZAKI-CKO. KITA-KU OSAKA. JAPAN ABD00031744 Material Safety Data Sheet The Dow Chemical Company Midland. Michigan 48674 The Dow Chemical Company, Midland, Ml 48674 Emergency Phone:517-636-4400 Product Code: 53940 Page: 1 Product Name: METHOCEL (R) F50 HYDR0XYPR0PYL METHYLCELLULOSE Effective Date: 02/10/92 Oate Printed: 04/14/95 MS0S:OOOO55 1. INGREDIENTS: (X w/w, unless otherwise noted) Hydroxypropy1 methyl cellulose 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 0SHA Hazard Communication Standard (29 CFR 1910*1200). In addition, other substances not 'Hazardous' 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: SOILING 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 S 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 o Printed on Recycled end Recyclable Paper ABD00031745 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: 2 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Oate: 02/10/92 Date Printed: OU/14/95 MSDS:000055 4. REACTIVITY DATA: STABILITY: (CONDITIONS TO AVOID) 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. ENVIROtMENTAL 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. Disposal 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 LD50 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 Dow Chemical Company ABD00031746 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 53940 Page: 3 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: 04/14/95 MSDS: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. I.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 ANO 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 4 , over) (R) Indicates a Trademark of The Dow Chemical Company ABD00031747 The Dow Chemical Company, Midland, MI 46674 Emergency Phone:517-636-4400 Product Code: 53940 Page: 4 Product Name: METHOCEL (R) F50 HYDR0XYPR0PYL METHYLCELLULOSE Effective Oate: 02/10/92 Oate Printed: 04/14/95 MSDS:000055 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. MSDS STATUS: Revised regsheet (WHM1S) information. For information regarding state/provincial and federal regulations see The Regulatory Information Section. (R) Indicates a trademark of The Dow Chemical Company ABD00031748 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: R-l Product Name: METHOCEL (R) F50 HYDR0XYPR0PYL METHYLCELLULQSE 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 responsibi1ity 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. CANADIAN TOG INFORMATION: For guidance, the Transportation of Oangerous 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. ABD00031749 The Do* 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 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 "Ha2ard 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: 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. CANADIAN 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. ABD00031750 28/02 '94 10:08 0279 412984 REVERTEX LTD 3)002/003 Harco MATERIAL SAFETY DATA SHEET Conformsio EC Directive 91/1SS/EEC Alcotex 78 1. CHEMICAL IDENTITY Alcotex 78 Is a 7888 hydrolysed pOty(vlny1 alcohol): CAS NO. 25213-24-5. CHEMICAL FORMULA:- -(CH,-CHOH)an(CH1*CH(OCOCH^a 2. COMPOSITION Poiy(vlnyl acetate, vinyl alcohol) total solids content 98.588 (min). 3. HAZARD IDENTIFICATION Alcotex 78 should be treated as a low hazard product and requires no specific precautions for transport or handling. Spilt Alcotex 78 Is slippery under wet conditions. 4 FIRST-AID MEASURES SKIN;- Wash thoroughly with warm soapy water. EVES;- 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 lo a doctor. INGESTION:- Wash mouth with water. Seek immediate medical hotp. Show this data sheet to the doctor. INHALATION: Remove the person from exposure. 5. FIREFIGHTING MEASURES No special fire precautions are necessary, in case cf fire use water, foam or dry powder extinguishers. 6. ACCIDENTAL RELEASE MEASURES POWDER: 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. e. 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 goggles. SKIN: Standard Industrial overalls. 9. PHYSICAL ANO 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 '94 18:08 t?0279 412984 ABD00031751 REVERTEX LTD Bl 003/003 10. STABILITY ANO 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 have 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 long 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 alcohol 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 in EINECS. The information contained herein does not constitute the user's own assessment of workplace risk required by other health and safely legislation. 16. OTHER INFORMATION CONTACT: Or S Ormondroyd Harlow Chemical Company Ltd TempiefieWs Harlow Essex CM20 2BH England Tel No. International + 44 279 436211 Fax: 44 279 444025 DATE OF ISSUE 25/06/03 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 properties. i ABD00031752 laterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 1 SECTION 1: PRODUCT INFORMATION NAME: 2-MERCAPTOETHANOL DESCRIPTION: 2-MERCAPTOETHANOL CAS NUMBER: 60-29-2 USE: CHEMICAL INTERMEDIATE MSDS NUMBER: P001299-MCDWDK APPEARANCE AND ODOR: WATER-WHITE LIQUID; MERCAPTAN ODOR EMERGENCY TELEPHONE: 800-929-9300 29-HOURS - CHEMTREC PRODUCT INFORMATION: 800-251-5952 EFFECTIVE DATE: 01/27/92 SUPERCEDES DATE: 09/15/91 PRODUCT CODE: 1217000019 SECTION 2: HAZARDOUS INGREDIENTS A HAZARD EVALUATION OP THIS PRODUCT HAS BEEN PERFORMED. THE COMPONENT LISTED BELOW IS IDENTIFIED AS A HAZARDOUS CHEMICAL UNDER THE CRITERIA OF THE OSHA HAZARD COMMUNICATION STANDARD C29 CFR 1910.1200). COMMON NAME/CHEMICAL NAME CAS NUMBER APPROXIMATE X 2-MERCAPT0ETHAN0L/THI0GLYC0L 60-29-2 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: _____ PROMPTLY 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 ---------l------------------------------------- tf /rt/A/ mo 111 /o/vr i/vvi ABD00031753 faterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 2 SECTION 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 ORGANCS) AND/OR SYSTEMCS) SHOULD TAKE APPROPRIATE PRECAUTIONS WHEN HANDLING THIS PRODUCT: LIVER. KIDNEY. ALWAYS WEAR APPROPRIATE PROTECTIVE EQUIPMENT, AS RECOMMENDED BY YOUR Morton International >/V L >/. .j, it j n/am.^/w) ABD00031754 faterial Safety Data Sheet 2-MERCAPT0ETHAN0L PAGE: 3 A INDUSTRIAL HYGIENE OR SAFETY PERSONNEL. WHEN EXPOSURE TO THIS PRODUCT CAN OCCUR. SECTION 5: 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-MERCAPT0ETHAN0L/THI0GLYC0L 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/kg 345 ag/kg 150 ag/kg 300 ag/kg 13.200 ag/a3 OTHER TOXICITY STUDIES: 2-ME WAS FOUND TO BE MUTAGENIC IN SEVERAL TEST SYSTEMS. INCLUDING THE MICRONUCLEUS 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 OSKA: 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 ABD00031755 Material Safety Data Sheet 2-MERCAPT0ETHAN0L PAGE: 4 RESPIRATORY PROTECTION: WHEN AIRBORNE CONCENTRATIONS ARE EXCESSIVE, WEAR NXOSH/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 CARBON DIOXIDE, HALON, FOAM, STEAM) OR WATER FOG. LARGE FIRES: USE WATER SPRAY, FOG, OR ALCOHOL FOAM. (E.G. DRY CHEMICAL, 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 ABD00031756 [aterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 5 CONDITIONS, SEALED CONTAINERS HAY RUPTURE BECAUSE OF THE BUILD UP OF INTERNAL PRESSURE. COOL CONTAINERS WITH WATER. VAPORS HAY BE HEAVIER THAN AIR AND HAY TRAVEL CONSIDERABLE DISTANCES FROH 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. SECTI0N_8REACTIVITY DATA STABLE UNDER NORMAL CONDITIONS OF STORAGE AND USE: YES MATERIALS TO AVOID: OXIDIZING AGENTS. STRONG BASES. CHEMICALLY ACTIVE METALSCE.G., NICKEL, 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 mi 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 //VI */,._.L O/. at... // /C/VCAX KOO ? rt/B/rr.J/YY) ABD00031757 Material 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 11; PHYSICAL DATA X NON-VOLATILES (BY WEIGHT): pH: VAPOR DENSITY (AIR=1): SOLUBILITY IN WATER: EVAPORATION RATE (n-BUTYL ACETATE31) < 0.1 7.0 NOT ESTABLISHED DISPERSIBLE <1 Morton International ABD00031758 aterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 7 X 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: PURITYj TYPICALLY > 99X NOTE: THE PHYSICAL DATA PRESENTED ABOVE ARE TYPICAL VALUES AND SHOULD NOT BE CONSTRUED AS A SPECIFICATION. SECTION 12: LABEL AND 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; LABEL(S): POISON. HM-181, IATA/ICAO AND IMO - PROPER SHIPPING NAME: THIOGLYCOL; HAZARD CLASS: 6.1; SUBSIDIARY RISK: NONE; UN NO.: 2966; PACKAGING GROUP: II; LABEL(S): POISON. SECTION 13? REGULATORY INFORMATION__________________________________;__________________ TOXIC SUBSTANCE CONTROL ACT (TSCA) 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 ABD00031759 Material Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 6 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 ABD00031760 [aterial Safety Data Sheet CHICAGO, IL 60606 312-807-3422 2-MERCAPTOETHANOL PAGE: 9 Morton International 100 North Rivtruid* Pfor/t. Chirnvo. /L60606-I598 312/807-2000 ABD00031761 w? v? ATERIAL SAFETY DATA SHEET 01.17.95 01/04 3J^INC.-P.O.DRAW. Y PENNY HOYAL RD-GEORGETOWN SC 29440,(803)546-B555 P jUCT NAME: POLIVIC S 202 35% 1.00 SECTION I. IDENTIFICATION CHEMICAL CHARACTERIZATION; in methanol solution. Fora : Liquid Color: Limp id-yellow Odor : Sweet Vinyl a 1 coho 1 -v iny1 acetate copolymer :.00 SECTION II. INGREDIENTS/HAZARD STATEMENTS CHEMICAL IDENTITY `Methano1 Methyl Acetate Proprietary CAS NO. 57-56-1 79-20-9 PEL TLV 200 ppm 200 opa PERCENT 47% max 12% WARNING STATEMENTS: The product is toxic by inhalation, ingestion and repeated or prolonged skin contact. After 5-30 hours, dizziness, headache, nausea, abdominal pains, visual disturbances may occur. A 30-120 ml ingestion dose can be lethal. Irritating effect on mucous msmbranas may oc:j; "This component is listed under Section 313 SAP.A TITLE III. The maximum concentration in the product is 47%. 9.00 SECTION III. PHYSICAL DATA MELTING POINT <'C> DENS ITT (c/al) VAPOR PRESSURE faa Hg at 20*C) Liquid 0.98-0.93 114 6-7 BOILING POINT <fC) : BULK DENSITY (g/al): VISCOSITY Ccp at 20"C> : SOLUBILITY IN WATER: 57-54 n.d. SC-120 Incomplete 4.00 SECTION IV. FIRE AND EXPLOSION HAZARDS FLASH POINT(METHOD): -1.89 *C(TCC) LEL: 6.7% UEL: 36% EXTINGUISHING MEDIA: (X) C02 (X) Dry chemical (X) A1coho 1-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. protect: 7E MEASURES TO AVOID F IP. E/EXP LOS ION: Do not store or mix with oxi dizers. 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 7. p 1 o s i v a. Vapor is heavier than air and can travel a ABD00031762 3V ATERIAL SAFETY UCT NAME: DATA SHEET POLIVIC S -202 35% 01.17.S5 02/04 considerable distance to a source o ignition and flashback. NFPA HAZARD RATING INDEX: (1) Health (3) Flammability (O'! Reactivity <NA) Special 5.0C SECTION V. REACTIVITY DATA STABILITY: f x) .Stable ' ) Unstable CONDITIONS TO AVOID: None under normal conditions o use. INCOMPATIBILITY ( ) water > strong acids ( > strong bases (2) oxidizers ( ) reducers ( ) combustibles (z) other: Keep away from alcohol reacting substances. HAZARDOUS DECOMPOSITION PRODUCTS On burning carbon oxides can be evolved. SECTION VI. HEALTH HAZARD INFORMATION ACUTE EFFECTS: Skin irritation <rabbit) eye irritation rrabbit): . 40 mg LD10 'oral, man): 6422 mg/kg Above health effects are for methanol. 500 ag/24H CHRONIC 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 SVALLGVING: 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 ABD00031763 3V ATERIAL SAFETY Pl^BUCT 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. VASTS DISPOSAL METHODS: Dispose in accordance with federal, state and local regulations. HANDLING AND STORAGE: Keep containers tightly closed. Ensure 1 good ventilation and exhaustion of the working area. Protect from r?st. Store 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 13 empty container-a. 9.00 SECTION VIII. CONTROL MEASURES RESPIRATORY PROTECTION: No respirator is required at methanol concentrations below 2QQ?pm. Supplied air respirator is required at m e t h a n: 1 concentrations above 2 0 0 p p m. Refer to NIOSH "Pocket Guide t: Chemical Hazards'* for proper selection for methanol. DERMAL PROTECTION: Rubber gloves, rubber apron and boots EYE PROTECTION: Chemical safety goggles VENTILATION: .Ensure- good ventilation 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 RG (lbs): 5000 for methanol TSCA STATUS: On Inventory SARA 313 LIST: Methanol is listed on SARA 313 list SARA 304 LIST: Not listed DOT STATES: Not listed NEW JERSEY EIGHT TO KNOW: Methanol is listed MASSACHUSETTS RIGHT TO KNOW: Methanol is listed PENNSYLVANIA RIGHT TO KNOW: Methanol is listed. waterways. rtWr. = not applicable n.d. = not determined "FOR CHEMICAL EMERGENCY" Spill, Leak, Fire, Exposure or Accident Call CHEMTHEC - Day or Night 1-800-424-9 300 The statements made herein are intended to provide product safety ABD00031764 1ATERIAL SAFETY : P^OUCT NAME: DATA SHEET POLIVIC S -202 35* 01.17.95 04/04 oroation, This material safety data sheet has been prepared with information currently available. Although care has been taken to provide accurate information, no warranties either expressed or implied are being made as a result of the presentation of this information. ABD00031765 MSOSCOOC; REVtStON: VCM 01/96 Vijta Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PWNT 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 Threadneedle Houston, TX 77079 TELEPHONE NUMBERS: CHEMTREC - Transportation Emergency (24-hr) Other Emergencies (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 Component* Number Weieht% 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 ABD00031766 MSOSCOOC: REVISION: VCM 01/M Vislo Chemical Company P. O. Box 19029 Houjfon, Texas 7722i*9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PRMTOATE: 03/21/M 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 toxitity 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 hemtopoietic 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. CaU a physician if irritation occurs. INHALATION: Remove to fresh air. If not breathing, give artificial 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 die instruction of a physician. Never give anything by mouth to an unconscious person. Page 2 of 10 ABD00031767 MSOSCOOE: REVISION: VCM 01/96 P. O. Box 19029 Houston, Taxos 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PWNT DATE: 03/21/96 5. FIRE FIGHTING MEASURES Flammable Properties FLASH POINT / METHOD: -108 *F (-78 *C) / PM AUTOIGNITION 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 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. CERCLA HAZARDOUS SUBSTANCE; Component CERCLA RO Maximum Wt. * VINYL CHLORIDE 1 lb. 99.99 Page 3 of 10 ABD00031768 MSOSCOOC: REVISION: VCM 01/96 Vista Chemical Company P.O. Box 19029 Houston, Texas 77724-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE; 03/03/96 FRMTOATE: 03/21/96 7. HANDLING AND STORAGE ELECTROSTATIC ACCUMMULATTON 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 ABD00031769 MSOSCOOE: REVISION: VCM 01/M Vito Chemical Company P- O. Sox 19029 Houston, Texas 77724-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/M PRMTDATE: 03/21/M 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 PeraUsfble Exposure Hafts TLV Threshold Lfalt Value TUA Tfs Weighted Averso* (8 hr.) STEL Short Tern Exposure Lfaft (IS afn.) Carcinogenicity VINYL CHLORIDE * Carcinogen according to die 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*FA)*C 2,943 77*F/25*C VAPOR DENSITY (Air-1); 2.15 BOILING POINT: 7.0*F (-14#Q MELTING POINT: -245*F (-153*0 SOLUBILITY IN WATER: 1.1 ml/1 77*F/25*C SPECIFIC 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 ABD00031770 MSOSCOOE: REVISION: VCM 01/96 Vista CHemtcal Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VISTA REVISION OATE: 03/03/96 PRMT OATE: 03/21/96 INCOMPATABCUTY WITH OTHER MATERIALS: Oxidizing materials, copper or copper alloys, aluminum or aluminum alloys, other metals which form acetylides. HAZARDOUS DECOMPOSITION PRODUCTS: Hydrogen dUoride, 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 ECOTOXICOLOGICAL INFORMATION: Not available. CHEMICAL FATE INFORMATION: Not available. Page 6 of 10 ABD00031771 MSOSCOOE: REVISION: VCM 01/tS Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PRMTOATE: 03/21/96 13, DISPOSAL CONSIDERATIONS SPECIAL INSTRUCTIONS: Evacuate the area and eliminate ignition sources. Contain the spifl. Wet down the area with large quantities of water. Dissipate vapor with water spray. Increase ventilation if in an endosed 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 die product may be required by the user at the time of disposal, since die product uses, transformations, and mixtures may change die 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 the 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 ABD00031772 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 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 75-01-4 SARA 302 STATUS: Component CAS Number Maximum Wt. % 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 7S01-4 99.99 (See Section 6 for CERCLA Reporting Requirements.) Page 8 of 10 ABD00031773 MSDSCOOfc REVISION: VCM 01/M Villa CKemkd Company P. O. Box 19029 Houston, Tejcas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 09/09/M PWNTOATE: 09/21/M International Regulations WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM (WHMIS) CLASSIFICATION: Cass D, Division X Subdivision A: Very toxic material. Cass D, Division X Subdivision B: Toxic material. Class A, Compressed Gas Pass 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: Chemical Name EINECS Number Ethene, Chloro- (C2H3CL) 2008310 JAPANESE MINISTER OF INTERNATIONAL TRADE AND INDUSTRY (MITT) INVENTORY LISTING: Name SECTION STRUCTURE Vinyl Chloride 2-117 AUSTRALIAN INVENTORY OF CHEMICAL SUBSTANCES (AICS) USITNG: Chemical ' CAS Number Vinyl Chloride 75-01-4 State Regulations CALIFORNIA SAFE DRINKING WATER ACT (PROP 65) LISTING: Component CAS Number VINYL CHLORIDE 7S01-4 Page 9 of 10 ABD00031774 MSOSCOOE: REVISION: VCM 01/96 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PRMT DATE: 03/21/96 16. OTHER INFORMATION Hazard Ratines HEALTH: FLAMMABILITY: REACTIVITY: NFPA 4 4 1 HMTS 4 4 1 the data and information contained herein are being furnished for informational purposes only. UPON THE EXPRESS CONDITION THAT EACH CUSTOMER SHALL MAKE TTS OWNASSESSMENT OF APPROPRIATE USE AND APPROPRIATE SHIPPING, TRANSFER AND STORAGE MATERIALS AND PROCEDURES FOR VISTA CHEMICAL COMPANY'S 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 FORA 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 ABD00031775 HARCROS CHEMICALS INC KANSAS CITY, KANSAS PRODUCT CODE! MATERIAL SAFETY DATA SHEET DATE7"'oi7oi/93"pAGE"oI 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-Phenylethylene; 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 Reactivitv:No Acute: Yes Chronic:Yes PHYSICAL DATA: Mixture:No Pure:Yes Soli3: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 l?een noted in workers repeatedly exposed to low concentrations of alpha-methylstyrene monomer. Eyes: Liquid alpha-methylstyrene monomer and concentrated vapors are extremely irritating to the eyes. IRDS: Eye-Rabbit 91 mg MLD. Skin: Prolonged skin gontagt can cause severe irritation, rashes swelling and blistering. Repeated skin gontact with alpha-methylstyrene monomer may produce dermatitis. Inhalation; 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 mg7m(3). Ingestion: When taken l?y mouth, alpha-methylstyrene monomer causes a pronounced irritation or mouth, esophagus and stomach. Oral LD(50) (Rat): 4900 g/kg. CONTINUED ON PAGE 02 ABD00031776 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 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 from contaminated atmosphere to fresh air. If not breathing, give artificial respiration, preferably moyth-to-mguth. If breathing is difficult, give oxygen which l? 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 alpha-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 ox boots. Emergency showers, emergency eye wash fountains and fire blankets. CONTINUED ON PAGE 03 ABD00031777 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 apparatys approved by NIOSH. Use water spray to cool t$nks. Fight fire from safe distance or from a protected location. BEWARE: Vapor is heavier than air $n$ may travel (i.e., crawl) along the ground to a source of ignition and flash back. Unusual Fire and Expiosion Hazards: Alpha-methylstyrene monpmer is a combustible liquid and can form explosive mixtures with air. Open flames, local hot spots, friction, static electricity and all 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 t ABD00031778 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 'f * SECTION V Physical Data Material is (At Normal Conditions): Liquid CONTINUED Appearance antf Odor: Water white liquid - characteristic sharp, aromatic odor. SECTION VI Reactivity Data Stability: Stable Conditions to Avoid: Combustible liquid. Keep away frpm heat sparks and flame. Electrically ground all hanal-ing equipment. Incompatibility: 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 392 dog. F. Strong ac;ds (e.g., concentrated sulfuric acia) 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 or released vapors. Isolate and adequately ventilate the spill area. Permit only trained personnel wearing full personal protective clothing and equipment (see "NORMAL HANDLING" in Syc. X) tp enter the $pill are?. Terminate the leak immediately, if possible. Contain the spill; do not allow alpha-ipethylstyrene to enter sewer or waterway. If necessary, dike with ary sand, earth or vermiculity. Spills of alpha-methylstyrene.should be reported to appropriate federal, state and local Environmental, Agencies, including The National Response Center T800-4?4-8802). If absorbed with earth, dry sand or vermicylite, place in drums, seal dryms and label 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. If disposed of as shipped, this material is a RCRA ignitable waste having a hazardous CONTINUED ON PAGE 05 ABD00031779 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 from heat, sparks and flame, Electrically ground all handling equipment. Keep container closed, yse adeguate ventilation (cf. Section III Respiratory protection). Observe OSHA Regulations on exposure limits. Avoid 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 daqiage. Store in accordance with QSHA Regulation 29 CFR 910.106 in a cool, well-ventilated location equipped with automatic sprinklers or fife , . extinguishing system. Keep away frqm 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 ABD00031780 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 ana 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 you have all current data relevant to.your particular use. Harcros Cheqiicals Inc knows of no medical condition, other than those noted on this material safety data sheet, which aregenerally recognized as being aggravated by exposure to this product. ABD00031781 MATERIAL SAFETY DATA SHEET <SP NO. -U5_ GENIUM PUBLISHING CORPORATION 1 t4S CATALYN STREET SCHENECTAOY. NY 12303-1636 USA (518) 377-8655 SECTION I. MATERIAL IDENTIFICATION nmmmmmmmmcum. SODIUM HYPOCHLORITE AQUEOUS SOLUTION -.rc <5-12%) OAfi February 1963 MATERIAL NAME: SODIUM HYPOCHLORITE, AQUEOUS SOLUTION (5-12%) OTHER DESIGNATIONS! Soda Bleach Liquor Bleach Solution# Hypochlorite Solution Ha Solution, SUNNY SOL Bleach (Jones Chemicals), Household Bleach (i.e. CL0R0X? PURE MANUFACTURER: Available from many suppliers, including! Canadian Industries Limited B!"iSaU Jones Chemicals# Inc. HESiffllL1!* mh Montreal, Quebec H3C 2R3 Tel: (716) 538-2311 SECTION II. INGREDIENTS AND HAZARDS Sodium hypochlorite (CAS 1007 661 529) Water, sodium chloride and sodium hydroxide (if present in excess). (Excess NaOK will pose an increased alkalinity hazard.) % HA2AR0 OATA ca 5-li No TLV Established 3alance Rat# Oral (12% Solution) 'Solution concentration can also be stated in terne of "available chlorine" which is- about 95% of NaOCl content by weight. "so C* 12 *5% coin is reportec to be much less toxic. SECTION III. PHYSICAL OATA Boiling point --- decomposes (see Sect V) Vapor pressure# 20 C# ms 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%------------------------- Freeting point# 12.0%# deg C - 1.09 1.1S 1.21 ca -25 Appearance 4 Odor: Clear# pale yellow or greenish liquid with a chlorine odor. Some products may contain an sxesss of NaOH end have a higher pH. SECTION IV. FIRE ANO EXPLOSION DATA rlMMtlMAtf Upper Nonflammable Jse extinguishing media that is appropriate for surrounding fire. Use water spray from a safe distance to cool fire-exposed containers# to dilute liquid# and control vapors. It is an oxidising agent. Vigorous reactions, can occur with oxiditable materials in a fire 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 caiTbe satisfactorily stable for months under proper storage conditions. Rate of decompoeition Increases with the concen tration and with the temperature. (12% NeOCl solution decomposes slowly. at,-40 C to yield NaCl and NaCIO J . Exposure to sunlight acceleratss decomposition It is incompatible with acids (liberates chlorine)# ammonia# urea, oxiditable materials, and metals such as nickel# copper# tin# menganese and iron (which cause liberation of oxygen) cw< C imo GENIUM PUBLISHING ABD00031782 SECTION VI. HEALTH HAZAItO INFORMATION Hon* Established eyelids. Then contact physician at once (ophthalmologist preferred?. ^ Skin Contact: Remove contaminated clothing. Flush 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. ingestionT Have physician contacted immediately. Rinse mouth with water. Give large Quantities of water or milk to drink. Induce vomiting. Repeat. Do not use acidic antiotes or sodium bicarbonate. An ounce of 1% sodium thiosulfate or milk of magnesia is helpful. SECTION VII. SPIU. LEAK. AND DISPOSAL PROCEDURES notify safety personnel of major spill. Clean-up personnel need protection sgsinst contact* with liquid and inhalation of mists and fumas. Contain spill and pick up whan possible for recovery or disposal. Keep concentrated hypochlorite solutions out of sewers and waterways. Do not usa combustible absorbents (such as sawdust) to pick up hypochlorite solutions. Small spills and residues can usually be flushed to a suitable holding area, and than with high dilution to the sewer. DISPOSAL: When necessary hypochlorits can be neutralized with weak reducing agents, and then the waste landfilled. Follow Federal, State and Local regulations. SECTION VIII. SPECIAL PROTECTION INFORMATION Provide general and local exhaust ventilation in the workplace to maintain fumas and mists at a minimum. (Workers should not have irritation affects from exposure.) Respiratory devices should be available for use in non-routine or emergency situations. Usa canistertype respirators suitable for chlorine (See USDS S3) with mist filters. tvoid 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 promptly and rinsed with water. Launder before reuse. Syewash fountains, washing facilities and safaty showers should be available in areas of handling and uie. SECTION IX. SPECIAL PRECAUTIONS ANOCOMMB4TS StorTTn closeJ^vnte3"^onEaXners"Tn"a cool, (below SSTTT^ry, well-venEIXaVed area away from direct sunlight, heat and incompatible materials (see Sect V) Keep separate from acids and ofgaaics. Usa adsquats ventilation. Protect containers from physical damage. Do not mix with acidic cleaning agents which can liberata chlorine gas .* Avoid inhalation of vapors, mists and fumas. Prevent eye and skin contact. DOT Classification: <7% Available Chlorine,* ORM-B I.D. No. NA 1791 Label: None - (49 CFR 172 101) >7% Available Chlorine, OORROSIVE. 1.0. No UN 1791 Label:CORROSIVE r\ Available Chlorine is about 7.35% NaOCl. . Incompatible with bowl cleaners containing OATA SOUACKS) COOfc 1,3-11,14,25,34,37,48,49 bisulfatss. _______________________ MED4CAI RtVtCWr 9 March 1983 GENWM PUBLISHING ABD00031783 CTTSin5ET3EriNITIUISr TABLES ABD00031784 APPENDIX C NODE DEFINITION TABLES ABD00031785 ABD00031786 ABD00031787 ABD00031788 ABD00031789 ATTRIBUTES OF THE DESIGN GUIDEUORDS ABD00031790 ABD00031791 APPENDIX D SITING/LAYOUT CHECKLIST ABD00031792 CHECKLIST ABD00031793 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. ABD00031794 2 2. LOCATION OF LARGE INVENTORIES 1. Are large inventories of highly hazardous chemicals located away from the process area? Yes, plant fay 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. 2. Is temporary storage provided for raw materials and finished products at appropriate locations? Yes 3. Are the inventories for highly hazardous chemicals held to a minimum? Yes 4. 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. 5. 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. 6. 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 3. LOCATION OF MOTOR CONTROL CENTER 1. Is the motor control center located so that it is easily accessible to operators? Yes 2. Are circuit breakers easy to identify? Yes, for the Express Project. ABD00031795 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 ofutilities (e.g., breathing air) - Transport ofhazardous materials from other sites - Possibility of long-term exposure of employees to low concentration of process material ABD00031796 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? ABD00031797 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 ofutilities (e.g., water) - Contamination from spills or runoff -Noise Yes Yes Yes Yes Yes Yes ABD00031798 6 - Transport of hazardous materials from other sites - Flooding (e.g., ruptured storage tank) - Odors Yes Yes Yes 7. UNIT LAYOUT AND LOCATION OF FACILITY RELATIVE TO NEIGHBORS 1. Are large inventories or release points for highly hazardous chemicals located away - from public access roads? - vehicular traffic within the plant? Yes Yes 2. 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. 3. Are workers in adjacent units protected and workers in this unit protected from the effects of adjacent units or facilities from all ofthe 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 4. 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. 5. 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? ABD00031799 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 of horizontal 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. ABD00031800 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. ABD00031801 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. ABD00031802 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 ofwind - Atmospheric dispersion ofgases 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. ABD00031803 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 ABD00031804 CHECKLIST ABD00031805 APPENDIX E HUMAN FACTORS CHECKLISTS ABD00031806 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. ABD00031807 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 ofall equipment? Yes. COMPONENT LABELING 3.01 Is all important equipment (vessels, pipes, valves, instruments, controls, etc.) clearly and unambiguously labeled? ABD00031808 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. ABD00031809 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. ABD00031810 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 ABD00031811 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. ABD00031812 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 ABD00031813 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. ABD00031814 f.hazop table: ABD00031815 APPENDIX F HAZOP TABLE ABD00031816 NOTE: The following are the frequency and consequence categories shown in the HAZOP table: FC: FREQUENCY CATEGORY F : CONSEQUENCE - SAFETY X : CONSEQUENCE - BUSINESS LOSS ABD00031817 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" ev s-i i-h 3 mo 0) o 4u> ~~ + _ 3-S VJ ^ ABD00031818 DESIGN IN T E N T IO N : STORAGE OF VCM 1 0 1 .1 0 HIGH INTERFACE /1 0 1 .0 TANK VESSEL - VCM STORAGE SPHERE ( c o n tin u e d ) ABD00031819 1 0 2 .7 H IG H CONCENTRATION ABD00031820 ABD000318! DESIGN IN T E N T IO N : REMOVE L IQ U ID VCM FROM VAPOR STREAM ^a 3< PI o " 3 -h s: Vi > H s S' 9 W> o J a 5o VH > 4) 2 e- O P) o E- < -H > c, H co Z 4) Q. 4) ---01- o> b O Vi 41 oE a -j 4) E 4J p> c -H T3 0 H c 3 EV w3 Z bXz H >H X u X QX 3 Zb CO CO Se Hxu ZpC IN m 4f tn 1--1 H rH LOW CONCENTRATION 1 0 4 .6 ABD00031822 D ESIG N IN T E N T IO N : TRANSFER OF VCM VAPORS TO UNLOAD R A IL CAR V) Th3 i3OVt l "O V3 0) 0<18 01 3O H1*4 8)" sc 0 VC 0) CO 01 0f3f)i OuJ a roi X rn 01 u o a C. g 0 a> E <00J 4OJ --fvno 3 <N 0a31 <N 4-H (CNN 0) i`,x 0a <71 o aHs ~O I<*N! & 0O1 QE. C0 ou >2 4) CT rs >cOH osOoS st ko>. Ea . c as (N m CS V 3 <>u0 O 2 3 DESIGN IN T E N T IO N : TRANSPORT L IQ U ID VCM TO PLANT ABD00031823 D E S IG N IN T E N T IO N : TRANSPORT L IQ U ID VCM TO ABD00031824 1 0 6 .4 H IS S IN G COMPONENT DESIG N IN T E N T IO N : UNLOADING L IQ U ID VCM PROM TANK CAR TO SPHERE ABD00031825 T3 431 C iJ C oo >-> 3 z ABD00031826 cn Mf3CVDlj3 U> 0C 1 0 6 .0 PROCESS L IN E - VCM STORAGE SPHERE RECIRCULATION (d w g : V S -0 9 3 1 0 S -P ID -D ) ABD00031827 DESIGN IN T E N T IO N : EVACUATE REACTOR IN PREPARATION FOR CHARGE JJ 3 3O -CH u 41 O TOJ VC c oc z (|J 4 J H a H o a. Q U a c* 1z5 M a. w Cu Ho CO *u <x o --m ro uo 41 <N <J 4) O TJ 41 0C c oc Z -H ycH uV aE<O410 *-^h3H u E w H w CO H u u a Os EM O. co e- X OM oz oQ Xz M < << HH o Oo (N (S <N EXTRA WRONG/ COMPONENT 2 0 1 B .6 ABD00031828 None o th e r (see h ig h p re ssu re in node 211) DESIGN IN T E N T IO N : CHARGE OF ING REDIENTS FOR POLYMERIZATION REACTION (r u .u* Xu ao <eo u -JoUV*j 1ch0Hi mc Jo3 OO3i s 0 H u <j - n 41 -- X* uo 0 (N 41 4) C -T3 00 zc X 01 H X c 41 -- u 41 X * 4-1 O O CN 41 4) C T3 OO ze M z M ro a bl H W * yuP--Ci H 0 < u X 4-1 4) 0 T) 0 41 C 4) 41 41 C cCc oc o o o Z -H Z Z z u c<e a xv - 0) 4a1 ev tH i3 Z LONG T IM E 2 0 1 C .6 ABD00031829 DESIGN. IN T E N T IO N : HEATUP OF REACTOR TO REACTION TEMPERATURE 0n1 33O' IM3 a QM i"! C 01 03 uC a0<1oi 41 e 4M) u3 >0 nNn u c 3V c o z 0 a. 3u r nn -03 E iJ C 3 U -H O -UH Ol o> u ns 3 3 rH I-H ns 3 a --. eo nO-i 3 33UO UV- mt>-I U C CO -rt 3 G <N 2 5 3 3 oi 03Ua1 01 -C 3 3 01 U Cu3. 0 3 V3 3 C o c o c o c0 z zzz ABD00031830 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) m-- .vc eo C -H zo 0<01 .U uc uv v> VMOO VM 3OC D1 V9 (9 -H C -rt I-H -> ~- Uoo uOMCrA-D I<mI0 c0y r-i u0 M3 >b. CV ffl eo <o p<H0 p-HH * uM M O C3 HVE 3 > XOV Hf>fl OU0 <VO0 pVH V 0) CV Z5 Q. v m e U -V <o0 u3 >n1 am V*4)i wV SCh3nUQEVM. -ppVH* >-- c M M VD *H V V <N u u C f V <D V0 M 1 > > pH > H V 01 Ma V rH e BS ID a V (3 H M 3 pH V (N y 01 01 3 u <n X 3 O W -- u U 3 S b. M vw 3 pH pH -M <D y WH cE M V JS u ya o V >. a. X a> u C o ABD00031831 u XH JO3 4J -O Oa Ou a. <1 V CO 703 zc -- as eo 4IU C tJl-H O -H CTl Z flj DESIGN IN TE N TIO N : POLYMERIZATION REACTION E 4> Z ABD00031832 u u < DESIGN IN T E N T IO N : NORMAL K IL L AT END OF REACTION m u*o 3 <8 V) O OM a. o V k00V311l kl a Hat VVm u U 41 v c o o -oa a> c oe z Z -H c H *o O c vvm kl v 0V1 ki c 0 C -H O -H Z * O aH. oM a 3v C -UH C oo m3 z 01 c o z 41 41 4) co c o C o zzz ca M 64 o z .H <N Cb Cb iH r-* Oo CN (N m lti Cb Ck Cb <oN o(N o<N U3 Cb H CN 0"N Ci-Hb OfN CoHb O(N CliOH ABD00031833 DESIGN IN T E N T IO N : IN REACTOR S T R IP P IN G AND RECOVERY OP VCM TcJn O <N 4) 41 oa V 4) 0 <N VV a. z V P oM CO "D0 zc C TJ O0 zc C TJ 0O zc C TJ O0 zc c o z CO H Zca ab U 4) <N O TJ O 41 C C 0c z NO SHORT TIM E/ 2 0 1 H .S ABD00031834 <o DESIGN IN T E N T IO N : ATMOSPHERIC DUMP OF POLYMER o OM CL * rH rao\ o *0 3O VV <n -cH 3 0 O3 4) 41 n v-- JUZ Ho 0 <N zO O<N O<N 11 GO z Vc oc ABD00031835 <u c r* 30 Ck U V 4) C0 T05 zc ou cv 4J 4) E c3 0 0 1-1 o tl Sui U 41 E c0 Urt Q 14 n<e --i u4) 0 oi 3 u sMCHii -mh j<:o xu 41 41 CH T3 O C 4a1 a si < U <4-1 4>J0 t0u -H -H 41 ' 0C) r--H4 c 4(0) H i5 41 <0 H Si 41 U 4J <H u4-1i aoi tn 4w> h a, c <>H0 (4U0i'H*4U-4cHJ -lIHQl U41 O H1-1 4411 U41 JT5 > O 5 M O Q. E m cH 30 30 4) 41 03 4) 41 CO 1O3 zc <uo0 41 4-1 41 41 C o z ABD00031836 u < None o th e r (see low flo w in node 221) omM Hu Xb. Cu U o> c-- mH Oa <n (H 0a co E0 zu (mn3U 4) c o z V c o z 41 4} c o c o zz eCl] 3 o z rH P* cn ^ i/i J H o J rH o -HO4 JH O *H3 O 04 04 04 04 04 HIGH REACTION RATE 201L.6 ABD00031837 DESIGN IN T E N T IO N : REACTION K IL L IN EMERGENCY S IT U A T IO N * 41 4) -cH 30 H<U *3O-4 41 4<r1> 41 ~H k <N O 04 41 41 C *0 00 zc mf k kOUfl 01 4u1 ow3 V k k C 4a) >4 <0 V -44) a k H4 C 41 4J -k mu h 4 Q 1 x ak faoii obK. Q5" Vz) ot-4 f*i p3i s tE4--i >Cil ua HVi Col* ouuzu5 uuzw5uCoO If K kk kOfkl 0C k 4a) 3 0 rX0HH 4o4C1) <a V3. k> Hh 4g1 u41 .--. 1kV-04 ko0 ka41 a a -- k iHa k00 k4a1 a 4J 4(01 k0 k k0 Co o <a kU 4) <4k0) c Ek * Jt -4kO> Uk g 0, u .-H 4> U > *u 0 0 t> c c 0* 44 -H Ci) t- tl 0 4 4) *-4 *-4 o v> Jj coo c 0 c 0 688 OS < M Jj iJ z z > o y T0J1 C T> o -4 c o yu E 4) Si -- Z UO M is 2, UJ pX zu M VI H a o X VI N o z U 4 H O z Q O W > Cd X o 4 X aCi.) uH ABD00031838 o >. c 57 H 4J > 4) O UO 3 41 mu a 41 wi r4,) a- u "Oc > -H o C -H 0u H IB ij e H O au a0- 3 <a a >, n cD c n H 4) 3 a> > 4) O O o nj 4-H UV <Ti 3 41 nu -J 0 4J n a 4) 4) a> a- u o H CO DESIGN IN T E N T IO N : VCM RECOVERY FROM REACTOR TO RECOVERY SYSTEM a>a. ev- jocj 4>> >M COJ O>. V> a o 441) >a. OV C4 X~ 3-g v <o Ol c -Ch -4a1 C 55 >- m u t> o > V .* .C -H 0H1 ,,O V Hi 03 cn O MJ Cn CO v> M None H IG H CONCENTRATION 2 0 2 .7 ABD00031839 4UJ < m o >9 gi 01 >- 3 z 2 0 2 .0 PROCESS L IK E - REACTOR TO RECOVERY SYSTEM ( c o n t in u e d ) T3 01 *3-> -0h u <9 30 U OS o Hb 01 < X 2 ua O a. H o r b0 <> u as b. O o H to o U z hH 7 2 Jo (0 oz 03 0> 0 i-- U u 3 o 0 M a ,, a> a. -H u 1) u 4J u uik9- MOQ O 3 0 0 OV O JVJ *J -< I" ao ro <n <r> o 4) JJ <n u O 3 o o 0V v< U a y -h s VM V a H o 01 03 VO u 01 1* c u H JJ oH I n V Ci b >9 o uc OH U --1 y <9 t> T0 w> > 01 O3 h 0 <u 1j 3-- a ro c (9 V > CC 2 <3U C\ OrH irHH <ON CON O<N 04 CM s s Cl. 3 3 o z rO* x u. <N <n O<N oo< None M IS S IN G COMPONENT 2 0 3 .4 ABD00031840 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 ke s to o long u < w3 Z oa aQe, o >. 4IQJ 4-)t Xu mE c Oh H CO fin> Q Q 4>1 * JS 2 Q< 01 Cl 41 a> o 4C1l *uJ H3 8S eH uO. n <*i aK. o *o V c o z -H j 4) 4C1 S'. u u I o z p* <x> ^ <*> rt W w o ooo fN <N <N <N 2 CaO O f* <n o<N o(N x s o z o<N ABD00031841 oaco. -uor->ti c-n C0 co a T3 o c. CO A DESIGN IN T E N T IO N ; CHARGE OF G H -2 0 TO REACTOR u0M1 4J u3 OO TOJ C Ua oVu 4J u MO -3c oo C m la-i, 01 -- 01 CO 41 -- --a co 41 U 2cO c0U 4) U 2cO c0U e oi ws-3 2 ax 2s Ch V0)i M U A01 -4AMr-1t iO-l 4J 4GJ AU -CH 0u) 0) C g. a o 03 U CuO u a a oa oas w u H (- o X ohH 3 Q X oM zX X oH CO <J\ * o <N a IN o <N (N ABD00031842 ............ 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 v a lv e manual : XuH OOX 2 Ck O Cd P 0 Ofs* c a H 0) J= T5 4J 0 C H-J V0 4) 0) 0) c _ f- X0 in1 (j Ck < Ck XO pH Cd O * 0e O (N 01 H V >3 a iJ 0 C wx 0 VCl B (D C K O O>-i P> O t-i < U a X 0a. 0 Ck t-1 0 Cd Cd OO *O 0 c fN 0H1 r 0u C DUV 0 ffj c -- f-C X Cd 0H ffi O < Ck Cd O X Cd OO (- C r-* O -H Z flj k41l uIV X -H 4J > 0 V 4aP k. u XV 0 iC >VD s41 O ^ 2 id fl I"1 r> <1 ki V m. /-->* iH41 0 U > c 0 41 01 .--t a r~>H C <0 >> 10 N 3 2 4J > 4> *4CIfl 0. aE C 4U> * 2 11 -OH c UU u rt M V c 0kl kl 4k)i 0>4 H 4) 3> O 41 V3 ki kl ca -* a *c s-js a* C0O. 4Q). 20 c o f<- f<- H* 2 3 Ck g gM i i * O2 O 43) C u c ou m so o<N rC-D rvj co o<N CN CO o<N r o r r e n a to r ope r O pe le ft M ISDIRECTED REVERSE/ FLOW 2 0 8 .3 2 0 8 . Q PROCESS L IN E - BME CHARGE TO REACTOR ( c o n t in u e d ) ABD00031843 ABD00031844 None o th e r (see low flo w ) DESIGN IN T E N T IO N : CHARGE OF HOT WATER TO REACTOR 5 4h0M1J) iHu0o 144-J1 OQ. <<-D( flj U41 41 41 Ufl TTJ) flJ S 3n rvH am - _u 35 .* 41 41 4) CO T0J ZC <n E a} -a< 4J C a6a3 .--ao4 o 0ue5 --n o> a u n o 4u3> O 4oJ M r-HH o 4) 4*1 u C V14 4-1 41 bj H3 dn I4I> zO41 -><Hua 63a <3u0 4> w3 Z w1-4 o-3 z u. S2 HZ S8 NO LOW PRESSURE/ 2 1 0 .8 ABD00031845 ue 0) 0) Q. C iQ U o> a ac E co 0> cQj ao. DESIGN IN T E N T IO N : CHARGE OF HOT WATER TO REACTOR oi a> V3j u3 4flJj r--H1 U IQ 01 V-l a *--t 01 0 2<Q O 4J -O C rl u0 ou UO 30 X i-i c JJ Uo o z l-H u JM CO to u CO Cd U Oas a. o |H 4) > H Q > flj a C T3 (0 01 0 0) 0> M fl X u iH 0) 3 0U1 I<T. 3 -h r~ I <<wQ >CO X ss $ c<0 V X> ev 2i >-> 3 Z ABD00031846 None 4) Vi D Ua 3 .c LH> 3 U * 0 &4) fl3 W rmv>"W > 01 3flj c 4C-1J 4V4) 4> CD aU, >m, 2 1 1 .0 PROCESS L IN E - IN IT IA T O R CHARGE TO REACTOR ( c o n tin u e d ) .mc rsn C o TJ 4) 3 CH U c 0 o m3 z -H > s >IQu Ws Wa. 1 <N s <n C -0H --4) c|Q atl 3 a > c41 s IN <N U4) u <En n uc<ud a vv. cO u3 a IQ 2 c o -C 3 0) V > Ifl to 4j r- I>Q 4M1 a o w a. -- 41 OS c c , 0 0H CTl 3 H 4-1 4rJt O 9) SZ o 0u c 41 a B O 4-1 a 41 91 o H 4) 0) Tf ft> k< s4z1 -OH E V -CrHD a Li c u 4) o 4 4) JZ u 3 a t3; C O a> a o z uX a 3L .c 4) 41 M0 30 AO4i <><>~a> 2 1 1 .1 0 LOW TEMPERATURE 2 1 1 .0 PROCESS L IN E - IN IT IA T O R CHARGE TO REACTOR ( c o n tin u e d ) m 0a IoQ eo H4) |UIO-- -- TJ ^ ret) *ovc0j orvJCXJwasuH. z t> r ABD00031847 at oH a P < Hi-i ZM pH H CN U o o z Xp Cl. a y 2 * VJ Cd Z >J< J 82 u at -3 J-i OH a a. |OWQ 4) sj 4) XI ao cp4 3 0 4H 0 c V -<-N1 & a* 23 b. 2 1 2 B .4 M IS S IN G COMPONENT O p e r a to r e r r o r : n o AMS le a d in g 4 F r e e z in g , no f lo w to h ig h e r fre e z in g p o in t . 4 ........... SOP, t r a i n i n g ABD00031848 2 1 2 B .0 PROCESS L IN E - MANUAL K IL L L IN E ( c o n tin u e d ) M IS S IN G COMPONENT - CO Z 52 f- XU OU 0 cv -- h r> <d 3 H 'H <n u vu <oN\ o. -- nnHO v>0u u oj o o s eu OlQ-Sl X 22 U. 2 1 3 .0 PROCESS L IN E - IN ER T VENT L IN E ( c o n tin u e d ) ABD00031849 ABD00031850 O3 X >. X ao cz 41 o cn hi w hi 41 c o z o CHfl D> X .-e4 Xc c* D hi uroa -- e hi -- -4 r * u> 1/1 -4 co 0j hi <--n 3 X C O-- T3 41 cx u X3 a 3 hi Xu ->H * 3 a a 33 1-4 to n aa. e*\ V n o) 41 V 9u $ as as s -->4. i-4 o 6 41 3a nw 3 , hi <hi C0 0H o 4J c o <0 a 4) 41 hi E -4 o hi V 3 hi Coo -H 3 hi a a c e> 0 0 u H0 hi a . 41 --ini hi 3 X hi ,, IS hi 41 41 Ua f3-t --4 E 41 hi h<0i X hi (7H1 41 X 3 Q - q. 41 hi 41 Dl 3 a C n IS 44 ID 41 hi 41 -H 3 hi 41 a a hi ac Vn 0) 4) - hi 3 41 <0 C hi X H u hi <3T> cn a 0 41 u hi H 4-H c a H 0 X *H o> hi >4 u X s u4 41 hi X H4 c -* V a-o hi ID E 4) ffl O o a, e 6E- 41 1c-4 3 TJ 3 T3 41 hi y 3 "D O hi O. O 41 aa hi hi o hi X4,) hi 0 41 E 0 z DESIGN IN TE N TIO N : AUTOMATIC SUPPLY TO K IL L REACTION C o aH > o 4h 3 "C4 hi c o H 3 uz uH >I C <0 X X y <n 2VE --<* *h -uH >w hi 3 w *c-* I O z M 4) V cc oo zz K X *h. a z i*. M Ol Ol Ol EXTRA WRONG/ COMPONENT 2 1 4 .5 Flow In d ic a tio n and tra n s m itte r on steam lin e (82-FT-083) ABD00031851 T5 O C a> >0 u U "O "4<O6) C 41 -- ti E ~y o ac 2z Z U o V O' z y r*t 3 1-1 o CL CL U O' 41 (X a: C -H n oH O fl fl fw -M 3 4) C i--1 u < a. T3 Li -h 3 0 3 0 41 o H U ay om 41 .-u O' U HU u e oJ c <0 41 4) (- o H 3 3 41 U U a a o' 0 0 u 3a u >. > ja a-* H <0 a CL O 4> 4i c L. a [v >J O <0 4J <n 0 O' 4) MU H a 4i D w y 4) E e -h 4 V) -H H 3 U C 4J -H 3a O3 ' M<uu Qa. 3-- gt W 4) ^a r* U U 3 o O 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 ) Broken n o z z le 3 e Hi ABD00031852 2 1 5 .0 PROCESS L IN E - S T R IP P IN G STEAM SUPPLY TO REACTOR ( c o n t in u e d ) <0 -- o -- 4) o c C -H -H H 4) E U flj 3 4) CD U CD CD 41 aU, CO O 4) O (TIN J CH N0 rOH <0n c -- -H U Q 41 4) a U UC 3 4) 3 CD o <9 4> CD 4) 0C *--1 *H a o> 3 CE 0 H H UV au c CO 9) 0 o M O 0 rH 41 4) UU C3 H CD CD CO 4) oU Qa > X 3o o 0 c VVn 41 c o z c o 4a1 3c 4J c o o Q Cil B uuhH. QS 23 tu Ui(HN1 4) C o V c o zz 4) c0 z u u a u0* 5 CaO* U o z r* go 0% o in H <n in H n in *M-* in H(N in H (N in pH CS in <N (N ABD00031853 <>0 UV v a* e 4< U41 -SH a 'H >n. C -B0H oX <Ja Ju 3 Xm u 0) 0 41 pH Ua 0 4J JZ c 0) p4 H jr C/) CJ c a0 --1 Q, M *4 4) 3 4J H Q0 EV (Q C Oi b< 0 Oi H 5 4J 03 f* 0) a3 u CO 10 * o 5 > 41 r--< |Q m c 4) H U -- c 3* -rt CO <S m CO o b 41 u 1-. CO Q.O. a 3 CN o O CD CO J -- a a c H B O >H 4J H CQ O a. 0 H B Q E a <a cn D <B > 41 H cu <O c <0 <0 4> u <0 4> >. > CO -ri U 41 c D1 41 3> r-4 4) 41 a a. 3U 3 .* CO cj n 0 41 f~t u ua 4) 4j J3 B Oi a CO O fi ao i--1 y -H C a o c -H H u IQ 41 3 O 3 IQ 0) > 01 41 41 UC Q. 0 oB u B S e O E 41 > 0) -H |Q u 0> c 41 |Q > 4) 4) MM 4 a. 3U 3 Jt 40 O o -1 M ua 41 *J c fi 01 H *H CO 0c QO 0B Hid Ucj -oh j= n<o c3i 4> o Uvo 4<<q1n <0 4) 0 ' ME <u 4) 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 ) -<uHq c>iC CSOi O (N s-- OX 41 (N O' ctCCHdt QX 123 tx EXTRA WRONG/ COMPONENT 2 1 6 .5 a uo ns C33 41 wns a. o & sOsC ABD00031854 t3^> -ooH uoy<au>0 c o u uV E <c0 a> VrO- u o <0 ti 3u U 41 *> >o 4) (j U 4lj1 c 4> C > 4J 4> 4i U X) ni 4u> taN\ a. -- tN Ce oo uu <ya <ya o a cc 30 c c 4) 3u E s. 2 1 6 .0 PROCESS L IN E - EVACUATION L IN E FROM REACTOR ( c o n t in u e d ) Em pty TJ V c o3 4a1 ao o z 4u> 3 4>-1 4J -Ul C0 C<0 U yc Z4) u<0 ABD00031855 M0 r~1 uH H (N Pi --CT\ O cA) --n> aa o0 ai DESIGN IN T E N T IO N : ATMOSPHERIC DUMP OF POLYMER FROM THE REACTOR JaS c4oJ 3 V4 -UI &PITS H 3 C UO 3 VM 4>) 3 <0 o uUc ev 21 M !E 6uaM QX a. u 2 R z 0 u XQ M <ad a XsX XQa 0H X O Z 0M X to t- CD c\ r* H <N fr--i <N rrH<N r H <N ABD00031856 ABD00031857 None o th e r (see no flo w ) 0> TJ V<0. gi V u-i >0 V) a 3 ns 0 Vi m aV c c 0 a3 4M) c o r--H1 -uH os c 41 -H Vl 41 e e 0rt V 10 u *H c H w-- co <n pnHs <T\ AS y H <** TJ ul C pH -H Ot--* 41 in Vi 10 a uu pH 01 ns H 41 u c jo= u a *cH o. D> v> 4J Cl. .e i M' o3s Ma. 0) ' 4i Vi OS 41 os <u 0 E 3 c3 01 IN H ON 4J IN Vi <7. u Vi h y Q K CO -- a -- a ns T , O *H c <ONS 0. Ci V CO *h0 IaN\ -H CO u -- H \On 3 nS y 4) h c o -H H * Vl a 0 u CO a -CH pH i--4* c* 41 41 Vi 0U1 3 ifl O Vi 4) 4i a E0 u 3 (0 a H iJ pH c. a y 41 0> 4i m V4 -H ot c 0 ns CO a T3 a a fn td o <p N n m f*l i*> a Vl OE 4> CH 01 41 Q. E 3 <V0l v> >H a Q. CO > Vl 4V>i 0 4) U 3 HO p3H H a c <0 p3HH 0 M<H0 41 HH uo 4) Vl pH <a y -eH H TJ pH ns ypi iOo 3 c 41 C r- as 10 Ol as 4> .c y 01 3 .U2 pH- Vl a 4) s CHU 4) O Z c- 41 C o z f+\ 3* 3 V V. o t) 4) 0e1 n o z NO LON PRESSURE/ 2 1 6 .6 ABD00031858 None o th e r (see low flo w ) r s a; 0 < n <*> ro >. >0 M a a u 0 a c a t> c rt rH TJ at (7> N 3N -> 0 a. c V > rH |Q > V U 3-- <-l W fl <9 r- N U) i--i n * f~ O' * > C 01 <Q X I OM V 0\ -- n 4) U * 4) Q c u c H hi 11 u I--1 -H w . -o Of i> 3C *rt a -i 1) n c -H u 4) U 3 "5 4-1 Q. <Q u3 Q. C ffl U 45 4) U 4) a * ev HH 3i z NO LOW PRESSURE/ 2 1 9 .8 2 1 9 . 0 PROCESS L IN E - RINSE WATER SUPPLY TO REACTOR ( c o n t in u e d ) ABD00031859 OM Cm CD a a Ma. ro O i ai 1 ot > a. 3o H a: o H ci 4 bJ a: 3 oU H u U >M h O H IH >< Q 9 o, a D CO U ccoo o bl O Jj a E -H tu 3 3 41 Q > fH <a oa a. a 41 -CH 41 V rH u N > 4U1 <>0 c <0 o .3 CN -w O .3-t --w 4) 1-4 o (N (N -H <W c 4l' >. C u *H I"> <0 f \ (ONt o cH Ifl o -c4 r-> a a O <0 fo >> H 41 > c 41 U o> o C CO <a x <--411 41 V C o 0c zz U 41 z o>--. 3 -O -aI- C U4> (aNt z-- _* Xc Q <0 u UV 4> <*> U COD 0 vu 3aQ*U Jj *u vFeH a 6 0*. wuv a~ None EXTRA WRONG/ COMPONENT 2 2 0 .5 m3 Z 9H(N) c\ o rH <N <N O ((NN (N n oc(N* oc<Nc on(N ABD00031860 <uO ru*i 3 mu u0 Q VU>0 u0ufi V gV> eo a V-- > u3 aint a Q <>o a rwv as 3- 2 2 0 .0 PROCESS L IN E - CLEAN N A LL A D D IT IV E TO REACTOR ( c o n tin u e d ) Secondary back-up system X. CJ uo o a} V 3 >U0 *1 a o z * o -- ac --o a u uU O CV Vu Oc c0 zo 4> c o z u U E UV QE i- 3 Z s S H 3 X o z X O r* rH rH O CN O (N O CN o CN O CN O <N CN (N CN CN <N CN 2* c ri 0 <n f3a 2O n ABD00031861 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 HIGH TEMPERATURE - > 4U> WK 3< s VI 03 S12US. 6 S( MS3i 41 -- .>-l O ns <n 'a 41 U OS 52 3 4) U -H ai 4) -hO' uo s O. ABD00031862 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 )/ i 2 cr> cn Z ae au fujuQ 11CQOzd >G1 >j* a. o< oat Dw w i rH (N NM uo zo>-* OH z <M HU >U Q ev MZ3i Z ABD00031863 DESIGN IN TE N TIO N : TRANSFER OF SLURRY TO BLEND TANK oIM O Tuuv3 Ua u 1u1 Va C H ne 4u3J S3 8 Q. 8? ax 2S b. ev i2- *o DESIGN IN T E N T IO N : STORAGE OF SLURRY ABD00031864 ABD00031865 <u JcH xa3> 0) c o z JC3 M3H fi 6 Si m3 Z gs U (J V c o z u ui 0 a. O r-4 ^ fH r-4 m r> <*) o oo ri n m 6 2^ DESIGN IN T E N T IO N : M A IN T A IN CONTINUOUS FLOW TO PREVENT S E TTLIN G 02 <0 Q X Cl- CO CO X ABD00031866 ABD00031867 DESIG N IN T E N T IO N : DEWATERING PRODUCT j ini V >1 4a) Ei- <*! f4-) <7\ -- - <n 4> U tc> 3 -H ij n Vc * 3 41 kH S3 V>Dii E4a1 C- O t4J1 3O *J U a O 41 U IIH 3 44-)i -Ch &m 4a) t4j> cre a ao iq a 4J 4) b UO VUi 4V) 0B) Mc c u o nj m c C0 -H C -H 8 4) -- -- C0 41 U C0 CO ZU -UH 10 I (N c> a- V0V< <0oH a* e t> ZH 3i os CHO OJ Z Ck ABD00031868 DESIGN IN T E N T IO N : TRANSFER PRODUCT FROM CENTRIFUGE TO DRYER a 01 0) c v -*H 01 a3 a 01 v c o z X o * E I 43aJ o z fa. O z C in <n ui v r** CD m ^ C oo M3 z vOrOo o m so so oo m f vo<*o> voo so V0 t+l VO t*t V <*> VD r> ABD00031869 "O Uo 4V1 Li ^>U. >sl. uc -3h 0<j 01 &l a u001 c uIB t_Qol. Li a -i -Q rH -H Ll H > 1 * -a V 41 JU* JUC U41 0 Hh l(lIHV 41 73 U ll B C *< IB H fl> Q, va ao <oH E 4> *-i 23 z> o CU 4) 73 O 4) 41 u41 OX V) Q HJ Zb. C/> W - Z o 2 O * j Cd ' > u z j S Q U U a. eo X ABD00031870 <4CJl DESIGN IN T E N T IO N : TRANSFER WATER FROM CENTRIFUGE TO CENTRATE TREATMENT Q Q 1O-4. c j 0 u41 --uo> 0n 41 4) C -o oo zc 4) c o z o t- o c oo ro~ ABD00031871 a Q M0. mO--<' >O 3CcoHub aCh: w a O3a ot- CpDCMabJ zVa). X Cb o 1wy X30a-. op DCO 5as. zoM igMJ M CcMoO yaa5.. zaMCuO O o <n om T) 3 -hj 703 3 oz T3 131 C CO V mco O oX 110))] II C zo ict zo O' B Om Oo' 3 0 8 .1 0 LOW TEMPERATURE ABD00031872 > -- o 3o aa>\ CM 3 uV o -- S3 3 0 8 .0 PROCESS L IK E - HPSW TO CENTRIFUGE ( c o n tin u e d ) QJ H O cs >< U u H '< oH 3 b. u O {-< < s >J> Q. a a w eu j u a u Q o z oX f- b. >J O a. a. Dw >J a 0. oMz D W <z 2o ua a 0) o a *h ij <ua co -H 0 u Vo O3 3o -0a a> u oz a E t> h 3 Z 0 U<0 TV3 ij n o 8 cu C<0 3 -h OM XQ WV) HJ M X 6. HIGH CONCENTRATION 310.7 ABD00031873 3 1 0 .0 PROCESS L IN E - DRYING A IR SUPPLY TO CYCLONE DRYER ( c o n t in u e d ) 0. T! OC CO IT) uV tn Mc * Gu O > u J <1 0. a, u so to 4> C zo oz *fc- S u 4) O id 3 UC no *4 *H ou eo 3 TJ O' O la xa <N <*uu 001 O -H u * V 4) CV 0o zc V - 3 Z cJ c3 <u il vX Q a2 U b. &X U til a to z o b M 5 CO u X 0. X 3 None H IG H PRESSURE 311,6 ABD00031874 4u> ~<n 3 OO 3 1 1 .0 DRYER - FLASH DRYER ( c o n tin u e d ) o -oo c 41 c <Q H 41 Uu 0) 3 ru 4J m 0u 41 01 a ce o 41 zU -JCh=n -40o1 Ve a 'H 41 U 41 3 u u 10 . 0u 4) 41 0. ce 0 4) zU 41 C o z 41 C a 4) UU 41 3 U U 10 0M 4) 4i a CE 0 4) Zu 4E> 041i UC U 01 41 3 -< XI c H u 41 C7> >. -H U X -o 3 a 0 u a u 41 a a n w m HU o o <h a H v> <D so a u 2H > H XZ ao u u z a. s u w S 03 a co 'Mo w Q. aC <0 o o 0) 41 -H c am 41 a o TJ u C u u OO U 0o 8S C*ii m S2 41 0 *3 b ucc t-4 Q S2US. E 41 >Z-> 3i M IS S IN G COMPONENT 312.4 c o VZ fi 3 e o 3 1 2 .0 PROCESS L IN E - CYCLONE DRYER WATER RECIRCULATION ( c o n t in u e d ) 4) c o z ABD00031875 X0 V c o z 4) c0 z f-i M m m n m m (+\ 2 If) tmH V c o z 3 1 3 .6 H IG H TEMPERATURE ABD00031876 <o TANK VESSEL - CYCLONE SEPARATOR AND PRODUCT RECEIVERS ( c o n t in u e d )/ u no a au vm j]a u2 co 7 hH D aZ oo a. *- a fc 4zW oH ac 2 u. M cc 2 MO <M CO Cl- . M u. O c 4 V 0) -- U-- 4 <0 vo 4-> O 0 ro 44 C "O O0 ZC > S' Z2 E4 Hi 8 eucc t-4 0X 23 1 u. HIGH CONCENTRATION 3 1 4 .7 DESIGN IN T E N T IO N : TRANSFER OF A IR TO ABD00031877 3 1 5 .8 /NO LOW PRESSURE ABD00031878 3 1 5 .0 PROCESS L IN E - PRODUCT FROM RECEIVER TO SCREENER ( c o n t in u e d ) tn T33 -- aw 0M6 > UUM a6 ofH awzwaaai zuucoe CO soabs. EOaoaaDc-. CO so au. ujo>< Mu u 05 r 0J <J c 3 J 0 *J 0u c ao H "0 XJ 0u OV 01(jih n <M 0 0 O UH 3 V <D 0 N 01 rH 'W V u>uuaj* ZoM HZU Vco z Unc M M 'H (1 II I) >>3 6 0 J2 eM DQOaa. i z0 CaO o CzMJJ CN uu ok3ol a c 4J H IG H PRESSURE 3 1 6 .9 ABD00031879 >m H *H 4) M O OJ u iq E a tn cH ,,*cH* 04. 4) <Ufl LOO > X) ' UX x(:n a> <*> H ft) X TJ ~ et Db aD o OaS a o CaL. 1z V > 0 uo ma co -H H a am m .* 0 o a .fl c 4> Si r*"4 o V a -- ev -ah ^<g c 2 Cu (0 os o z 'T i 3 u j X M f-4 O3 2S -* S/5 W S2 (- Au n X o X Z &- z Ci] V z X (N r*1 r ui SO r- r*> H r* H r- or4 r rt f*> r* r-< ro None HIGH SPEED 3 1 7 .9 ABD00031880 <u 0uo1 s 0H31 V) Q a a. V0 c <13 01 c> c M *u u001 a. o<A DESIGN IN T E N T IO N : TRANSFER OVERSIZE PRODUCT TO COLLECTION TANK PJ j<au03: .0 C J3 V C c H 0X X o 4v> n 1- 41 -- -UC PH0 <*i 41 4J CO TO3 zc o 00 m S' c o 41 41 C o c0 zz T3 431 C 'u c ou i 3 z o z oo nr-H 41 41 co c o zz 41 c o z ABD00031881 OJc Do*H SO >ffl. O Q, 4 os cM oo> 3 a cH j (N n U u<a on --sr H O * o J UH r>4H-1 H3 ^K *4 -r1H4 V MM n3 u -H H l? ft? XI UQ, 0 <W *H 0 a 0) c0 tyi UHC u CPQ Q KH-l <+) m * 0 *4 Oc' U* U <u0 -- <0 <1 <s a -> Vup o 4J o OH m H c v >a. !->> <OSi V CM Q a J>Qs U o14 u ucou ao>a- <Vua c4) a o 3 6 0V4 Q. 4M O 4J 01 U C3 XHw V014 a <n 4> />--4 <0 > u 4VJ ii >H Vc -OH w ti O m -aH Mo S'. VD 3 C C0u 3 Z None 3 1 9 .1 0 LOW TEMPERATURE ABD00031882 <o ............ 3 P r e v e n t iv e m a in te n a n c e p ro g ra m 3 D u stin g o f p ro d u c t, p ro d u ct lo ss Torn bag in vent V) w o X o< OS b. OS "3O qu 35 Ka oo f- eCO CO -*CJ --m O fO 4j V H 3m 1J -CHTl 0 8*. * 3 3o CH iH (N i/i r* a> o 4J c oo HI 3 z o> --1 ro O oO in rs (N mm o o oo (<N*> (nN <fN*> <<*N1 <N o<r>N INTERNAL LEAK / RUPTURE 3 2 0 .1 2 ABD00031883 <uU a ABD00031884 &o Q. t t- a pH O' vm 3 uo li 4J V c >o V M <N H H pH J t> t- JZ ' O' m H O' x-- r-H c M 1 * Ol 0 J --O' a En V O' H-- H V o c 3 H B m3 i M /-OH aa 3 O pH U 6> DESIGN IN T E N T IO N : SCRUBBING OF A IR USED IN DRYER U 2 ph 3 Z X 13 U CD $2 uiB -4OJ MB 4) O I <U0 1M -- pH > O' IQ pH 1/1 U <0 a *> xo u(i n> 41 O' Z 3-- LOW INTERFACE 3 2 2 .9 ABD00031885 /3 2 2 .0 TANK VESSEL - CYCLONE SCRUBBER ( c o n tin u e d ) 3 2 3 .1 1 HIGH TEMPERATURE ABD00031886 0 > -Q Dpt B C 5, JQ O TUl a, <0 o Cu "O V o C en O tn O3 J _< VV ccc o00 co a zzz <N c 0 z 0x "1 sb. ABD00031887 WO < 23 H ~ *0 <30 C <*n H O DESIG N IN T E N T IO N : STORAGE OP CENTRATE WATER 3 2 5 .1 0 HIGH INTERFACE c0 <a 4a1 3 C 4J c oo eu. >ai cu 23 J 3 o2 <*> tj *n io r- U<ON> I<</N*Il 4ffN*Pl in (rNoJ in in rNo (N in IN U -mH Si 4> 3 m o U -H V cw 23 O *H r4) >"5 8- 3 a 41 3 *o c o z 8 fc s S CD * in <mN iMmn ABD00031888 ABD00031889 D ESIG N IN T E N T IO N : STORAGE OF COAGULANT FOR CENTRATE TREATMENT 3 2 7 . 1 0 HIGH INTERFACE o < tn TI3k IQ 3 w41 Q -H T4J1 3 C C 0 m3 Z CE H IQ S' a a. O M O' c o o 4c) 3o XI o 41 U a no o in i>1J10 c 41 a V CO o c T5 uU * O O 3 <Q e IIQk 4J ao w o 4> a Si kk u 4) IQ Ik E0kk |Q r kk 4) iu a HJ 3 O 03 w u C 4H1 u . ai pk 41 C i- 41 u PcI H u U4) 0 -l co -4 3 aH 0i- w PI c 0 41 II O0' *J JC 4) Ik 3 IQ 4) E O U IQ 4kk1 3 H>. aa IQ m3 Oc ' 4c1 U 4) zo a-; 41 X 4J zo oz oz <N m *r <n kg p- p* r- p> r r~ r- IrNt IN IN IN r> m m Ii-N> ImN CO r r- n pi nin EV -I 3 Z 0) TUJ to a a u. <c A o DESIGN IN T F N T IO N : SUPPLY OF COAGULANT FOR CENTRATE TREATMENT 41 -- JuOS rc<*-*> -< V C l-i u *H 55 ABD00031890 caCol 01 0 C *0 oc a m vo cen *8 ? oc 0c 41 0 C0 C0 Z0 5 C0 *U3H a * 55 3 2 8 .9 HIGH PRESSURE O perator e rro r: manual v a lv e clo se d 4 Poor f ilt e r in g system . 4 ........... SOP, t r a i n i n g 9u>1 Ho Q. 0*0 U UO ABD00031891 3 2 8 .0 PROCESS L IN E - COAGULANT FROM TANK TO RECIRCULATIO N L IN E ( c o n t in u e d ) dOS V c% 0* ZU Uao1H9 roH Q UM 0411 cd V -H O 01 <0 n 3 ao f-uH aco O. 4) E0 -CH UO MC J3} v u0 aoHa ->H* ct?i aa-u* 3a u4) o C o 4>1 H 3 Z ABD00031892 V < /3 2 9 .0 TANK VESSEL - HYPOCHLORITE STORAGE TANK ( c o n tin u e d ) c V-- -C O' 4OJ InN 4) 4t C0 TO! zc V c o z 41 cc oo zz r> omm o\ IIN*! oc Vu cc oo zo O' IN "O hcn co 3 3 0 .8 N O / LOW PRESSURE None o th e r (see low le v e l in node 329) ABD00031893 3 3 0 .0 PROCESS L IN E - HYPOCHLORITE FROM TANK TO PUMP SUCTION ( c o n t in u e d ) 3 3 1 .1 0 HIGH INTERFACE ABD00031894 ABD00031895 OC. T3 -w C uO "a a <1 uu c0a 8-0 e jj >2-> i3 DESIGN IN T E N T IO N : PROVIDE CONTINUOUS FLOW TO PREVENT SETTLING 3 3 2 a . 11 HIG H TEMPERATURE ABD00031896 40f0aJ11l 0) TmH3 c V* U41 CD (C0J 0 aH *cH X T->J aOw. C -H H -3Q DESIG N IN T E N T IO N : STORAGE OP FLOCCULANT FOR CENTRATE TREATMENT K. U J0=) <M0 * D> 8*5 Ou 4cJ U4) M -<3UH0 U0 00 S' ue o 0) c0 zz O3ol c 4j coo -* a z cs n ^ i/t s e*y r> mm m m <*> <*n 0\ h f*i r> mm r<>n ABD00031897 DESIGN IN T E N T IO N : SUPPLY FLOCCULANT FOR CENTRATE TREATMENT 3 3 4 .1 1 HIG H TEMPERATURE m unD 3ivn Q Q l-H a. a: CTV <3- 01 c c o c01 Xx0t>l tl Jj 4J o t> 01 0c) n3 upH 0) c TT 01 c0 z 0) u cc 0o c o O3aJ C u C oo 1 3 z QX W tn g w t- z Xo CO o VU<uD0 4J >, c -uoH u otHi a 0 c f0VH1 a Ve JpH I0eH> 1*1 3 a t0i) 3 m o> co z 0) c o z 6- Xs o ^ UN H ABD00031898 -- u u 0) 4a1 -hu 4) SI - 23 ABD00031899 o < 0o1 3 COin * VI o ta xa. 03a1 CH 01 g I 01 u 0c1 Ho a <a a T3 4pJ 01 CM * N 40 c 14 4J o a c c H 4) oi 0 4> u U H u C 01 u 4> o 4) c H M4 H 3 aj <W 6* O p4 c 4! c a. o c h n C 0) H IQ >0 rH k> 01 U U - a oi O -H co a 0u1 u0) -- 3u^ oi -* o oi r- oi n i U CH aa uj 4J H c CO 4J 0 c -o- iJ o 1* u V o 41 4H *H iJ %4 T3 pH c a -H UH u <a o H o c H 0 Cl. Q 1 o Mz a< iH (?\ X jj T3 c C -H oHc -H >H T5 11 ffl C U k4 -H 3 Jj n Xa % o 4) a 1--< M O Cu a V5 DESIGN IN T E N T IO N : F IL T E R CENTRATE WATER o in c o u3 TJ 01 3 *CH c. u c0u z3 -hU u3a a c oi <a * u01 *>*J xu<8 z > oz inn n z0co) 0e) zo 01 c zo s 3 fUc aM: a* oz 23 X fa. M *> KO ^ rn**i en ri M IS S IN G COMPONENT 3 3 6 .4 ABD00031900 o < '0 3 O41 ' ifl w cn *cH c * u a Ch C h <U0 Qi Uu<c OU qa a a - co cOo QO cr>n o >* a 41 Cl C c41 iJ C * 4uij >H Jj c V > a Oco ou a 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 C O -Col 3C u u E Ci C o w3 Z 4!h1 *4J 41 rH X4J o er*> 4) C z0 o -a 41 41 41 V 41 Ccc o0o zzz g o ce X Ig-1 ~-v CO z <o 2 0. f- xco P0 z o-l o u zo u 2Q J <n zoHH H co a z ou X ohH X CO o \o <c n m r*> r> <*) m H>o oa o 71 7i 3 * 4) 41 41 > U CH 0 > a 4-1 41 flj CIt -3o e pci u 3 uO 3 C 9 3 0Cl c o <n 411- 3 n CD 41 u a X 3 3- S a. 22 s oz rs r- m r*> r- mn * MS3i 2 ABD00031901 U < 3 3 7 .0 PROCESS L IN E - CENTRATE F IL T E R BACKWASH L IN E ( c o n tin u e d ) O SQ z u. CWO z 8* ABD00031902 u U < E<Q U S' Mc ao a c <0 ku0uJ1 c o a -0(C-0H C0H a a< a n *<u-a> uuII > -rt SJ o\ ->h --ca* oua n cn DESIGN IN T E N T IO N : D R A IN AND VENT F IL T E R DURING SCOURING 3 Z U 3 at o <OD 3 U V c o z C u3 -H Z s u. 2 s 00 m > 0u1 >w 3Z H IQ a) 01 -oH ao ca a rH U -H 01 c o z 0> c o z 01 c o z 0) 01 c o z c 0 z i 2 tad. s 03 23 1 Ch o z C4 rt ^ 1/1 ^ f** co O oH 9 m 00 rfli CroO C<"O) ro m CO <<^r>> CD 9 rm**> fn*> 40 nm CD <f*t> ABD00031903 DESIG N IN T E N T IO N : SUPPLY A IR FOR F IL T E R BED SCOURING 3 3 9 .1 1 H IG H TEMPERATURE 0} uj rMa oa a j5 au 35 (N 2 -o aa ma ao U rt a ij c Ha Q. U-l 0 a a Q -5 8 V. a w 3a a a u 0. a *34 W a *4 an oH Uo ea a *h j: 3 U& aa u <n W e 14 3 a 14 *t4 a o c a Q. w C0> 0 -H u a3 ao 4Q Ua ea SI h 3 Z ax MS fiu ABD00031904 GDKAWING^-------- ABD00031905 APPENDIX G DRAWINGS ABD00031906 8 ? 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