Document rprGj5D8Jg0eM8VY65M8a9pxJ

ABD00029496 COPY No. 2 CONDEA VISTA COMPANY ABERDEEN EXPRESS, PHASE 3 ABERDEEN, MS PROCESS HAZARD ANALYSIS REPORT RAYTHEON ENGINEERS & CONSTRUCTORS RUST DIVISION PROCESS TECHNOLOGY DEPARTMENT September/October, 1996 ABD00029497 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: ABD00029498 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. ABD00029499 CONTENTS ABD00029500 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 PKA Team Analysis Aids 5.0. 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 5.11. 5.12. ANALYSIS Hazards of the Process Potential Safety and Health Effects Background Engineering and Administrative Controls Consequence of Failure of Controls Reactor Operation Previous Relevant Incidents Siting and Layout Human Factors General Deviations Formal Analysis Action Items 6.0. SUMMARY AND CONCLUSIONS APPENDIX At APPENDIX B: APPENDIX C: APPENDIX D: APPENDIX B: APPENDIX Ft APPENDIX G: Previous Relevant Incidents Material Safety Data Sheets Node Definition Tables Siting/Layout Checklist Human Factors Checklist HAZOP Table Drawings ABD00029501 TTNTRODUCTID?r ABD00029502 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 ABD00029503 27TROCES5^ DESCRIPTION ABD00029504 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 II 1.3 Physical data M IT 1.4 Reactivity data n 11 1.5 Corrosivity data ii II 1.6 Thermal and chemical stability data ii 1.7 Hazardous effects of inadvertent mixing No mixing hazards identified 2. PERTAINING TO THE TECHNOLOGY OF THE PROCESS 2.1 Block flow diagram or Process safety simplified proc. flow diag. information manual 2-1 11 J.Minga ABD00029505 PROCESS SAFETY INFORMATION # INFORMATION LOCATION 2.2 Process chemistry M 2.3 Maximum intended inventory " DATE RESPONSIB LE n " 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 II J.Heywood " 3.4 3.5 Relief system design and design basis Ventilation system design Equipment files, PSM room N/A (*) 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-093128-PID-D D 05-06-96 Product Storage - 600 Series Silos DY-093129-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 ABD00029506 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-093141-PID-D F 09-20-96 Centrifuges and Centrate DY-093142-PID-D E 09-20-96 Dryer and Separator DY-09314 3 -PID-D F 09-20-96 Dryer 10 Scrubber DY-093144-PID-D F 09-20-96 Dryer 10 Transfer DY-0 9414 5-PID-D D 05-06-96 Dryer 10 DY-093146-PID-D E 09-20-96 Dryer 11 DY-0 9314 7-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-093127-PID-D E 08-02-96 NM Normal Kill Systems NM-093128-PID-D E 08-02-96 NM Clean Wall Supply Systems NM-093133-PID-D D 08-02-96 Stripper Rinse and Flush System NM-093136-PID-D D 06-06-96 NM Emergency Kill Systems NM-093139-PID-D A 08-02-96 NM Dump Pumps and Strainers NM-093141-PID-D A 08-02-96 NM Low Mole Stripper Feed Tank NM-093143-PID-D E 08-02-96 NM Reactor RX-746 NM-0 93144-PID-D E 08-02-96 NM Reactor RX-747 NM-093147-PID-D E 08-02-96 Catalyst Injection Pots NM-093149-PID-D B 08-02-96 Hot Water Charge and Rinse Systems OM-093101-PID-D E 08-02-96 OM Hot Water Charge and Rinse Systems 2-3 ABD00029507 LIST OF DRAWINGS NUMBER REV DATE TITLE 0M-093137-PID-D E 08-02-96 Recycled Centrate Distribution UT-093113-PID-D E 08-02-96 Plant Cooling Water System UT-093118-PID-D B NO DATE Fire Water Deluge System UT-0 93122 -PID-D F 08-02-96 Plant Cooling Water System VS -093105-PID-D C 08-02-96 VCM Sphere VS-093107-PID-D D 06-06-96 East VCM Tank Farm Compressors VS-093108-PID-D E 08-02-96 East VCM Tank Car Unloading VS-093110-PID-D C 06-06-96 East VCM Unloading KO Tanks 2.4. Procedures Operating and maintenance procedures are currently in use in the existing facilities. ABD00029508 3. METODUTOGY ABD00029509 3.0. METHODOLOGY 3.1. Techniques The technique selected for the analysis is the HAZard and OPerability Analysis (HAZOP), which is considered the best identification technique for chemical process systems. It was used to determine the consequences of deviations in the process conditions. The HAZOP technique was specifically developed for chemical processes, such as the one being considered here. The P&ID's are divided in nodes or sections, colored and numbered for easy identification. A set of deviations is then postulated for each type of node by the team. These deviations are obtained by application of the HAZOP guidewords to the design intention of each node and to its attributes. Each deviation is then analyzed by the team to determine if there is a credible cause for it, and if so, to determine if the consequences are of concern, when both probable cause and consequences of concern are present, a potential hazard is identified. Safeguards for reducing the probability associated with the causes, or mitigating the consequences are then identified. If these safeguards are deemed insufficient by the PHA team, then recommendations or "action items" are listed to reduce the risk associated with the hazard. The following are the guidelines used for the definition of nodes and deviations: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Each major process component is defined as a node. Any component in which a level has to be maintained is defined as a node. Each tank or vessel with considerable volume is defined as a node. Each component in which a motor is attached (e.g., for an agitator) is defined as a node (with exception of fans and pumps). At least a line node is defined between component nodes. Each line with a process stream is defined as a node. Only one line node is defined for a series of components if there are no other flow paths (thus the line node may include pumps, fans, heat exchangers, valves, condensers, etc., unless any of these components must be defined as a node due to other guidelines. Each line branching off a process line is defined as a node. Only one node is defined for multiple equipment in identical service. Nevertheless, note that any action items recommended for the equipment analyzed will also apply to the other which were not analyzed for being in identical service. If two or more streams of different substances come together, the resulting stream is defined as a node, unless one of the lines is water for dilution, in which case the resulting stream is considered continuation of the non water stream. If two or more streams of similar substances come together, the resulting stream is not defined as a new node, but it is considered as continuation of one of the converging streams. Lines representing feeds of a given substance to different points of a piece of equipment are considered a single node. Utilities lines are not defined as nodes. For each type of node, at least a set of applicable deviations is defined, but more than one set may be defined for a given type of node, if there are substantial differences between sub-types, e.g., a set may be defined for a simple line (without pumps or heat exchangers) and a different set for a complex line (which includes pumps,...). In addition to the deviations obtained from applying the guidewords to the design intention and to its attributes, deviations of a general nature are also used (e.g., internal/external leak/rupture, external fire, sampling, thermal expansion in long lines, venting systems, etc.). The application of these guidelines leads, in some cases, to redundant 3-1 ABD00029510 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 ABD00029511 ABD00029512 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 ABD00029513 3 EXCESSIVE 4 UNDESIRABLE 5 INTERMEDIATE >5 LOW Mitigation planning should begin immediately. Corrective action should be taken within three months. Mitigation should be initiated within 12 months. Review existing safety controls and/or procedures to ensure their proper use and adequacy. No mitigation required. Where the risk is determined as a function of criticality and frequency by means of the following risk matrix: RISK MATRIX CRITICALITY FREQUENCY 1234 12345 23456 34 567 45678 3-5 ABD00029514 4. REVIEWS ABD00029515 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. fl Process Technology Process Technology Houston Smith Ken Campbell Deevie Rambus Luke Threadgill Steve Wilkes Rodney Strickland Dean Honeycutt Janice Minga Condea Vista Co. ft If II II II II M 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 ABD00029516 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 ABD00029517 5. ANALYSIS-" ABD00029518 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 ABD00029519 * Backup cooling water (firewater) A number of administrative controls intended to provide a safe work place were identified, such as: * Safe work practices (lockout/tagout, hot work permit, use of respirators in hazardous areas, use of personal detection badges, etc.) * Emergency response plan/team * Preventive/predictive/proactive maintenance program and procedures * Operating procedures * Maintenance procedures * Training program for operators, maintenance personnel, contractors, firefighting activities, emergency personnel, etc * Restricted access to hazardous areas, thus reducing potential exposure * HAZMAT training and procedures * Management of change system * Evacuation procedures after maintenance * Color coding of utilities lines * Use of generally accepted standards (for engineering, piping, painting, etc.) * Company standards, based in years of experience in working with the chemicals involved in this process, for its safe handling, storage, and processing. * Annual physicals for all employees * Use of hand held detection devices * Periodic noise surveys During the PHA meetings, credit was taken for the safeguards provided by specific and generic controls, as shown in the HAZOP table. 5.5. Consequence of Failure of Controls The potentially hazardous conditions which could lead to the hazards identified in 5.1 are systematically addressed in the formal HAZOP processes, and listed in the table shown in the Appendices of this report. The consequences listed in this table assumes failure of controls, which are then listed as safeguards for either reducing the probability of the event or mitigating its consequences. Whenever these safeguards were deemed insufficient by the team members, action items were included to further improve the safety of the system. Refer to the enclosed HAZOP table for specific scenarios of potential hazards, the risk associated with them, and the engineering and administrative controls, listed under safeguards, which reduce the associated risk. 5.6. Reactor Operation Since the reactor operation is a batch operation, each of the steps involved was analyzed together with the nodes involved in the step. The following is a description of the operation used during the analysis: * STEP 1: EVACUATION Design intent: To remove air from the reactor. Activity: By means of steam jet eductors, the reactor is evacuated to 27-28" Hg in about 8 minutes. Parameters: Flow, pressure. Nodes: 201A, 216 Notes: Skip this step in the case of "closed dump". * STEP 2: CHARGE Design intent: Activity: To charge ingredients to the reactor. Reaction ingredients are charged into the reactor using an automatic sequencing control system, as follows: 5-2 ABD00029520 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. 2 01B, 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: 2 01C, 211 the STEP 4: REACTOR Design intent: Activity: Parameters: Nodes: HEATUP To heat reactor contents to reaction temperature. Steam is mixed to the reactor jacket cooling water in external eductors. Steam flow is stopped once the desired temperature has been reached. Temperature, pressure. 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: 2 01E, 205, 208, 213 STEP 6: NORMAL Design intent: Activity: Parameters: Nodes: KILL To stop the polymerization reaction. When the polymerization slows down, as signaled by the reactor pressure dropping off, a chain terminating kill agent is transferred to the reactor. Flow, composition, pressure, temperature. 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 ABD00029521 Parameters: Nodes: Notes: to the blend tank. Flow, pressure. 2 01H, 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. 2 01J, 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: 2 OIK, 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: 2 OIL, 221, 223 Notes : This is an emergency procedure, typically in power failure affecting agitation, loss of water, or excess initiator. case of cooling * GENERAL PARAMETERS/DEVIATIONS: Deviations: Step/sequence, Nodes: 201M internal leak/rupture 5.7. Previous Relevant Incidents A list of previous relevant incidents is enclosed in Appendices of this report. The action items arising from the analysis of the previous incidents are included in the Action Items Tables. 5.8. Siting and Layout The possible safety considerations associated with layout and siting were addressed by means of a Siting Checklist. The completed checklist is shown in the Appendices of this report. The action items arising from the analysis of this checklist are included in the Action Items Tables. 5.9. Human Factors Human factors and their impact on the safe operation and maintenance of the process were addressed at all stages of the analysis. To insure more complete 5-4 ABD00029522 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 ABD00029523 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 ANALYSIS OF PREVIOUS INCIDENTS P 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 ABD00029524 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 ABD00029525 W 3 jj U vt -- rH o u JJ JJ V a&a >. >. ITJ u sE o TD 4) 41 4) 41 >1 4 OV >0 <0 XE T> D 1) a> 41 41 p >, Jj (4 o CO JJ rH o S <N U-l -- h m U <4 CN <0 ll U 01 H U <v H U 0 a -i (tj a 4i 4-> Vj 4P 0) -- 'H h 0 -h jj o a -h (0 u rH m -e jj HI JJ C Tl (0 nH a> h <0 41 u o (0 JJ pi 41 flj V U a; u 41 (J U 1< N O C <0 pi.* pi C tj H -H 4) -C (4 O T3 Vj -H JJ 0 0 J H fl H <o 41 C/1 *H JJ IJ H iJ fl fl) ih u n o s aa O -H Jj JJ A cH H CN e 4) JJ M 1 rH (N c H Jj m 41 g E o o 41 W fl 4) co rH 23 TJ pH Vj 4) F. a> s: 4i JJ JJ rH JJ -Q (4 0 0 jj pi W <4 S rH 41 rH 0} 4) -H 3 0) 3 (4 H 4) H Sh rH O rH a jj h (4 (0 4i <n U Vj H 4i .c JJ 3 JJ >4 41 H 41 3 41 41 u C JJ H TJ u 41 5*. JJ Vj mh o -- JJ JJ O H o in u (4 is U (* ll H I H K > CO (N JJ rH CO Vi 41 Jj rH > -H T! Q. (4 0 (TJ jj jj 41 C > -H 41 rH M H U m (4 TJ (N <4 0 IVj CN 4) CO 9) D OSM -- H rH --V JJ H > (N (N oCO H t41 0 0 41 >. JJ H P" i-i CU KO V r* \o r- 41 (N oH <N <N <N mV r-i 4-* (N <N * rH rH <N 1--1 a. JL --_____ a-- sss== --===== ==== ===== === ========== ====J ABD00029526 >1 >1 >, ID id ID SB X 4> 41 0 V JS 5 IB cO XX Tl o o T3 m i> 41 4) 4) V 41 1) 05 at as OS TJ SE 2u Vj 0) JJ T3 41 o JJ > J3 o p. u Sa 41 rl ii 01 H iJ JJ Jj 41 XS ID e 41 i m 11 o C H E 01 x: 41 J3 r-H 0 *H JJ TJ d >D oi Co c Vj 3 i) H XI T3 u jj i-- 41 '-- jj U H0 o H 3 O 0 H 0a < r--I JJ 0) --i a IJ-I 41 ID ID 11 3 >. 01 01 <j\ U Vj J= ijj O ou E (B CO H 11 jj 0u 41 3 ID 41 ro Q. U TJ Vi 41 0 d> c U U H 0 JB 1) i--l E 0 0 u 11 -C >, jj jj CH 0c1 *H 0N a 4) 41 01 Vj c U-l 41 U 41 41 0 JJ Vj <0 a 3 IU Oi c 01 C O H B Vi <V aa 0 m -H XJ *M-- XI JJ jj ID U to E -H 41 >, o N 44 H 01 41 41 Vi 01 Vi aj M tj c a JJ 4-1 Q) Qc H o 01 Vj 01 u 0) W IB u 41 c Vj XJ c x: H Vj Ol U H 0 Vj 41 c IB TJ JJ 3 0 ID >* 6 4-4 U 3u 41 41 3 tj -H rl Vj O Vi H 0 Q> n CO 3 Vj 41 u JJ > O 41 c 0 O 4-1 a d) 0) 41 Vt x: o o tl4 0 o > T5 OS a 3 u in 0 *H U CU a> L> C Vj 41 11 41 Z VJ5 iH CO (N m CO CO !** rH rH rH CT> *3* <N ABD00029527 K SUMMXRFAND" CONCLUSIONS ABD00029528 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 e 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 ABD00029529 X. PREVIOUS ~ RELEVANT INCIDENTS ABD00029530 APPENDIX A PREVIOUS RELEVANT INCIDENTS ABD00029531 INCIDENTS AT CONDBA 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 501 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: 7. Incident: 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. Worker was loading empty catalyst cardboard boxes in a dumpster. Instead of folding the empty boxes up before ABD00029532 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. 8. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker pinched a nerve in his back while working on a pump from a squatting position. July 3, 1989. Excessive pulling and straining while trying to loosen some bolts. One, pinched nerve in worker's back. 1) Pump couplings halves are to be sprayed with an anti seize solution at all subsequent similar maintenance; and 2) if more than normal effort is required to do a job of this nature, the pump is to be pulled and taken to the shop. Herbert Jackson back injury, July 21, 1989. 9. Incident: Date: Cause: Injuries: Mitigation: Reference: 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 CONDSA 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. ABD00029533 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 mans 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 ABD00029534 BTMATERHL SAFETY DATA SHEETS ABD00029535 APPENDIX B MATERIAL SAFETY DATA SHEETS U^. DEPARTMENT Occupational Safety and Health Administration MATERIAL SAFETY DATA SHEET OM M9. 4*^*1397* Required under USOL Safety and Health Regulations for Ship Repairing, Shipbuilding, and Shipbreaktng (29 CFR 1915, 1915.-1917) SECTION I MWA*,-*UI-AC^IttMl NAM( _ _ 1 CMtnoCMCY TCCCMOHC NO. The Nippon Synthetic Chemical -Industry Co.,, Ltd. | 06-314-1962 *UAtls ( irr. ieir.W/ir CMr; Q=6 W02akl-OhQ. Kft.s-lrn QaaVn CMtMlc*wroiVAvTnyriyAhoi HHfMiCAcvHii'V"' Foly.ynmer 49ft .lapan' roiiMguP 35wv"* SECTION II HAZARDOUS INGREDIENTS PAINTS.'RESERVATfVES. A SOLVENTS i - | TLV -1 ***** . _ ALLOYS AHD METALLIC COAT1MOS | % ( IUM^ ricmcmts H/ \ BASC METAL . - ,, . jf/ji CATALYST n ALLOTS. If * VEHICLE SOLVENT* AOOITIVU OTHtaS n METALLIC COAT1MOS n FruILnLECROMAETITNAOL OR CORE FLUX it OTHERS n. HAZARDOUS MIXTURES OR OTHER UQUIDS. SOUQS. OR CASES J it ft % fUTnLhVri None . OtkiM* PO'NT (*J va*o oecawec *nj vAnpe eCNtiiv iair*ii SOLUR'LltV IN WATER SECTION III PHYSICAL DATA m more imvitv ^o*ii m OCRCSMT. VOLATILE avvokt/uc m s_ CVARORATtee RATE t ... -It No Llai L_____________________ White- oovder with no odor fc et 20*4] \ Jless tHea $f {j 1 SECTION IV FIRE AND EXPLOSION HAZARD DATA \ tf1t CKTiMeutSHIMO MEDIA IIFLAMMASLt LIMITS 4 \p----uLi-------)i-------o- L* --\{ 1 Special Fiat f ichtinc aaoCEOURCS ... 1 unusual Fiat ano cxruosion maearos None especially PAGE ni (Continued on revarsa tide) ' Form CSHA*2l R*. M#r T* ABD00029537 . . SECVION V - HEALTH HAZARD DATA THRESHOLD L'Wii VALut .. ., . V3'- * ` None determined BFFCCrSOF MWl k.*POSu*l It may happen to effect the resoiratorvorean's as sar> - as dust in case of inhaling fine powder for a long time. 1 mi M(i|.NCv ANO I IHST A PROCEDURES It is not considered a toxic hazard. 4 Eves: to wash out without rubbing Skin: to. eliminate after handline * *1 ABlUTV UNSTABLE SECTION VI - REACTIVITY DATA GONOITIONS TO AVOIO STABLE imCOmpa rABILITY (Aisirrmt tv irtmdf X MAZAROQNJft OICCKAOUTlOw PmOOOCTS * ^* HPOAZLAYRMDEORUIZSATION MAY OCCUR WILL NOT OCCUR CONDITIONS TO AVOIO X .... .. .. .* - V - . ' SECTION VII - SPILL OR LEAK PROCEDURES STEPS TO BC 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 sweDt uo ( not be washed nut with wxt.eN ). WASTE OlS*OSAL MCTHOO _ to burn uo_'___________:: -** - - - . SECTION VIII SPECIAL PROTECTION INFORMATION RC&PiR..A..r.O..Rv protection (Samir f F^k trpri It is desireble to wear filte. r mask, when VLNl ILAMON local'exhaust cne very aus ty grace isj SPECIAL MECHANICAL (Gmenl) other PMOICCIIVL CLOVES EYE PROTECTION None especially None esneeiaiiv OTMkR PROTECTIVE EQUIPMENT None _e_s_pec. ia_l_ly . SECTION IX '. SPECIAL PRECAUTIONS PRECAUTIONS TO SC TAKEN IN HANOLING ANO STORING Non* ^owarally ; OnaT4y d<tR not rhenpe. at room * temperature and humidity.______ OTMLR PRECAUTION* .N. one genera, l,ly *. . ________ __________ _ PAGS f2l c * c f.4s Form OSHA*20 THE NIPPON SYNTHETIC CHEMICAL'INDUSTRY OJ..L1U. * N0.S-5.N0ZAKI-CK0. KITA-KU OSAKA, JAPAN US. DEPARTMENT Occupational. Safety and Htalth Administration MATERIAL SAFETY DATA SHEET OM| nm, MUIh Required under USOL Safety and Health Regulations for Ship Repairing, Shipbuilding, end Shipbreaking 09 CFR 1915, 1918,*1917> | CMCAOCMCY TKUtAHOMC NO. The Nippon Synthetic Chemical Industry Co. tr_ Ltd, I 06-31$-1962 - 9-6 Nozakl-cho. KIt-.a-lri. ------ ..... roIVvTnVm^ohol Polymer Panic. COQ .Tanan' rJUiOiuk 1 * . SECTION II - HAZARDOUS INGREDIENTS ' TAINTS. *RfSt*VAT!VlS. * SOLVENT! MOMENTS *% TLV RMhd N/ . ` \ ALLOYS AND anSTALUCCOATINQS AA** MCTAL CATAtVST a ALLOYS. VCMICLS SOLVENTS AOO'TIVCS OTMtOS n METALLIC COATINGS FILLER MCTAL tt run coatino on eoc fwx n oyhsrs n HAZAftOOUS MIXTURES or OTMtR LIQUIDS. SOLIDS. OR CASES None \%\ jf/j i tt rr-- It a TLV' % (Uahri # . uUMi i*rj MciwatVA*OM |<Mt vmo ocmshv (Aia*n SOCUeiLlTY IN WAtC* SECTION Ilf * PHYSICAL OATA . wore eAAvrrv egravCeSWuMT. VtOrLaAtT1LS | CVAROAATIO*! PATS l. *n No Llal^ 1.2-1. 1 at 20M less t i*n 51 | I1 1 } L_ AeetAMANCC AMR oooa White' powder with no odor SECTION IV FIRE AND EXPLOSION HAZARD OATA CKTl*CUfINe MlDlA _______________ 1 i .i \J-------- ------ A S'ICiau Fiat riCNTiNC PROCEDURES ... None esoeciallv _________________ ___ - \i *icunusual ano explosion mazaros None especially * PAC (1| (Continued on revarse tide) Form CSHA21 an. M*r 7* ABD00029539 SECTION V HEALTH HAZARD DATA TMR*HOlD VALWt ,,None d. e,termined "Vf?E!T o* *'vi M.Kp6iuC It may happen to effect the respiratorvorgans as sar* as dust in case of inhaling fine powder for a long time I Lit M(l|NCv AMO * INST Ato PROCEDURES ______ It is not considered a toxic hazard Eyes: to wash out without rubbing Skin: to. eliminate after handling StABILITY UNSTABLE SECTION VI - REACTIVITY DATA CONDITIONS TO AVOIO STABLE incoma rability fUatcrvm t*t artmaf MA2AKOOUS OCCtWtfOtiTlON RmUOUCTS I4A/.AROOUS POLYMERIZATION MAY OCCUR WILL NOT OCCUR CONDITIONS TO AVOIO X * SECTION VII - SPILL OR LEAK PROCEDURES '* STIRS TO BE 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 sveot up ( not be washed out with water ) WASTE DISPOSAL mcthoo to burn up SECTION VIII SPECIAL PROTECTION INFORMATION RESPIRATOR* PROTECTION /Wr 1 Fm*' f*rpwrl It is desirable to wear filt^er mask, VENTILATION local exwaust theJ very dliSty grace is SRECIAW mechanical /(jnienV OTHER when RHUIECTIVL CLOVES None especially EVE PROTECTION None especially UTMkM PROTECTIVE EQUIPMENT None especially SECTION IX SPECIAL PRECAUTIONS PRECAUTIONS TO SC TAKEN IN HANDLING AND STORING - Mon# ffanaranw : niialUy rfftM nnt AhAmloallv rhgng*.___at rQQ ` temperature and humidity OTHER PRECAUTIONS None generally PAGE (21 C6 IB.I4 Form OSHA-20 IH NIPPON SYNTHETIC CHEMICAL* INDUSTRY OLL1D. *. *t ti NO.S-ENOZAKI-CKO. K1TA-KU OSAKA. JAPAN ABD00029540 Material Safety Data Sheet The Oow Chemical Company Midland. Michigan 48674 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 53940 Page: 1 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: 04/14/95 MSDS:000055 1. INGREDIENTS: (% w/w, unless otherwise noted) HydroxypropyI methylcellulose Water Sodium chloride CAS# 009004-65"3 85"99* CAS# 007732-18-5 1-10* CAS# 007647-14-5 0.5-5* This document is prepared pursuant to the OSHA Hazard Communication Standard (29 CFR 1910.1200). In addition, other substances not 'Hazardous1 per this OSHA Standard may be listed. Where proprietary ingredient shows, the identity may be made available as provided in this standard. 2. PHYSICAL DATA: BOILING POINT: Not applicable. VAP PRESS: Not applicable. VAP DENSITY: Not applicable. SOL. IN WATER: See section 9* SP. 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 w Printed on Recycled and Recyclable Paper ABD00029541 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 Date: 02/10/92 Date Printed: 04/14/95 M$DS:000055 4. REACTIVITY DATA: STABILITY: (CONDITIONS TO AVOID) Avoid dust clouds or layers. INCOMPATIBILITY: (SPECIFIC MATERIALS TO AVOID) Oxidizing materia). HAZARDOUS DECOMPOSITION PRODUCTS: Same as for wood or paper. HAZARDOUS POLYMERIZATION: Will not occur. 5. ENVIRONMENTAL AND DISPOSAL INFORMATION: ACTION TO TAKE FOR SPILLS/LEAKS: Sweep up and use if possible, or discard using disposal method listed below. DISPOSAL METHOD: Preferable method is to dispose in landfill. Disposal can also be accomplI shed by incineration under controlled conditions to eliminate dust explosions. In both methods, disposal techniques should be in compliance with applicable federal, state, and local laws and regulations ' regarding management, use, handling, treatment, storage, disposal, and transportation of used chemicals. 6. HEALTH HAZARD DATA: EYE: Solid or dust may cause irritation or corneal injury due to mechanical action. SKIN CONTACT: Essentially nonirritating to skin. SKIN ABSORPTION: A single prolonged exposure is not likely to result in the material being absorbed through skin in harmful amounts. INGESTION: Single dose oral toxicity is low. No hazards anticipated from ingestion incidental to industrial exposure. The oral LD50 for rats is >10,000 mg/kg. INHALATION: Single exposure to dust is not likely to be hazardous. SYSTEMIC & OTHER EFFECTS: Based on available data, repeated exposures are not anticipated to cause any significant adverse effects. Birth defects are unlikely. Exposures having no (Continued on page 3) (R) Indicates a Trademark of The Dow Chemical Company ABD00029542 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: 3 Product Name: METHOCEL (R) F50 HYDR0XYPR0PYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: 04/14/95 M$DS:000055 6. HEALTH HAZARD DATA: (CONTINUED) adverse effects on the mother should have no effect on the fetus. 7. FIRST AID: EYES: Irrigate immediately with water for at least five minutes. Mechanical effects only. SKIN: No adverse effects anticipated by this route of exposure. INGESTION: No adverse effects anticipated by this route of exposure. INHALATION: No adverse effects anticipated by this route of exposure. 8. HANDLING PRECAUTIONS: EXPOSURE GUIDELINE (S): Dow Industrial Hygiene Guide is 10 mg/m3- VENTILATION: Provide general and/or local exhaust ventilation to control airborne levels below the exposure guidelines. RESPIRATORY PROTECTION: In dusty atmospheres, use an approved dust respirator. SKIN PROTECTION: No precautions other than clean body-covering clothing should be needed. EYE PROTECTION: Use safety glasses. 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 HANOLING AND STORAGE: Use reasonable caution and personal cleanliness. Cellulose ethers are water-soluble polymers which form aqueous dispersions by swelling and by successive hydration of their structural layers. There is no sharp solubility limit. CAUTION: (1) Under certain conditions a fine dust of this material in (Continued on page 4 , over) (R) Indicates a Trademark of The Dow Chemical Company ABD00029543 The Dow Chemical Company, Midland, Ml 48674 Emergency Phone:517-636-4400 Product Code: 539^*0 Page: 4 Product Name: METHOCEL (R) F50 HYDR0XYPR0PYL METHYLCELLULOSE Effective Date: 02/10/92 Date 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 (WHMIS) information. For information regarding state/provincial and federal regulations see The Regulatory Information Section. (R) Indicates a trademark of The Dow Chemical Company ABD00029544 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: R-1 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: OVH/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 MSO Sheet for health and safety information. U.S. REGULATIONS ssaasssaBsaiassama SARA HAZARD 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 111) 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 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. ABD00029545 The Dow Chemical Company, Midland, MI 48674 Emergency Phone:517-636-4400 Product Code: 539^0 Page: ft-1 Product Name: METHOCEL (R) F50 HYDROXYPROPYL METHYLCELLULOSE Effective Date: 02/10/92 Date Printed: Ok/U/95 MSO$: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 sa&sssamsasBSsaassBa SARA HAZARD 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 TDG INFORMATION: For guidance, the Transportation of Oangerous Goods Classification for this product is: Not regulated. (R) Indicates a Trademark of The Oow Chemical Company The Information Herein Is Given In Good Faith, But No Warranty, Express Or Implied, Is Made. Consult The Dow Chemical Company For Further Information. 28/02 94 18:08 0278 412984 ABD00029546 REVERTEX LTD 0002/003 Harco MATERIAL SAFETY-DATA SHEET conforms to_C Directive 91/1SS/EEC Alcotex 78 1. CHEMICAL IDENTITY Alcotex 78 is s 78% hydrolysed poly(vlnyt alcohol): CAS NO. 25213-24*5. CHEMICAL FORMULA:- -(Ca-CHOH^fCH^CHfOCOCH,)*,, 2. COMPOSITION Polyvinyl acetate, vinyl alcohol) total solids content 98.5% (min). 3. HA2AR0 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. EYES:* Wash eyes with running water lor at least 10 minutes gently prising open eyelids to ensure sufficient washing. Eye injuries from chemicals should oe referred to a doctor. INGESTION:* Wash mouth with water. Seek immediate medical holp. Show this data sheet to the doctor. INHALATION: Remove the person from exposure. 5. FIREFIGHTING MEASURES No special Hre precautions are necessary, in case of 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. 8. 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 AND CHEMICAL PROPERTIES APPEARANCE: Pale yellow powder. ODOUR pH Slight characteristic. 6-7 (4% aqueous solution) BOILING POINT: MELTING POINT: About 165'C (decomposes) FLASH POINT: FLAMMABILITY: >40*C (Pensky Marten Closed Cup).' Does not suppon 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 5 SOLUBILITY IN WATER: Soluble. OTHER SOLVENTS: Not soluble. 28/02 '94 18:08 0279 412984 ABD00029547 REVERTEI LTD 31003/003 10. STABILITY AND REACTIVITY Hazardous decomposition products at temperatures above 200*C include aldehydes and acetic acid. 11. TOXICOLOGICAL INFORMATION Polyvinyl alcohol Is of a low order of acute toxicity. Similar products have been shown to have LO 50 (PAT) > 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. * Vatues are actual results for analagous material Alcotex 72.5 12. ECOLOGICAL INFORMATION Polyvinyl alcohol Is readily degraded by adapted sewage sludges. 13. DISPOSALCONSIOERATIONS 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 safety legislation. 16. OTHER INFORMATION CONTACT: Or S Ormondroyd Hariow Chemical Company Ltd Tempiefieids Harlow Essex CM20 2BH England Tel No. International + 44 279 436211 Fax; + 44 279 444025 DATE OF ISSUE 25/06/93 . ISSUE NO. 1 The information contained herein Is based on the present state of our knowledge and is intended to describe our products from the point of view of health and safety requirements. It should not be construed as guaranteeing specific properties. t ABD00029548 Material Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 1 * SECTION It PRODUCT_INFORMATION________________ _____________ NAME: 2-MERCAPT0ETHAN0L DESCRIPTION: 2-MERCAPTOETHANOL CAS NUMBER: 60-24-2 USE: CHEMICAL INTERMEDIATE MSDS NUMBER: P001249-MCDWDK APPEARANCE AND ODOR: WATER-WHITE LIQUID; MERCAPTAN ODOR EMERGENCY TELEPHONE: 800-424-9300 24-HOURS - CHEMTREC PRODUCT INFORMATION: 800-251-5952 EFFECTIVE DATE: 01/27/92 SUPERCEDES DATE: 04/15/91 PRODUCT CODE: 1217000019 SECTION 2: HAZARDOUS INGREDIENTS___________________________________________________________________ A HAZARD EVALUATION OF THIS PRODUCT HAS BEEN PERFORMED. THE COMPONENT LISTED BELOW IS IDENTIFIED AS A HAZARDOUS CHEMICAL UNDER THE CRITERIA OF THE OSHA HAZARD COMMUNICATION STANDARD (29 CFR 1910.1200). COMMON NAME/CHEMICAL NAME CAS NUMBER APPROXIMATE X 2-MERCAPTOETHANOL/THIOGLYCOL 60-24-2 90 - 100 SECTION 3: EMERGENCY AND FIRST AID PROCEDURES EYE CONTACT: FLUSH EYES WITH WATER FOR AT LEAST 15 MINUTES. LIFT EYE LIDS FREQUENTLY. GET PROMPT MEDICAL ATTENTION. 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 ----------1--........... ................. " ~~ 100 North Riverside Plaza, Chicago. !L 60606-1598 312/807-2000 ABD00029549 Material Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 2 SECTION 4; HEALTH EFFECTS SUMMARY PRIMARY ROUTE(S) OF EXPOSURE: EYE - YES SKIN - YES INHALATION - YES EYE CONTACT: CAUSES SEVERE IRRITATION. VAPORS AND/OR MISTS CAN CAUSE MILD TO MODERATE IRRITATION. THE SEVERITY OF REACTION DEPENDS ON DURATION OF EXPOSURE AND FIRST AID PROCEDURES ADMINISTERED. SKIN CONTACT: CAUSES SEVERE IRRITATION. HARMFUL WHEN ABSORBED THROUGH THE SKIN IN SUFFICIENT AMOUNTS. THE SEVERITY OF REACTION DEPENDS ON DURATION OF EXPOSURE AND FIRST AID PROCEDURES ADMINISTERED. INHALATION: CAN BE IRRITATING TO MUCOUS MEMBRANES, ESPECIALLY FOLLOWING PROLONGED EXPOSURE TO MISTS AND/OR VAPORS. INHALATION CAN CAUSE DIZZINESS, HEADACHES, AND INCOORDINATION. NAUSEA, VOMITING, AND GASTROINTESTINAL UPSET CAN OCCUR. INGESTION: INGESTION CAUSES SEVERE IRRITATION OF THE MOUTH, THROAT, AND ESOPHAGUS. CAN CAUSE NAUSEA, VOMITING, AND GASTROINTESTINAL UPSET. ADDITIONAL EFFECTS: DEPENDING ON THE ROUTE, FREQUENCY, AND DURATION OF EXPOSURE, TOXICITY MAY EFFECT IN THE FOLLOWING ORGANS AND/OR SYSTEMS: RESPIRATORY SYSTEM. EYE. SKIN. AGGRAVATION OF EXISTING CONDITIONS: SOME OF THE COMPONENTS IN THIS PRODUCT MAY AGGRAVATE EXISTING MEDICAL CONDITIONS. INDIVIDUALS WITH MEDICAL CONDITIONS INVOLVING THE FOLLOWING ORGAN(S) AND/OR SYSTEM(S) SHOULD TAKE APPROPRIATE PRECAUTIONS WHEN HANDLING THIS PRODUCT: LIVER. KIDNEY. ALWAYS WEAR APPROPRIATE PROTECTIVE EQUIPMENT, AS RECOMMENDED BY YOUR Morton International too North Riverside Plaza. Chicago. IL60606-I598 312/807 2000 ABD00029550 4------- ------------------------------- ---------------- --------------------------------------------------- .---------------------------------------------------------- ---------------- ---------------------------------------------------- ' * . -- . ----------------- A- 0aterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 3 INDUSTRIAL HYGIENE OR SAFETY PERSONNEL, WHEN EXPOSURE TO THIS PRODUCT CAN OCCUR. SECTIQM_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 M0/kg 345 ng/kg 150 g/kg 300 g/kg 13,:200 mg/m3 OTHER TOXICITY STUDIES: 2-ME NAS FOUND TO BE MUTAGENIC IN SEVERAL TEST SYSTEMS, INCLUDING THE MICRONUCLEUS TESTCMOUSE), DNA INHIBITION(RAT-LIVER), UNSCHEDULED DNA SYNTHESIS(MOUSE), AND CYTOGENIC ANALYSISCHUMAN LEUKOCYTE). HOWEVER, 2-ME WAS FOUND NOT TO BE MUTAGENIC IN THE AMES TEST OR THE MOUSE LYMPHOMA ASSAY. CARCINOGENICITY - LISTED BY: ACGIH: NO IARC MONOGRAPHS: NO NTP ANNUAL REPORT: NO OSHA: NO SECTION 6: OCCUPATIONAL CONTROL PROCEDURES EYE PROTECTION: WEAR CHEMICAL SPLASH GOGGLES. AN EYE WASH FACILITY SHOULD BE READILY AVAILABLE. SKIN PROTECTION: WEAR RUBBER BOOTS AND APRON, PROTECTIVE CLOTHING, AND IMPERVIOUS GLOVES. BECAUSE A VARIETY OF PROTECTIVE GLOVES EXIST, ALWAYS CONSULT GLOVE MANUFACTURER TO DETERMINE THE PROPER TYPE FOR SPECIFIC OPERATION. Morton International 100North Riverside Plaza, Chicago, /L60606-1598 312/807-2000 ABD00029551 taterial Safety Data Sheet 2-MERCAPT0ETHAN0L PAGE: 4 RESPIRATORY PROTECTION: WHEN AIRBORNE CONCENTRATIONS ARE EXCESSIVE, WEAR NIOSH/MSHA APPROVED EQUIPMENT. DETERMINE THE APPROPRIATE TYPE BY CONSULTING THE RESPIRATOR MANUFACTURER. OBSERVE THE RESPIRATOR USE LIMITATIONS SPECIFIED BY NIOSH/MSHA OR THE MANUFACTURER. HIGH AIRBORNE CONCENTRATIONS MAY NECESSITATE THE USE OF SELF-CONTAINED BREATHING APPARATUS (SCBA) OR A SUPPLIED AIR RESPIRATOR. IN ADDITION, RESPIRATORY PROTECTION PROGRAMS MUST BE IN COMPLIANCE WITH 29 CFR 1910.134. VENTILATION: MINIMIZE EXPOSURE BY PROVIDING ADEQUATE VENTILATION. GENERAL (DILUTION) VENTILATION MAY BE ACCEPTABLE. HOWEVER, LOCAL EXHAUST VENTILATION IS RECOMMENDED WHEN VAPORS, MISTS, OR DUSTS CAN BE RELEASED. PERSONAL HYGIENE: WASH THOROUGHLY AFTER HANDLING, ESPECIALLY BEFORE EATING, DRINKING, SMOKING, OR USING RESTROOM FACILITIES. CONTAMINATED CLOTHING AND SHOES SHOULD BE THOROUGHLY CLEANED AND DRIED BEFORE REUSE. AIRBORNE EXPOSURE LIMITS 2-MERCAPTOETHANOL/THIOGLYCOL ACGIH TLV-TWA: NOT ESTABLISHED OSHA PEL: NOT ESTABLISHED SECTION 7: FIRE PROTECTION INFORMATION----------------------------------------------------------------------------------- FLASH POINT: 150 F, 66 C TEST METHOD: SETAFLASH CLOSED CUP EXPLOSIVE LIMITS: LEL (X) - NOT ESTABLISHED UEL (X) - NOT ESTABLISHED AUTOIGNITION TEMPERATURE: NOT ESTABLISHED EXTINGUISHING MEDIA: SMALL FIRES: USE AGENTS APPROVED FOR CLASS B HAZARDS (E.G. DRY CHEMICAL, CARBON DIOXIDE, HALON, FOAM, STEAM) OR WATER FOG. LARGE FIRES: USE WATER SPRAY, FOG, OR ALCOHOL FOAM. SPECIAL FIRE FIGHTING PROCEDURES: FIRE FIGHTERS AND OTHERS WHO MAY BE EXPOSED TO THE PRODUCTS OF COMBUSTION SHOULD BE EQUIPPED WITH NIOSH APPROVED POSITIVE PRESSURE SELF-CONTAINED BREATHING APPARATUS (SCBA) AND FULL PROTECTIVE CLOTHING. UNUSUAL FIRE AND EXPLOSION HAZARDS: WHEN EXPOSED TO FLAMES OR HIGH TEMPERATURES ENCOUNTERED DURING FIRE Morton International 100 North Riverside Plaza. Chicago. IL 60606-1598 312/807-2000 ABD00029552 Material 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 MAY BE HEAVIER THAN AIR AND MAY TRAVEL CONSIDERABLE DISTANCES FROM THE MATERIAL HANDLING POINT. VAPORS CAN BE IGNITED BY A SPARE, FLAME, CIGARETTE, ELECTRIC MOTOR, STATIC DISCHARGE, ENGINE, PILOT LIGHT, HOT SURFACE, OR OTHER IGNITION SOURCE. SECTION 8: REACTIVITY 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, ft TOXIC FUMES (e.g. CARBON DIOXIDE ft CARBON MONOXIDE). SUPPLEMENTAL SECTION 8 INFORMATION: 2-ME DECOMPOSES AT 157-158 DEGREES C AT 742 mm Hg. SECTION 9: SPILL AND LEAK PROCEDURES; RESPONSE TO SPILLS: STOP DISCHARGE, IF IT CAN BE PERFORMED SAFELY, AND CONTAIN MATERIAL. IF A SUBSTANTIAL QUANTITY IS SPILLED, RECOVER WITH PUMP OR VACUUM TRUCK. EXPLOSION-PROOF EQUIPMENT SHOULD BE USED IF THIS PRODUCT IS FLAMMABLE OR COMBUSTIBLE(SEE SECTION 7). OTHERWISE, USE AN ABSORBENT SUCH AS FULLER'S EARTH, CLAY, OR OTHER APPROPRIATE SYNTHETIC ABSORBENT. PLACE CONTAMINATED MATERIAL IN A SUITABLE CONTAINER FOR DISPOSAL. APPROPRIATE SAFETY MEASURES AND PROTECTIVE EQUIPMENT SHOULD BE USED (SEE SECTION 6). DO NOT FLUSH TO SEWER, STREAM, OR OTHER BODIES OF WATER. PRECAUTIONS: ELIMINATE ALL SOURCES OF IGNITION. DISPOSAL METHODS: IF DISCARDED IN ITS ORIGINAL UNUSED FORM, THIS PRODUCT DOES NOT MEET THE DEFINITION OF A RCRA HAZARDOUS WASTE UNDER 40 CFR 261. Morton International 100North Riverside Plaza, Chicago, IL60606'I598 312/807-2000 ABD00029553 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 1U PHYSICAL DATA____ A NON-VOLATILES (BY WEIGHT): pH: VAPOR DENSITY CAIR=1): SOLUBILITY IN WATER: EVAPORATION RATE (n-BUTYL ACETATE*1) < 0.1 7.0 NOT ESTABLISHED DISPERSIBLE <1 Morton International 100 North Riverside Plaza, Chicago. IL 60606^1598 312/807-2000 ABD00029554 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: PURITY: TYPICALLY > 99% 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; LABELCS): POISON. HM-181, IATA/ICAO AND IMO - PROPER SHIPPING NAME: THIOGLYCOL; HAZARD CLASS: 6.1; SUBSIDIARY RISK: NONE; UN NO.: 2966; PACKAGING GROUP: II; LABELCS): POISON. SECTION 13.i_. 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 100 North Riverside Plaza, Chicago, !L 60606-1598 312/807-2000 ABD00029555 Faterial Safety Data Sheet 2-MERCAPTOETHANOL PAGE: 8 FIRE HAZARD: SUDDEN RELEASE OF PRESSURE HAZARD: REACTIVITY HAZARD: IMMEDIATE (ACUTE) HEALTH HAZARD: DELAYED (CHRONIC) HEALTH HAZARD: YES NO NO YES 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 r 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 100 North Riverside Plaza. Chicago, lL 60606-1598 312/807-2000 ABD00029556 Material Safety Data Sheet CHICAGO, IL 60606 312-807-3422 2-MERCAPTOETHANOL PAGE: 9 * Morton International 100 North Riverside Plaza, Chicago, IL 60606-1598 312/807-2000 ABD00029557 ATERIAL SAFET7 DATA SHEET 01.17.95 01/04 .INC.-P.0.DRAW. Y FENNY ROYAL RD-GEORGETOWN SC 29440,(803)546-8556 P iUCT 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 -viny1 acetate copolymer :.QQ SECTION II. INGREDIENTS/HAZARD STATEMENTS CHEMICAL IDENTITY `Methane I Methyl Acetate Proprietary .CAS NO. 67-56-1 79-20-9 PEL TLV 200 ppm 200 ppm PERCENT 47% max 12% EARNING STATEMENTS: The product is tonic by inhalation, ingestion and repeated or prolonged skin contact. After 6-30 hours, dizziness, headache, nausea, abdominal pains, visual disturbances may occur. A 30-120 ml ingestion dose can be lethal. Irritating effect on mucous membranes may oc*:.: '"his component is listed under Section 313 SARA TITLE III. The maximum concentration in the product is 47%. 3.00 SECTION III, PHYSICAL DATA MELTING POINT < DENSITY (g/ml' VAPOR PRESSURE <mm Hg at 20*C> ?H r' Liquid 0.98-0.93 114 6-7 BOILING POINT (*C> : BULK DENSITY (g/ml): VISCOSITY Cep at 20"C) : SOLUBILITY IN WATER: 57-64 n.d. 6C-1Z0 Incomplete 4.00 SECTION IV. FIRE AND EXPLOSION HAZARDS FLASH POINT(METHOD 1 : -1.89 *C(TCC) LEL: 6.7% UEL: 36% EXTINGUISHING MEDIA: (X) COZ (X) Dry chemical (X) Alcoho1-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. PROTECTI 7E MEASURES TO AVOID FIRE/EXPLOSION: Do not store or mix with oxi Risers. 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 exp 1 os i v e. Vapor is hea^isr than air and can travel a ABD00029558 1ATERIAL SAFETY DATA SHEET 01.17.95 02/04 UCT NAME: PQLIVIC S -202 35X cons iderabls distance to a source o ignition and flashback. NFPA HAZARD RATING INDEX: fl) Health (3) Flammability (Q> Reactivity (NA> Special 5.QC SECTION V. REACTIVITY DATA S7ABIL A. i i fx) Stable Unstable CONDITIONS TO AVOID None under normal conditions of use. INCOMPATIBILITY < ) water ' strong aci ds ( > strong bases ( X ) oxidizers ( ) raduce rs ( ) combustibles f::) other; Kae? away from alcohol reacting substances. HAZARDOUS DECOMPOSITIQN PRODUCTS Cn burning carbon oxides can be evolved. 5.00 SECTION VI. HEALTH HAZARD INFORMATION ACUTE EF? eye irrit L Z L 0 (ora A zTr e h e a CTS : Skin irritation ^rabbit) ticn 'rabbit'!: 40 mg , man * : 5422 mg/kg th effects are for methanol. 500 ag/24H CHRONIC EFFECTS: The prod.uct 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 MAY BE AGGRAVATED BY EXPOSURE: Unknown FIRST AID PROCEDURE SWALLOWING: DERMAL EXPOSURE: EYE EXPOSURE: INHALATION: 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 position. Immediately remove contaminated clothing, wash with soap and water. Contact a physician if irritation develops. Rinse ayes under flowing water for 15 minutes. If irritation develops, contact a physician. Mova to fresh air. Administer oxygen and seek medical assistance if difficulty breathing. 7.QQ SECTION VII. PRECAUTION FOR SAFE HANDLING AND USE ABD00029559 3V ATERIAL SAFETY PHDUCT NAME: DATA SHEET POLIVIC S 202 35% 01.17. 95 03/04 STEPS TO sand, or residues methanol TAKE IN CASE OF SPILL OR RELEASE: Absorb with sawdust, similar and collect in a suitable container, wash with water. Do not breathe vapors due to residual content. WASTE DISPOSAL METHODS: Dispose in accordance with federal, state and local regulations. HANDLING AND STORAGE: Keep containers tightly closed. Ensure good ventilation and exhaustion of the working area. Protect from fro=t. 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 to empty containers. SECTION VIII. CONTROL MEASURES RESPIRATORY PROTECTION: Mo respirator is required at methanol concentrations below 2 0 0 ? ? a. Supplied air respirator is required at aethar.: 1 concentrations above 2 0 0 p p a. Refer to NIQ3H "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 vantilation and exhaustion for the working area. PROTECTIVE EQUIPMENT: Eye wash safety shower within 25 ft. 3.00 SECTION IX. ENVIROMENTAL AND REGULATORY INFORMATION ECOLOGICAL EFFETS: Do not discharge into drains or CSRCLA RQ (lbs): 5000 for methanol TSCA STATUS: On Inventory SARA 313 LIST: Methanol is listed on SARA 313 list SARA 304 LIST: Mot listed DOT STATUS: Not listed NEV JERSEY RIGHT TO KNOW: Methanol is listed MASSACHUSETTS RIGHT TO KNOW: Methanol is listed PENNSYLVANIA RIGHT TO KNOW: Methanol is listed. waterways. a not applicable n.d. * not determined "FOR CHEMICAL EMERGENCY" Spill, Leak, Fire, Exposure or Accident Call CHEMTREC - Day or Night 1-800-424-9300 statements made herein are intended to provide product safety T,3V MATERIAL SAFETY DATA SHEET ABD00029560 01. 17.S 5 04/04 F^;DUCT NAME: POLIVIC S -202 35% iraation. This material safety data sheet has been prepared with information currently a"ailabie. 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. ABD00029561 MSOSCOOE: REVISION: VCM 01/96 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION OATE: 03/03/96 PAMTOATE: 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 Threadneedie 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 Components CAS Number Weight% VINYL CHLORIDE 75-01-4 99.99 See Section 8 for Exposure Guidelines and Section 15 for OSHA Classification 3. HAZARDS IDENTIFICATION Emergency Overview Colorless gas. Liquid under pressure. Faint, sweet odor. CANCER SUSPECT AGENT. FIRE OR EXPLOSION: DANGER! EXTREMELY FLAMMABLE GAS UNDER PRESSURE. MAY CAUSE FLASH FIRE. Keep away from heat, sparks and flame. Keep container closed. 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 ABD00029562 MSOSCOOE: REVISION: VCM 01/96 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION OATE: 03/03/96 PRINT OATE: 03/21/96 SKIN: Prolonged exposure may cause hardening of the skin (scleroderma). Contact with liquid vinyl chloride may cause burns or frostbite. INHALATION: Short-term, high level exposure may lead to smothering (asphyxia), inability to sense pain (anesthesia), dryness of nose and throat, headache, rapid respiration, mental dullness, incoordination, nausea, unconsciousness and death. Damage to the liver and kidneys has been reported in animals following short term, high level exposure to vinyl chloride. Prolonged exposure of animals or people to vinyl chloride has been associated with toxicity to the liver, kidney, brain, bones of the hands, circulatory system, testis and lungs. Vinyl chloride can also cause cancer in humans (see Cancer below). Cancer: There is evidence that repeated, high level exposure to vinyl chloride can cause angiosarcoma (blood vessel tumors) to the liver in humans. Certain studies of vinyl chloride exposed individuals have also shown an increased incidence of other forms of cancer, i.e., hepatocellular cardnoma, brain tumors, lung tumors, gastric and gastrointestinal cancer, melanoma, and malignancies of the lymphatic and hemtopoiedc system. However, for various reasons, these studies do not conclusively link these tumor increases directly with vinyl chloride exposure. INGESTION: This product is a gas at room temperature and should not be a significant hazard via ingestion. (See Section 11 for Toxicological Information) 4. FIRST AID MEASURES EYES: Immediately flush eyes with large amounts of water for 15 to 30 minutes. Seek medical attention. Remove contaminated dothing. Apply loose, dry, sterile bandages. Call a physician. SKIN: Immediately flush skin with plenty of water. Remove contaminated dothing. Wash affected area with mild soap. Call a physician if irritation occurs. INHALATION: Remove to fresh air. If not breathing, give artifidal respiration. If breathing is difficult, give oxygen. Call a physician immediately. (Medical Toxicology, 1988). INGESTION: If swallowed, call a physician immediately. ONLY induce vomiting at the instruction of a physician. Never give anything by mouth to an unconsdous person. Page 2 of 10 ABD00029563 M8O8C00C: REVISION: VCM 01/96 Vista Chamicd Company P. O. 8ox 19029 Houston, Texas 77224*9029 VINYL CHLORIDE MONOMER REVISION DATE: 03/03/96 HUNT DATE: 03/21/96 5. FIRE FIGHTING MEASURES Flammable Properties FLASH POINT / METHOD: -108 *F (-78#C) / PM AUTOIGNmON TEMPERATURE: 882*F (472*Q 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 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. CERCLA HAZARDOUS SUBSTANCE: Component CERCLA RQ Maximum Wt. % VINYL CHLORIDE 1 lb. 99.99 Page 3 of 10 ABD00029564 MSOSCOOE: REVISION: VCM 01/96 Vista Chemical Company P O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION OATE: 03/03/96 mMT DATE: 03/21/96 7. HANDLING AND STORAGE ELECTROSTATIC ACCUMMULATION HAZARD: None. USUAL SHIPPING CONTAINERS: Tank can, ships and barges. STORAGE / TRANSPORT TEMPERATURE: Ambient. STORAGE / TRANSPORT PRESSURE: Dependent on ambient temperature. See Section 9. LOAD / UNLOAD TEMPERATURE: Ambient. STORAGE AND HANDLING MATERIALS: Carbon steel is suitable. Aluminum or aluminum alloys, and other acetylide-forming metals are unsuitable. 8. EXPOSURE CONTROLS / PERSONAL PROTECTION Engineering Controls Provide adequate explosion-proof, general and exhaust ventilation to meet TLV requirements and keep out of explosive range. Ventilate low-lying areas such as sumps and confined spaces. Personal Protective Equipment EYES: Chemical goggles or safety shield. SKIN: Full protective dothing, boots, and gloves. RESPIRATORY PROTECTION: Wear NIOSH-approved air-supplied or self-contained breathing apparatus for non-routine and emergency work. Page 4 of 10 ABD00029565 MSDSCOOE: REVISION: VCM 01/95 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE; 03/03/95 FRMT DATE: 03/21/96 Exposure Guidelines; Component VINYL CHLORIDE OSHA PEL 1.0 ppm, 8-hour TWA 5.0 ppm peak exposure for 15-min. ACGIH TLV 5.0 ppm, 8-hour TWA PEL * Peraissible Exposure Liaits TLV * Threshold liait Value TUA Tim Weighted Average (8 hr.) STEL Short Tera Exposure liait (IS ain.) Carcinogenicity VINYL CHLORIDE Carcinogen according to the NTP Annual Report. * Carcinogen according to OSHA. Carcinogenic to humans according to IARC. 9. PHYSICAL AND CHEMICAL PROPERTIES APPEARANCE: Colorless gas. Liquid under pressure. VISCOSITY: 0.281 cp -4*F/-20*C ODOR: Faint, sweet odor: VAPOR PRESSURE (mm Hg.): 1,293 32*F/0*C 2,943 77*F/25*C PHYSICAL STATE: Gas, liquid under pressure. BOILING POINT: 7.0 *F (-14*C) VAPOR DENSITY (Air-1): 2.15 MELTING POINT: -245T (-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 ABD00029566 MSOSCOOC: REVISION: VCM 01/M Vijta Chemical Company P. O. Box 19029 Houiton, Texas 77224-9029 VINYL CHLORIDE MONOMER VISTA REVISION DATE: 03/OS/M PWNT DATE: 03/21/M INCOMPATABILiTY WITH OTHER MATERIALS: Oxidizing materials, copper or copper alloys, aluminum or aluminum alloys, other metals which form acetylides. HAZARDOUS DECOMPOSITION PRODUCTS: Hydrogen chloride, carbon monoxide. HAZARDOUS POLYMERIZATION: Polymerizes slowly in presence of air, sunlight, or oxygen and rapidly in the presence of peroxides, generates considerable heat. 11. TOXICOLOGICAL INFORMATION EYES: Dryness of eyes has been reported in humans exposed to 500 ppm vinyl chloride. SKIN: No known data. INHALATION: Short-term inhalation exposure to high concentrations (> 500 ppm) of vinyl chloride has been shown to cause mucosal irritation and impairment of die 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 ABD00029567 MSOSCOOC: REVISION: VCM 01/tS Vista CHamtcal Company P.O.Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER REVISION DATE: 03/03/96 PfMNT DATE: 03/21/06 13. DISPOSAL CONSIDERATIONS SPECIAL INSTRUCTIONS: Evacuate the area and eliminate ignition sources. Contain die spilt Wet down the area with Urge 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 die EPA Hazardous Waste Number of U043. Re-evaluation of the product may be required by die user at die time of disposal, since die product uses, transformations, and mixtures may change die dassifications. 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 prompdy returned to a drum reconditioner, or properly disposed of. (See Section 6 for CERCLA Reporting Requirements) 14. TRANSPORT INFORMATION DOT DESCRIPTION: This product is regulated as a hazardous material as defined by die Department of Transportation. PROPER SHIPPING NAME: Vinyl Chloride HAZARD CLASS: 2.1 IDENTIFICATION NUMBER: NA 1086 PACKING GROUP: None ADDITIONAL INFORMATION: RQ (Vinyl Chloride) - 1 lb. ICAO / IATA DESCRIPTION: This product is regulated as a dangerous good as defined by IATA for air transportation. PROPER SHIPPING NAME: Liquefied gas, flammable, n.o.s. HAZARD CLASS: 2.1 UN NUMBER: UN 3161 PACKING GROUP: None ADDITIONAL INFORMATION: RQ (Vinyl Chloride) - 1 lb. (vinyl chloride) Page 7 of 10 ABD00029568 MSOSCOOE: REVISION: VCM 01/96 Vista Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VISTA REVISION DATE: 03/09/96 PRMTDATE: 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: fmpan*ni 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 7WJ1-4 99.99 (See Section 6 for CERCLA Reporting Requirements.) Page 8 of 10 ABD00029569 MSOSCOOC: REVISION: VCM 01/M Vista Chemical Company P. O. Box 19029 Houston. Texas 77224-9029 VINYL CHLORIDE MONOMER VISTA REVISION DATE: . 03/03/M PRMTOATE: 03/21/M International Regulations WORKPLACE HAZARDOUS MATERIALS INFORMATION SYSTEM (WHMIS) CLASSIFICATION: Oass D, Division 2, Subdivision A: Very toxic material. Cass D, Division 2, Subdivision B: Toxic material. Class A, Compressed Gas Qass 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: Nawif EINECS Niimhef Ethene, Chloro- (CjHjCL) 2008310 JAPANESE MINISTER OF INTERNATIONAL TRADE AND INDUSTRY (MITI) INVENTORY LISTING: Chemical Name SECTION STRUCTURE # Vinyl Chloride 2-117 AUSTRALIAN INVENTORY OF CHEMICAL SUBSTANCES (AICS) LISTING: Chemical Name CAS Number Vinyl Chloride 75-01-4 State Regulations. CALIFORNIA SAFE DRINKING WATER ACT (PROP 65) LISTING: Component VINYL CHLORIDE CAS Number 75-01-4 Page 9 of 10 ABD00029570 MSOSCOOE: REVISION: VCM 01/96 Visfa Chemical Company P. O. Box 19029 Houston, Texas 77224-9029 VINYL CHLORIDE MONOMER VIS1A REVISION DATE: 03/03/96 PWNT DATE: 03/21/96 16. OTHER INFORMATION Hazard Ratines NFPA HEALTH: FLAMMABILITY: REACTIVITY: 4 4 1 HMIS 4 4 1 THE DATA AND INFORMATION CONTAINED HEREIN ARE BEING FURNISHED FOR INFORMATIONAL PURPOSES OM.Y, UPON THE EXPRESS CONDITION THAT EACH CUSTOMER SHALL MAKE ITS OWNASSESSMENT OFAPPROPRIATE USE AND APPROPRIATE SHIPPING, TRANSFER AND STORAGE MATERIALS AND PROCEDURES FOR VISTA CHEMICAL COMPANY'S PRODUCTS. ALTHOUGH BASED ON INFORMATION SOURCES WHICH VISTA CONSIDERS ACCURATE AND RELIABLE, VISTA MAZES NO WARRANTY. EITHER EXPRESS OR IMPLIED, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, REGARDING THE VALIDITY OF THIS INFORMATION, THE INFORMATION SOURCES UPON WHICH THE SAME ARE BASED, OR THE RESULTS TO BE OBTAINED, AND EXPRESSLY DISCLAIMS LIABILITIES FOR DAMAGES OR INJURIES RESULTING FROM THE USE THEREOF. PREPARED BY: PHONE NUMBER: Vista Safety, Health and Environmental Department (713) 588-3491 Page 10 of 10 ABD00029571 HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: 05/05/93 PAGE 01 CAS # 000098-83-9 FORMULA: C(6)H(5)C(CH(3)):CH<2) CHEMICAL FAMILY: Aromatic Hydrocarbon CHEMICAL NAME AND SYNONYMS: Alpha-Methylstyrene: I 1-Methyl-l-Phenyletnyl sopropenylbenzene; ene; 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:Ye$ Pressure:No Reactivity:No PHYSICAL DATA: Mixture:No Pure:Yes Solia:No Acut$: Yes Chronic:Yes Liquid:Yes Gas:No SECTION 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 keen noted in workers repeatedly exposed to low concentrations of alpha-methylstyrene monomer. Eyes: Liquid alpha-ipethylstyrene monomer and concentrated vapors are extremely irritating to the eyes. IRDS: Eye-Rabbit 91 mg MLD. Skin: Prolonged skin contact can cause severe irritation, rashes swelling and blistering. Repeated skin contact with alpha-methylstyrene monomer may produce dermatitis. Inhalation; In cpncentration 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 ky mouth, alpha-methylstyrene monomer causes a pronounced irritation or mouth, esophagus and stomach. Oral LD(50T (Rat): 4900 g/kg. CONTINUED ON PAGE 02 ABD00029572 HARCROS CHEMICALS INC KANSAS CITY, KANSAS f* MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: 05/05/93 PAGE 02 SECTION ri 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 whil? 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-mputh. If breathing is difficult, give oxygen which i? administered only by trained personnel. Obtain medical attention promptly. Ingestion: If swallowed, DO NOT INDUCE VOMITING. Get medical attention immediately. Keep patient warm and quiet. Other Information: None SECTION III Special Protection Information Respiratory Protection: Less than 1,000 ppm; Chemical cartridge respirator with an organic vapor cartridge and with a full face piece. More than 1,000 ppm: Self-contained breathing apparatus with a full face piece. Escape: Self-contained breathing apparatus. Ventilation Required: Ventilation must be adequate to keep the atmospheric concentration of 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 of boots. Emergency showers, emergency eye wash fountains and fire blankets. CONTINUED ON PAGE 03 ABD00029573 HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PrSdUCT CoSii""l6^4^8P STYRENE~420# """""DATB7""o57o5755"pAGr03 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 ajr $n may travel (i.e., crawl) along the ground to a source of ignition and flash back. Unusual Fire and Explosion Hazards: Alpha-methylstyrene mongmer 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-1): 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 ABD00029574 HARCROS CHEMICALS INC KANSAS CITY, KANSAS MATERIAL SAFETY DATA SHEET PRODUCT NAME: ALPHA METHYL STYRENE 420# PRODUCT CODE: 16-00446-02 DATE: 05/05/93 PAGE 04 SECTION V Physical Data Material is (At Normal Conditions): Liquid CONTINUED Appearance and Odor: Water white liquid - characteristic sharp, aromatic odor. SECTION VI Reactivity Data Stability: Stable Conditions to Avoid: Combustible liquid. Keep away from heat sparks and flame. Electrically ground all hanal-ing equipment. Incompatibi1ity: 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 deg. F. Strong acj.ds (e.g., concentrated sulfuric acid) cause polymerization at room temperature. SECTION VII Spill and Leak Procedures Steps to be taken if material is released or spilled: Eliminate all sources of ignition in the vicinity of spil} 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 S$c. 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 vermiculite. Spills of alpha-mechylstyrene.should be reported to appropriate federal, state and local Environmental Agencies, including The National Response Center (800-4?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 m-at-e---r-i-a1 l is a RCRA ignitable waste having a hazardous CONTINUED ON PAGE 05 ABD00029575 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. ysevadeguate 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 damage. Store in accordance with QSHA Regulation 29 CFR 1910.106 in a cool, well-ventilated location equipped with automatic sprinklers or fife extingyishmg system. Keep away frpm 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 ABD00029576 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 reliaple. Harcros Chemicals Inc provides no.warranties, either expressed or implied and assumes no responsibility for.the.accuracy or completeness of the data contained herein. This information is offered for your infor mation, consideration and investigation. You should satisfy yourself that you have all current data relevant to your particular use. Harcros Chemicals Inc knows of no medical condition, other than those noted pn this material safety data sheet, which aregenerally recognized as being aggravated by exposure to this product. ABD00029577 MATERIAL SAFETY DATA SHEET <SP NO. -112- GENIUM PUBLISHING CORPORATION 1145 CATALYN STREET SCHENECTAOY. NY 12303-1636 USA (518) 377-8855 SECTION I. MATERIAL IDENTIFICATION onmmmmmmta tom. sodium HYPOCHLORITE AQUEOUS SOLUTION AATC (5-12%) February 1983 MATERIAL NAME: SODIUM HYPOCHLORITE, AQUEOUS SOLUTION (5-12%) OTHER DESIGNATIONS: Soda Bleach Liquor Bleach Solution* Hypochlorite Solution- Na Solution, SUNNY SOL Bleach (Jones Chemicals), Household Bleach (i.e. clorox PURE MANUFACTURER: Available from many suppliers, including: Canadian Industries Limited . SSf'iS*11 Montreal, Quebec H3C 2R3 Tel: (716) 538-2311 SECTION II. INGREDIENTS ANO HAZAftOS % HA2AR00ATA Sodium hypochlorite (CAS >007 681 529) Water, sodium chloride and sodium hydroxide (if present in excess). (Excess NaOH will pose an increased alkalinity hazard.) :a S-li No TLV Established Balance Rat, oral (12% Solution) Solution concentration can also be stated In tense of "available chlorine" which is- about 95% of NaOCl content by weight. LD50 ca 12 mg/kg *5% soln ie reportec to be much less toxic. SECTION III. PHYSICAL OATA Boiling point decompose# (see Sect V) Vapor pressure, 20 C, na Hg ------- 17.5 Water solubility ----------------------------- complete pH ("neutral" solution)* ----------------- 9-10 Molecular weight -------------- 74.4 Specific gravity (20/4C): 5,25% (Household bleach) - 12.0%----------------------------- Freezing point, 12.0%, deg C - 1.09 1.15 1.21 ce -25 Appearance t Odor: Clear, pale yellow or greenish liquid with a chlorine odor Some products may contain an excess of NeOH and have e higher pH. SECTION IV. FIRE ANO EXPLOSION DATA Flash Fani end MafKod Am Monition ton#. rtorwnobiiify iMOtft in At Lower Upper Nonflammable Use extinguishing media that ie 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 oxidlsable materials in a fire situation. It can be decomposed by heat. Chlorine liberated on contact with acid. If safe, remove containers from fire area 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^hes^^Miter^oTution^cenTbr^atTsFactorn^^taETe 2or months under proper storage conditions. Rate of decomposition increases with the concen tration and with the temperature. (12% NaOCl solution decompose* slowly at.-40-C to yield Nacl and NaClO.). Exposure to sunlight accelerates decomposition. It is incompatible with acids (liberates chlorine), ammonia, urea, oxidlsable materials, and metals such as nickel, copper, tin, manganese and iron (which cause liberation of oxygen). Aoy GENIUM PUBLISHING ABD00029578 no- - U5 SECTION VI. HEALTH HAZARD INFORMATION uv Non* Established iixaxxnity, possible chlorine generation, and the oxidant properties Ingestion of a few ounces at 12% cone, can cause corrosion of mucous membranes. Mrfara. tioun ofi esophnagus eanda sctoammaecchn*, anda laryngeal edaema; may ll'ee--aaddJ --ttoo cc--oo---nn--vv--uullssiioonn*. coma* deIaOt-h. 9i!?jila?l IjgiAiBj! J?SSitft?!,0J.SM,oLiupSlBcanna.r_yca,_euds_ee_bron- Additional effects have included circulatory collapse and deliritm. Liquid contact can irritation of the the eyes or skin with blistering and eczema (especially at 12%) FIRST AID; t.ye contact: Irrigate eyes with running water for at least IS minutes, including under eyelids. Then contact physician at once (ophthalmologist preferred). Skin Contact: Remove contaminated clothing. Plush affected areas with copious amounts of water, or shower. If irritation persists or if large areas of body are affected, contact physician. Treat burns as needed. Inhalation: Remove to fresh air and obtain medical help. ingestions' Have physician contacted immediately. Rinse mouth with water. Give large Quantities of water or milk to drink. Induce vomiting. Repeat. Do not us* acidic anti* otes or sodium bicarbonate. An ounce of 1% sodium thiosulAfate or milk of magnesia is helpful. SECTION VII. SPILL, LEAK. AND DISPOSAL PROCEDURES Notify safety personnel of major spill. Cleanup personnel need protection against contact with liquid and inhalation of mists and fumes. Contain spill and pick up when possible for recovery or disposal. Keep concentrated hypochlorite solutions out of sewers and waterways. Do not use combustible absorbents (such as sawdust) to pick up hypochlorite solutions. Small spills and residues can usually be flushed to a suitable holding area, and then with high dilution to the DISPOSALi When necessary hypochlorite can be neutralised with weak reducing agents* and then the waste landfilled. Follow Federal* State and Local regulations. SPA (CWA) RQ is 100 lb. (40 CFR 117). Hypochlorite can be harmful to aquatic life. SECTION VIII. SPECIAL PROTECTION INFORMATION Provide general and local exhaust ventilation in the workplace to maintain fumes and mists at a minima. (Workers should not have irritation effects from exposure.) Respiratory devices should be available for use in non-routine or emergency situations. Use canister* type respirators suitable for chlorine (See MSDS S3) with mist filters. Ivoid 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 contaadnated with liquid to be rmeved promptly and rinsed with water. Launder before reus*. Eyewash fountains* washing facilities and safety showers should be available in areas of handling and ude. SECTION IX. SPECIAL PRECAUTIONS ANO COMMENTS Store in closed, vented containers in a cool, (below air), dry, well-ventilated area away from direct sunlight, heat and incompatible materials (see Sect V) Keep separate from acids and ofganlcs. Use adequate ventilation. Protect containers from physical damage. Do not mix with acidic cleaning agents which can liberate chlorine gas .* Avoid inhalation of vapors* mists and fumes. Prevent eye and akin contact. DOT Classification! <7% Available Chlorine** ORM-B l.D. No. NA 1791 Labels None (49 CFR 172 101) >7% Available Chlorine, CORROSIVE. I.D. No UN 1791 Labels CORROSIVE /% Available Chlorine is about 7.35% NaOCl. Incompatible with bowl cleaners containing DATA SOUftCHS) COOS: 1.3-11.14,25*34,37,48,49 bisulfates . GENIUM PUBLISHING ABD00029579 (T^ODETJEFINITrON TABLES ABD00029580 APPENDIX C NODE DEFINITION TABLES ABD00029581 ABD00029582 ABD00029583 ATTRIBUTES OF THE DESIGN GUIDEWORDS ABD00029584 ATTRIBUTES OF THE DESIGN GUIDEUOROS ABD00029585 ABD00029586 ABD00029587 D. SITINC/LAYOUT CHECKLIST ABD00029588 APPENDIX D SITING/LAYOUT CHECKLIST ABD00029589 I CHECKLIST 23: LAYOUT AND SITTING I. 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. ABD00029590 2 2. LOCATION OF LARGE INVENTORIES 1. Are large inventories of highly hazardous chemicals located away from the process area? Yes, plant lay out has the unloading and storage area away from process areas. Units are designed to hold less VCM than is needed for a reactor change. 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. ABD00029591 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 of hazardous materials from other sites - Possibility of long-term exposure of employees to low concentration of process material ABD00029592 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 ofprevailing winds - Types of reactions and processes - Operating pressures and temperatures - Ignition sources - Fire protection facilities - Drainage facilities 6. Ifwindows are installed, are they ofrigid 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? ABD00029593 5 15. Is the control room rooffree from heavy equipment and machinery? 5. LOCATION OF MACHINE SHOPS, WELDING SHOPS, ELECTRICAL SUBSTATIONS AND OTHER LIKELY IGNITION SOURCES 1. Are likely ignition sources (e.g., maintenance shops, roads, rail spurs) located away from release points for volatile substances (both liquid and vapor)? Yes 2. Are process sewers located away from likely ignition sources? Yes 3. Are all vessels containing highly hazardous chemicals or components containing material above its flash point located away from likely ignition sources? Yes 4. Are the flare and fired-heater systems located to minimize hazards to personnel and equipment, with consideration given to normal wind direction and wind velocity and heat potential? Yes 6. LOCATION OF ENGINEERING, LAB, ADMINISTRATION OR OTHER BUILDINGS 1. Are administration buildings located away from inventories of highly hazardous chemicals? Yes 2. Are administration buildings located away from release points for highly hazardous chemicals? Yes 3. Are workers in administration buildings protected from all of the following? - Toxic, corrosive or flammable sprays, fumes, mists, or vapors - Thermal radiation from fires (including flares) - Overpressure and projectiles from explosions - Contamination of utilities (e.g., water) - Contamination from spills or runoff - Noise Yes Yes Yes Yes Yes Yes ABD00029594 6 - Transport of hazardous materials from other sites - Flooding (e.g., ruptured storage tank) - Odors Yes Yes Yes UNIT LAYOUT AND LOCATION OF FACILITY RELATIVE TO NEIGHBORS Are large inventories or release points for highly hazardous chemicals located away - from public access roads? - vehicular traffic within the plant? Yes Yes Is the unit, or can the unit be, located to minimize the need for offsite or intrasite transportation ofhazardous materials? VCM comes from the Lake Charles plant. It is unloaed safely. Are workers in adjacent units protected and workers in this unit protected from the effects of adjacent units or facilities from all of the following? - Releases of highly hazardous chemicals - Toxic, corrosive or flammable sprays, fumes,mists or vapors - Thermal radiation from fires (including flares) - Overpressure from explosions - Contamination from spills or runoff - Odors -Noise - Contamination ofutilities (e.g., sewers) - Transport of hazardous materials from other sites - Impacts (e.g., airplane crashes, derailments) - Flooding (e.g., ruptured storage tanks) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Could specific siting hazards be posed to the site from credible external forces such as high winds, earth movement, utility failure from outside sources, flooding, natural fires and fog? This area is susceptible to high winds and tornadoes. Designs are per applicable codes, e.g., ASCE. Is there adequate access for emergency vehicles (e.g., fire trucks)? Yes Are access roads free of the possibility of being blocked by trains, highway congestion, spotting of rail cars, etc? ABD00029595 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. ABD00029596 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. ABD00029597 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. ABD00029598 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 of gases and vapors - Estimated radiant heat density that might exist during a fire - estimated overpressure 4. Are appropriate security safeguards in place (e.g., fences, guard stations)? Yes 5. Are gates located away from the public roadway so that the largest truck can move completely of the roadway while waiting for the gates to be opened? Yes 6. Where applicable, are safeguards in place to protect high structures against low flying aircraft? Not required by Code. 7. Are adequate safeguards in place to protect employees against exposure to excessive noise, considering the commutative effect of equipment items located close together? Noise is considered in equipment design. Efforts are made to design and purchase equipment with low noise levels. The plant does noise level surveys, where necessary signs are posted requiring ear plugs. 8. Is adequate emergency lighting provided? Is there adequate redundant backup power for this lighting? 9. Are procedures in place to restrict nonessential or untrained personnel from entering hazardous areas? Yes, plant policy requires training before entering units. ABD00029599 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 ABD00029600 E.HlTM A NF'ACTORS CHECKLIST ABD00029601 APPENDIX E HUMAN FACTORS CHECKLISTS ABD00029602 CHECKLIST 24: HUMAN FACTORS HOUSEKEEPING AND GENERAL WORK ENVIRONMENT 1.01 Are working areas generally clean? Ves, 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? Ves, 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? Ves, 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. ABD00029603 2 2.02 Is communications equipment adequate and easily accessible? How would others know that a worker is incapacitated in the process area? There are several types of communication systems: radios, phones and gaitronics. Operators in the field carry radios to coordinate tasks with panel operations and request assistance when necessary. Permit systems coordinates maintenance acitivies in the field. 2.03 Are the right tools available and used when needed? Maintenance procedures cover proper tools and procedures for using tools. 2.04 Are special tools required to perform any tasks safely or efficiently? Yes, the plant has purchased special tools when appropriate to improve safety. Examples are: power torque wrench for working on reactor condenser seals. Process safety information is kept updated and available. 2.05 What steps are taken to identify and provide special tools? When problems are identified they are brought to supervisors and possible solutions are discussed. Or employees come to supervisors with suggestions for improvements in doing routine tasks. 2.06 Is the whole workplace arranged so that the workers can maintain a good working posture and perform a variety of movements? Project Designs are reviewed to ensure accessibility in and around equipment. Safety training is used to teach and reinforce proper methods for bending, lifting and carrying. 2.07 Are all controls accessible? Yes, controls are designed and constructed for accessibility. 2.08 Is access adequate for routine operation and maintenance of all equipment? Yes. COMPONENT LABELING 3.01 Is all important equipment (vessels, pipes, valves, instruments, controls, etc.) clearly and unambiguously labeled? ABD00029604 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 ofthe 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. ABD00029605 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 ofthe 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. ABD00029606 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 ofthe 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 ABD00029607 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 Held. ABD00029608 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 of protective 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 ABD00029609 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. ABD00029610 FTHAZOP table ABD00029611 APPENDIX F HAZOP TABLE ABD00029612 NOTE: The following are the frequency and consequence categories shown in the HAZOP table: FC: FREQUENCY CATEGORY F : CONSEQUENCE - SAFETY X : CONSEQUENCE - BUSINESS LOSS ABD00029613 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" ABD00029614 e- t^g IvNo r* <N rg I J 1) U C0O. 3i CD O 0Ij1J ----O' aE J3O "3UD "D C a\ H O li h o UQ. Ji H IQ iH 31 i >A i JII Hfl OO DESIGN IN T E N T IO N : STORAGE OF VCM 1 0 1 .1 0 HIGH INTERFACE ev ss M3 Z DESIGN IN T E N T IO N : STORAGE OF VCM 1 0 2 .7 H IG H CONCENTRATION 1 0 2 .0 PROCESS L IN E - VCM VAPORS FROM STORAGE SPHERE TO KO POT ( c o n t in u e d ) ABD00029616 ABD00029617 0) XO!i IQ & U-l H 0>) INI 01 s 3 0011 4>0O) DESIG N IN T E N T IO N : REMOVE L IQ U ID VCM FROM VAPOR STREAM 3S 01 4011 3 5i H C IQ UU H 3 Z Z 3 o H fn m oo LOW CONCENTRATION 1 0 4 .6 ABD00029618 m 0) au -- jHj mW 3 IN Q v. IN IN V IN ti JOHCl i X-- C0 o H IN H C CD 30o Vna 43J JwS C -H <0 J3 3S DESIG N IN T E N T IO N : TRANSFER OF VCM VAPORS TO UNLOAD R A IL CAR ABD00029619 w c o o CQ HCXi] Cl c0 H u ns Q>HI va 3 C uH C oo II 3 z DESIGN IN T E N T IO N : TRANSPORT L IQ U ID VCM TO oH HI T0S C V H0)I In HI u O HI Co z rH CH 1*0 T3 H0)I 0 roH HI > rH US > 4J HHI u 30 73 *H & -jH 2 u a g u CU VI uu VI u z3 u z o o CJ O J ac a. u XX 2 o o 1--1 o CJ3 M J Xz X rH (N r*i *JI m o in o m o V) o rH H iH rH o H> T03 C HI HmI M uHI 0 a> z u UJ g J Cl) 5 < Cl] > 2 Cl] Cl] u O< < Ci. 23 Ci] a. J J Cl] Cl X u y 2 H xU H 3 o J > uJ Cil bzIH bzM XXX 3 o OM X o z aIH 3 Q X .2 CIH5 X o 10 c- a> Vl rH in orH no H in o rH rionH in oH iornH ABD00029620 aOh) --m< O o C <(4N UV DESIG N IN T E N T IO N : TRANSPORT L IQ U ID VCM TO 1 0 6 .4 MISSING J X aoU <<hv-i g5 UM kOn 3 H ao -- DESIGN IN T E N T IO N : UNLOADING L IQ U ID VCM FROM TANK CAR TO SPHERE ABD00029621 ABD00029622 icn 0 co nj Q<>U T0!) C3 >-> Z3 1 0 8 .0 PROCESS L IN E - VCM STORAGE SPHERE RECIRCULATION <dwg: V S -0 9 3 1 0 5 -P ID -D ) ABD00029623 B> 3 5p2 2 a. zoM 3a. H< zM B u3nm4) a jJ=tHSn $w (i 35 0, a44)) h VHO 12 4) <N J3 41 to < J 4> rH *p O TJ J3 0 a 4 b < > u 41 e z0 O 4) C C 0c Z -H 4) c z0 -H 10 (0 0 0. j z E0 hO .Vc fN O 4) sc ss Cis M3 JS EXTRA WRONG/ 201B .6 ABD00029624 None o th e r (see h ig h p re ssu re in node 211) ao su ID ID J4>j 104-1 MC J43) .. M a. 2 H Cl. O a a. 3} ,u z2 M jM o u 0. 0} 0) *4 0) U-l 0 o - r*1 <N <N 4) n 4) -- a *r u uo o 0 IN 41 1> C TJ 0o 2 2C U 1) 0 T0J 4) C c 0c 2 a juv: <D X LONG T IM E 2 0 1 C .6 ABD00029625 DESIGN. IN T E N T IO N : HEATUP OF REACTOR TO REACTION TEMPERATURE glZ u U-l CV 4) -M 4J a0. iMVu B0u 4c) 4> U -H ucfl SUO 3 UOh i-3* i7-4O3at)1' -- io 'm3 r*> 0 o m r- U 4) I 4) <8 M > u cw 3 m Uw -4a) Xi M 41 C (N tml4 -cH ou --c* ABD00029626 a g ita to r m otor (92-IT -772) Q. J3O u 01 ~c AO JJ 0 4J 4a1 -4hJ o 01 Za uc 01 0) 4J > sue 4J -H (0 4J c4a1-H41 i(-ti so> 41 -H 41 JJ OJ r-t 0-1 -0H1 3CCD J-OH3l 3 -H hUOkj --<(J9> kU<00)) COu rj-\ u0 2I -UtHo -H O 1 s8 UH o zCO a0kao1 mouai, 3 jmkjj >n, o-i 01 4) JS 0.-H CO E -H lHU01H41 3 g & o C C- 41 a 01 0 OJ o a a 0 1-1 H 1 rO >01 ex Its 1 U01 <N V) -- >H a n 41 u uX a 0) H>01 01 cH U . C a cn fCi -3H CHTl X 3 0 Ch -H a a OJ oH ae a A JJ a oa Q0. >1 a ev w3 Z ABD00029627 2 0 1 E .0 REACTOR - REACTOR, STEP 5 : POLYMERIZATION ( c o n t in u e d ) Vua 4) M mA sH Jo3 Uc41 iu3J UO T03 a *a (3 u z4CO1 -D0co j4M:i 4a1 s --co U 4) ZC0 -JWH5 -UHp<0i MQM Zo W ft uJa, uu) 52 EV 2h ^Z3 DESIGN IN TE N TIO N : NORMAL K IL L AT END OF REACTION o Z -rc4 ABD00029628 C -H O Z -MH ABD00029629 DESIG N IN T E N T IO N : IN REACTOR S T R IP P IN G AND RECOVERY OF VCM 41 4) zC0 T0cJ 41 4) zC0 T0c5 41 4) zC0 70c3 4) 41 zC0 VOc >Q as O' 3 j TJ o5. & b. 5O Q b5) OM 5 a uxS a Maos OJ u X 41 30) CD 4) U Q. S3 WH S3 41 i4-1l (iHN U 4) S 4) C C 0 c Z -H 41 <-< 3 Z NO SHORT TIM E/ 201H .5 ABD00029630 DESIGN IN T E N T IO N : ATMOSPHERIC DUMP OF POLYMER 01 0> C0 TO> ZC L01 -- J3 CO 0) 01 CO -CH Z -H E 01 Zi w3 Z U2 2 M H Oz o J re H o <N CO u a. as. s3 U OS a, X u Ore a. V) X 3x 3o 3 u zo M s hH 3 Oz pH IN U1 MMM M H pH H pH rH pH oo o O o <N (N M IN <N ABD00029631 0ha) thCr jot^<;noj so cc CJ\ o autw-. 5 5 QS oi ho 8 52 3a UmzH as 1 K zo 4m1 u 4) -- <* 4J rH 0 <N 41 4J C T> z0 0c -mcH r-,hQH a 41 4m10) U Jh1 xU: Hv M4H) rH rH H u Uoj atoo * Jou0u(UJ u W cH fH <H 4UHi >0 4W) rH -1HJ c01 Jj 0 a rH 'H<14o H41J u V A u CHO 0M 01 z0c T0431 C 41 3 M3 z ABD00029632 tn c0 None o th e r (see low flo w in node 221) UV 0C TOJ ZC E 0> Si M3 Z 3 oz O0S*. XoM X zuH X 3 iH OJ *r-f *H o(N O r* O cm u t- Xw J-1 H XoH X oz i 3 in rH O (N OH CN *H O CN HIGH REACTION RATE 2 0 1 L .6 ABD00029633 2 0 1 L .0 REACTOR - REACTOR, STEP 1 1 : EMERGENCY K IL L ( c o n tin u e d ) o 0 IaQ> 4u4 a <a u >, ns i-i * * ai u oi uA 55 O H 4J a. ns pH pH o j= uu U 4J o rq * as oi H0 41 3 0 0 0 44 s u 0 S3 3 (H V4 o wM aA 0 0 0 4J u 4J o 44 u b. 5 me z hi j: Oa 3V a a 0 <0 M s 44 u ou 4) 4) 44 0 44 til CO -4 C 4J U 41 J iH 4) D rH 41 9> a a c J C 91 Zj ns a >. 4) -H M ui 4) h ns 4) 4J 2 O' 4-1 u 41 S4 iH 5 Cb r-l 41 4* V 4) a 4) h E O' iH 01 44 9) ca M nj va o 0 41 4) h 4) 1 44 ns 0 H 4J 3 4J uo <0 Qi 44 44 CV II 'H ffl 4J H x* 0a V m u 41 V > 4444 o >a 40-1) -0cH1 -OaHS r-i r--I 588 >oo an o C TJ -H V A W S4 44 4J 0 iH 44 oi a cau H V 11 S4 M 0. 3O "0 c 0 TJ U -H c 41 flj 4N4 Ifl - 3 -H 41 S4 U <n0 iV o3i ) 5. a U H III Exd oa uo. ;i h OS i 3 4-4 os 5 H o 0] as a rH O OJ uV 3U iH 41 -<ho cea 44 v o rH C ns O oo H C 41 ns A A 4J uo HU >HH >3 0 ia 5s a z as M eX oX w 4- o z r* CD j hi H iH OO 04 01 U HH H O Z Q J (71 J O 01 hJ W >u h3 X C3 M X O iH hi r4 O 01 un, u h tHn Hj ABD00029634 DESIGN IN T E N T IO N : VCM RECOVERY FROM REACTOR TO RECOVERY SYSTEM > & Vl a u 0 u 0) JcJ nyc >H 1) tfl 3& ua 11 n Vi 0 u v y> H TJ a C> H au 0 L> H ID iJ E 'H 0 01 u oa a nj V ii 0 TJ u J iB l) aa ca >. Vi 11 > D0 Vl U 3 11 0) u 01 ii 11 au. A Vl u 0 u fl 11 o> i"H co nj > c u -r4 0 4J m 0 05 VI 0 CU 3fl Uo 0 11 uC E m 11 u m -h 01 0 rH V c u0 o >. CM Vc H 0c1 3 0) 0} > u0 o o Vl U 0! 3 11 4-1 01 Vl o ii 0] Vu MA 0, u aA o Ol H xw 1) a 0c1 U 'HOl O> U>1 ul>0) s.: D --u> 1) 0. 1) Ifsl nuj ricH >w CO X -C I U IN U (TV Z" a yii AM 01 c C l> H T3 c n >o mu 5> -HS 0>) >1 0H) V1)l ovu> >ou uX Uu c nl m > i>i 0 11 M A <-> Ol -H O XU e M QX u oz in X Hz u < zo c2 a u uz o u U z p CJ X 55 o M2 w M Hx zo 3 Q 0 M fa z u u J X ro ** m fS OJ CN Ooo CN CN 16 r- CN CN Oo CN CN NO LOW PRESSURE/ 2 0 2 .8 ABD00029635 mc 0 (D 41 VE > -H Vu m TJ O' u3 cO unuj MUQ U --I 3a -mC oE 3 O1) ' W<5 um 30 JJ *i) 4O1' E^ CO r'j -m <y\ <>d rJ*i h Q. E O3i --fi n3 r* -H r- fUlj (N H - 41 V O' UM 3* -H si >0* o m O' a rH *r4 u -oH T33 c nj a Si r-1 U *H 25 C0 Q3 23 b. None M IS S IN G COMPONENT 2 0 3 .4 E 4J Si uifl ao. as >. U r-t 3r0 V U ABD00029636 2 0 3 .0 PROCESS L IN E - VCM CHARGE L IN E .T O REACTOR ( c o n tin u e d ) i fDCS tim e - o u t w i l l s h u t down charge ta k e s to o long Ui. HO CM U SS ABD00029637 2 0 4 .0 PROCESS L IN E - G H -20 CHARGE TO REACTOR ( c o n t in u e d ) V j: Si Cc o 14 2 o n a 5s 0> u <9 v cH s01i <0 s 4J T3 * -H IQ a 41 & O -H CO ZH o i--1 U i--1 IJ -H s> .. y ay z 0) s' a 0) u o Si u uy M H3 o U3 Ch o -o CN 0 U 2 yo 1 yo W ch s Cu a C3 m a 4) 1|Q4 c0 a-* 0) SI b <0 Q. sUi 0c s' V O tn* C0 cu -4 C 5s a. -a o c. co <9 0 0o0 rH f4 c SI u 4) V 4) 3 4> -- 11 ~ 4) a 0 nc --0 CD C --0 01 1--' H H H a M SI H si H 41 ifl V <Q 4) u si h J3 H si V s' s' s' S' SI a 0C 0C 0 m V 01 4) U 41 y V SI ac ec c 44 00 00 0 o zy zy z .. .8 hb4lO41 .uuVCHsHuaoi si C |Q C 4) H -h y C s a3 oo H > 3 e SI w3 Z ABD00029638 01 c0 ............ 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 GO % a 43C1 E 41 c0 2^ M3 ci Z DESIGN IN T E N T IO N : CHARGE OF ALCOTEX TO REACTOR AOS 30] O oi --V01 0G0) 4) m -H > Q aM ai. m r(eoH*|\) Oofi-S CSl as a O(- as OH oLOi G Ci. <wt os [1. o U O-i Vo CN 41 "OCO --41 -0ca >0H1 404 ai n --oi c0 Min *nHj O -T>1H!1 41 MQ a, rn0rHo1T O aofs 2 b<2 VO9I a: OfH aOs P0 oM >M <2c as Oa. o u, O hH Czd z HH 0 l-l CO CO u CO a W U u 4O4 Vo CN 41 -O --"40c0) r0H) OC 44 O 41 0) --01 C0 -rt 4-1 41 Id -H > O 41 a 41 C0 rrHH Z <0 a1 MDap1*i HPOoNi aos bp s 3 as *-- OH aoHbs <w as a a. o M zz H 0 H* CO CO u CEOd o U O 05 a, OCO it u 01 n PI 4J 4>1 rH U rVt <>0 41 u G H oa 4>> Cl c H rH . j 3 G X CO a >. a e I>d N 41 G 41 X 41 0 44 u c H Ifl c 0 0 rH 41 u 4) 3 > u o 41 41 c 3 0) 41 r4 a u 41 a u 0 4J ao CO 41 ua 0 Q 41 0 u 4J Xc 41 MH a 41 o c--1 3 Q o4a1 cao 4a1 Xo oXb. X 3 o Z in o(N KO(ND O<N COO CN <N CD (N manual v a lv e : r o r r e n a to r ope r pf te lOe MISDIRECTED REVERSE/ FLOW 2 0 6 .3 ABD00029639 so3D0l u-i W 2 0 8 .0 PROCESS L IN E - BME CHARGE TO REACTOR ( c o n t in u e d ) c o Tu3 3 ucH oC0 1) 4) 41 zco zc0 zc0 V c zo Ve zo u u 3w(L 5 OH LO f** ON fOlO <O COO OflO O COO COO AO CN (H <N (N M <N <N M <N ABD00029640 None o th e r (see low flo w ) DESIGN IN T E N T IO N : CHARGE OF HOT WATER TO REACTOR a U0 uO -uH <0 Ifl uM TtCJl <4d1 <0 "O 41 * 3M 4H1 J= C U cn cn - H 3S5 4) u 4) tJ c, Ji 4> H a} 4eO1 V t0j 2C u ca 41 10 H 6-S > H II II ! i 3 O-- a - 4ou)> u <o ano u41 JSfl o -H 3 UU^ r-l 4) -H 3 -H <0 TJ H W O fl 4) -H 4) -< 01 V 5 nl XU UO QJ NO LOW PRESSURE/ 2 1 0 .8 ABD00029641 2 1 0 .0 PROCESS L IN E - HOT WATER CHARGE ( c o n t in u e d ) V CD Q. C 5 3 4J 4<Jfl -iHJ Uu Em o. c E in 41 1- Hu <3n 3 oh j44=-11 O4a01) t4n1 4i*H-i aoeb<uas-: o4aH4-4. HM nn 0 VE h 41 H 4-1 3a uI4f1l 14C41Tt i0 fl V H rH Uc4a1>- 3H M11 (D -mCH 4f3-1l Tc4aJ1"D40u3-1 o6-< u o 2"C zM oCb ou a oH t<-H a .. z o 4-1 - 101 T3J 0U a ci 4a01). 3U CO Q. CoQO 4a01 Q. S rH U41 0M o rH C 0 <0 U "0 C0 r0H DO 1101 M30 1h 3 41 4J 41 iD U3 3 -h ^ -H fH ID O 4-4 U rH -a oc i4 ID 4-1 C0 U0 u s. o 41 3 41 < oE 14 U3 H 3 CO H .. rH c H r a. <N u u M 4) -H i X o 0 0. <0 > z1H 11 14 14 uu 0 14 c* X o 11 1) 1) 4J r--i ( rH 14 <0 cs CO 1H 03 U CO 1Lo1 11 -H o -H w c CO w 2 >0 G. 10 4) It 0) a. us u> > 8- U 52 Mz ABD00029642 None "1D) o DC HI H (hJ 4o)> ca ioq] E3 0c1 IQ <>u -0H1 CO T5 4u1 m>. Q. 01 DESIGN IN T E N T IO N : CHARGE OF IN IT IA T O R TO REACTOR -Uh(0 H-H (CQI, 40 rt > 3 mI-Qi *"H 1s(N0I (as0. IQ <X C CHJ -- 4) COS sua: > c V c o H U IQ a>a> Q 3 CO CHO QJ Cl-Ol r u. z T-cHJ --m C0H O3l uH o^ 0O1 u a E CH O 4) CJ -H 41 <H uX Caj p m - c 4) 41 n a. Po 2 1 1 .1 0 LOW TEMPERATURE ABD00029643 ............ 4 SOP, t r a i n i n g 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 , n o f lo w to h ig h e r fre e z in g p o in t 2 1 1 .0 PROCESS L IN E - IN IT IA T O R CHARGE TO REACTOR ( c o n t in u e d ) 4) V m , c o H u 0 H 4-1 n 0 m Q. d w ns 0 o> u -- VV "O U u um V H 0} e 4> Hi C U 0 a> a JZ 41 U a om z0 X -H 4) mo i T3 aos J f- w4 w H wH w > HI z IH b) o a, o 2 EC U uo Ha w EC >* p 8 <a zo M Hz u J Cd 2 M IH CO a HI H H IN OS Qoz z P M 3 Q u J uz M u Q oz u sp aoz H wz > z M J J a. p a. M JD 3w M Q Xd u 0) --- 03 4ifJl U U U -H C 4) UVu 4ao4 3 2 a s BuaM O3 S3 3 Z b. H IS S IN G COMPONENT 2 1 2 B .4 ABD00029644 2 1 2 B .0 PROCESS L IN E - MANUAL K IL L L IN E ( c o n tin u e d ) 2 1 3 .4 MISSING TcJ -- H 1*1 n> aVu --(ffN> au a 0 C0 c * sb S --u U <0 N A4VJ ->HH-) 0 >0 C Vc > * <h4) V> AO <9 O CV DU 2 1 3 .0 PROCESS L IN E - IN E R T VENT L IN E ( c o n tin u e d ) ABD00029645 ABD00029646 l"H 0 rH rH <H G 41 71 41 0 >< X 0 c Oz 4) 0 >U r-H a ai w u tH IQ H -- 4> > C >T E c X 0 z 0 w M 0 c H 0 6 Co 0 o 4J CD a 4 u in * in U c iH 0 CO H 4 a p1r B mn u< s rH A rH 41 CD CO 41 41 c 4J 1 41 Jj Jj pr >H H 4) > IN > V T1 CD y c , ,, X rH A 4) Vm 0 -4h y 01 M H 3 Ot V K U 3 4) 4F 3a a C U cU H 3 X3 >U yU J 41 c in a . <W ua 0 0 4) a C O 3 g 4> y He DO rH V rH a CO rt TJ H *J rH c uC a -H 0 a O y <o . y A Mg 401 H vv - 3 0a1 no a u 4) oi s c a <o h n t> HlIH raH n. u4 4o1 gu 4 oU aE aS Hn 0M -h a 3 H tl a au C m n3 n3 4n1 S 3 2 a H < r H > I? O (N LOW CONCENTRATION 2 1 4 .6 ABD00029647 Flow In d ic a tio n and tra n s m itte r on steam lin e (82-FT-0B3) DESIGN IN TE N TIO N : AUTOMATIC SUPPLY TO K IL L REACTION 18 3 O' 41 M <g w T3 V ___ 3CH U O C a>. 41 a c 0 IN a tn 0c a3 um a H --- i-H H 3 3 u i-4 u 4J 4 ki H ns in i< a) o U oH 41 o o fl an o a. o uu H o xu u ns c 41 3 ns c O 41 3os 41 4-1 n0s) 41 41 w Q1 o a1 X o M p0Hr H C. 41 E 9 <9 O 3 4) I a U CO a 4u1 x O C 0 a1 (0N5 0 ki i 4) 41 0. E0 H U rH 41 MC Ua ns a -rH -c0.1 uH a 0 a rH o n 41 uc c H E ns <0 41 Ou oa 2 oa 41 XX C rH in O {- o ns ns X U) -H 3 41 Li TS a c rH a 0 41 t X u kH -H 0a o r--1 o -H )H HU a 5 41 Ol ki 1-1 *4 o -E OJ c_ a ns k41i U41 E- o X -H n a ot o r-l 0 3 - ii-gl >a. >* jX Xo a-H H SZ u 41 4> c sz u Or X u V 1) 0 os 41 IH D 71 41 u o 3 U 41 -uC O 4 41 -1 N - U 4J H H a -v ki 41 41 H 3 ki S jj CH 3 m OS 3 Jp 2 Cu H Hw X o C3 cu 4H1 OS OC rH -H iUnH aQ. as c 0 z 91 ki as o XkT c o 4u1 skii a o Q. ki z IH >J< XX XX 371 -H H X c h ua 0> IH D Bw w z o IN PS (N k! a o 41 a9> IH HH O N" ns u u ns 4) Q, v tn -- ucu H 41 ue E M3 Z f_i u H< 2 2u Xa. 5 CO < X u O CO Cl] Or z o u 3 O J u cc a Or 2 [i u fH X *>. X X o IH X o z o M X 3 Q J C5 IH X 0C" a o iH % rH rH fl* r fl* r-4 rH iH rH iH C+ IN <N <N IN B roken n o zzle 3 ABD00029648 m oc a 4u) -^* x U T41f VH O C 3 T4J) 3 4) 41 r0t C UQ| CuO 4uJ aa -3H ao co a X o 0 4) 4) a) 4) .uc o u c zo 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 ) E 4) Sw 3i Z qs 23 Z Ch u zo zo OZo as M HZ (c z U u oz hH CO 3 Hz u < zoa. U Uzo u uzo o s CO 4 3 o M z Xco p0 Q J M s tn VO r~ to lO to |H H r-H H cs (N <N fS 4) c zo Ua. o lO Or-)t ABD00029649 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 ) 9i pH pHH > xo0 u u3mm ua V 4cHJ aDHl <oA A C0 u 3 3 c3 >oau 33 jJ oc H pHH 3 JE3U0Oj1 a H J3cJ uaVm coH J33J 3> UVHa4 3ya 3 A CuO a y 3> y 3 -<OdcHHl j3Jjj a. OW 0 g Q Hf(0lj au> 994311 9o+t Ua woi. J3Q (CNO -UocH 3 DyH CH c0H jHj ano C 3u 03 o 4J 3 0 -jHj c0e 33Ol 3 U>Z 2H 0 H uam a3 C mE jcfgHfjl Jom>J. ->H Oul H43) a JcJ 0>Vu. 01 p.-HHH V 3 Ji yo >H uVcH u3m3IaA0H1 woQ e0 -- co -r* c J3yHJ cHo u3 3 3 a. ---1 eoH J33U3J > C0 uCu0ocHO 3301 3 H < a3aVu CH g V>H JaVJ > Q. 3 irHJH 3 1I--Oot1 JcVHj CH Vu3aaua AOHl MOQ A Co 3O z o eo 3 A U JJ H X Cl. M3 JJ o mj 3 D X u c o> M H c 3M < 3o 3 -H A a WJ JJ 3U o 0u 3 3 a j2 c D 00 rH -H > H U uu ua 0 y 3 *--i JJ U X 3 y id 3 -H y3 0 u z > jj u CM o M 3 o jj 0A H z U au w y pi <t> A 0) 171 33 3 3O <0 3ohc 3 r>*i ws s: i yy ian\ y (xN Z O' EXTRA WRONG/ 2 1 6 .5 ABD00029650 2 1 6 .0 PROCESS L IN E - EVACUATION L IN E FROM REACTOR ( c o n t in u e d ) Em pty O*>4) 0>0u> >01 40J) M J3 a u in C H s: 11 (N av a. -- CO U uc Q3 a 1 ce mo rt H L> m< <T> x o a: yw 2X H O) Z o T5 X CO 3 CJ a * a e3o zz Cd T5 j tH >0 M 2V 01 CO M 4J CO 44 uZ aa n) aa EE oM 33 c X CO aa 01 X u MQ m o V V 4) u u> a 41 u r~ H H3 H3 (fl H H > (N <0 <0 1 1) *4 f--1 -<u-oI ueO cu <0 01 Ifl Zu ABD00029651 2 1 7 .0 PROCESS L IN E - LOW MOL ATMOSPHERIC DUMP L IN E ( c o n t in u e d ) u0 tHHI UI PH> f<ST> <~ a c-- nj m z 0 IN M w TJ <0 55 M 1> A za 0M 3 w a w 0 4J 0 u> 3 rH H IS H > * S-S -I A __ U Olfl uH 30 3 rn ro 0 rH 0H 4J u a. W uz 8 0z 0 0 s Q a w u XOi zX 2O 2 0M X 0z 0M X r~ CO G\ r* H <N rH (N rtHN rrH<N ABD00029652 2 1 7 A .1 1 HIG H TEMPERATURE ABD00029653 COH f\V0 c H H QC 0 rH 4J V 'H ce * U In tg Q. tH 0 -H H hj H TJ b> <-t a 4J to -- a -< ITS fl to <n H O H 4) 0 ITS f rH JJ JS *W i--i <n V 1/) Cu 1 ^1 V C to 3 K. Sh as H u b. a a. v c j: i OS M ai tv MH o l+H lH 3 -H 0\ lH C\ H o Cfc to -- a. -- O ns a - -H C\ iH CO U -- iH b. 0 H c\ U > 3 rl a -H 3h 0 HJ u <a C rH 3 0 (0 0 -H A) O )H 0 H AS 0) va Or lH lH E0 3 fl H ij 0 U cC 0 0 0) 0) V 0 </i -rt M -H OQ CO Q. 73 O Q* None o th e r (see no flo w ) DESIG N IN T E N T IO N : CLOSED DUMP OF POLYMER FROM THE REACTOR c r* 5- -o H <* iH 3 O0 % NO LON PRESSURE/ 2 1 8 .B ABD00029654 None o th e r (see low flo w ) DESIG N IN T E N T IO N : CLOSED DUMP OF POLYMER FROM THE REACTOR e ai 21 Bl a: 3 3 o H as OS ofH CO f- o< c<o 3 a. CO w o E- zl-l as 5J- Co CU o a. D >< w JQ. OS a. Ci] D fH V) < 3 Cl] w ZoIX zM H Z as CO E zM CO zM J z u IX M M CO WQ CO O O aQ. o T\ rH IN ro |X| CO >. a a u o *0 e 4) c -H iH o 0) 4> Ol -H a> N 3N -a1. 0c ID > H > .. 0u) 3 -- i-H CO h m A r>u v vo *--i m 0 t" o' -X > cw x C i UM li a. Z-- u V 4-1 rfl 3 4> C uH c X u V o H H u . *0 V oi oi a 3C rH *H a< r-H 41 <n c H u 4> U 3 iH X IM -x a <a CJ 3 X Q. c mx x: 4i uU 41 IQ Z3 a3 w>-< oJ Z Cx NO LOW PRESSURE/ 2 1 9 .8 ABD00029655 <N IN Cr-D ~a e a. IS I v <N u SO v> -- 6a o 41 V H^ 30 iH 4H 30 0) 40)) Ch o 14 41 41 C zo zc0 o o in IN CO u Q. u a. cc U CL Cd H H 33 3 O3O M OM X JS oH ON <--* H ON <jn ON H iH <N (N <N ro >. - JJ rH 4) a H E <4H > rH 0 IS a 0) > c h at V rH H i (4 4) U 3 C N 3-- H H0 rH CO *H c -h m to is r- %4 Vs hh -v. co PH H H U --i o\ IS rH Q, is t- o 0) O ' rt a H > c v u c c/5 nj in o <S X JZ X 1 o 3 T5 U (N 41 rH c 4J O' a -- 3 m i-- rH is 3 c <s 4) rH V c -rt rH 4) > 4) rH M 3C 5 <S J Hi uEi4f)l m HH o 4) zCO z4c0) ma JQ wXuM g> CXi] V fj QU o 3 3Cu h uX IH V ozhH Xo IH X awM o3J h CO CMO r IN po OcPHs ooo (N (N (N (N (N <N None EXTRA WRONG/ COMPONENT 2 2 0 .5 ABD00029656 2 2 0 .0 PROCESS L IN E - CLEAN WALL A D D IT IV E TO REACTOR ( c o n t in u e d ) S econdary b a ck-u p system 1) -- 3Vl CUDl tnn r~i vJ Vi w a a. N 32 3 0 rH 11 --. 01 c --0 rl Vl U 01 10 -S Vi iJ U 0C V VO cc 00 zo & o Ho H J J > Ha * QQii >* 3 yw Wo 0M ( H M ? ij Cu o ob V iJ U -H U -H o H U ao >0 0 0) U Vi >. - uC H 0 H *rt HU U <0 >0 C 01 H Vl * uo 4J V 0 u-a 32 a- u o r* 9\ H 3 Z o cs C* (S o (N <N forS* ((oNN O z rs ABD00029657 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 41 C C o jO <N U4 Q VC COO <d n Ma) TJ > v CaO. ^-- It 3a OS 4J in o n Ma ro\ W Ou o eO m 0) to iH 4M1 -H a a5 OH' U0 X 0. 3 O' -- 4) 'O ^ <O3 a >-l 4a) 3 SB 4M) --0. aC C4) 4a) 0* o 0 Jhj "041 -zH *rt zo oz M u Qg MH 5 H CO fjg CO u 2 h til jg X 5 82 M Z Cd CoozJ a, 3 O J CO CO u X Cu X Q 3 oX M X oz X o M X VO r~ a> O' H *H H fi <N M (N (N CN IN <N /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 ) ABD00029659 DESIGN IN T E N T IO N : TRANSFER OF SLURRY TO BLEND TANK M-l uoua^o>i t0Haf uaa>. cH U sJ u3 uG0 0Ma & zo o Xo uaa.t CL X til X H zo*H z oz r* z u 3Q z X oM X o r <a 9\ iH H rH H H iH O o o rn om o ABD00029660 fr - 4 1>) O 11 VO aCTt rait 00 UMV c D wD Q* OO <rH*> * o uU30uo 0u a ao V c DESIG N IN T E N T IO N : STORAGE OF SLURRY 41 o n o ro c 0A 4J 4H Q>V MUS4 4U C oVo. oVa u 3 u CL 5 H oz 2 3 H CN (+1 0*1 V0 r* OJ om (N om fN om (OmN <ON rn <N o <N om CD CON <n 0N fOmS roj rn ABD00029661 II zCo uH l c u3 IUVC -fHHl & Q3 MO MJ Z M M M Z gl ac> * F 3 3 O fiHH m mm o<*> r*> m ABD00029662 ABD00029663 DESIGN IN T E N T IO N : DEWATERING PRODUCT & a 4(-01 U LMT' I a4) Hi 4E) <J> E- -- 9) m > uu3r-nch U fl 3 4> M .0 &. 73 5 S QUO 'D4^tlU3 uv-t -ah jnz o -a c > j * Im) 4<0 U 1) 41 ^ OU HU 4>). 01 MC 'CHMflHO >4 (71 C C* o .c c *H 8 4J ~ --m eo 44 JHj 41 SZ U 4oJ 4e-) 4> 4) U CO C0 zu a-- rUH i---4HI NCMO H <4-1 I & JuZ n> n' & 8 kg S 4) Si MZ ABD00029664 DESIG N IN T E N T IO N : TRANSFER PRODUCT FROM CENTRIFUGE TO DRYER uE <a\1 H-- 4vc-> aev eu >s- -3i Z 3 Q b. XC>COO X aCO H oCO a HZCO z 5 a. E O O oz 0ZoX 3H '*- uZ zo 1-4 H <X HZ co uzo Zo H X< HZCO uzo u X 0 h-l X M Q3 Mi QJ Ci. M U1 M M e o uX Ou u 3 Q J X 0 hX-t <N n Lfl VO r* o oVO VO VO UD vO VO Oo Oo m m m 4*1 ABD00029665 JaupJ4 < -- 0) cc Q <JJ 0|. CO VO Hmov i 01 fUHl a t0n) 0] Fr n u Cb u 1tt) m ---- X T3 Wa au QCd Q M0. oe- Qq <a OoDQ a 2a O z <H a 03 2dj H ua22 as 1 ao zu C-t 22 u w zM \z 01 MWJ a ua COO \ a o u O O m m <'H44 V00Mo1J JJSJ u u >CCil> rH CO >0>BOU). JJ JHJ o ipHHH Cl H > (0 C0)l o 01 JJ <004114 rH MJC0BJ1l C0)l J0HJ) 1--011 'O10 * 01 IT 001) <44 0) Cl JcOJJ H <3n u J0J F01 a .a ou HI JJ u 0C4l Col l--C0oDt) m 0H1 (0 cH 0V3j1 u >011 B u o B 4J Ju= Cl z> cH 01 p3H (0 o1H0 c A E H JJ u TVJ -3CH W c jF0j1 01 i oo o a * 3 \ z H vOroO 3 0 H4J 30 0401J) II a V c 0c1 o z oo zz 1) Co z >a a a H ou aM QX W M QJ Ea (a 2 oa jg g o z M w w M E Si CXiJ ou C4 <*) vo r** co 0\ <0 VO o ro <a vo o n V*O om <0 om 0H) ES me au <a u 0 4J U3 iH 0) 0) -H U Ifl a0 3n >M cW H c *H uiut 8 VuoVaoM0 nvM a3 01 a, a a. o CO uCo Q -4*o> 3 0 0 wc J M i o) mw -sH u -o ac a0 -UoH II 0 CO <w H-S ev S-8 ABD00029668 3 0 8 .0 PROCESS L IN E - HPSW TO CENTRIFUGE ( c o n tin u e d ) 41 Q U-- a .c 5 7) IQ IH I--I X IQ Cuv Ma-- v & cn c H IQ X H-l M X a xX 3P 2 wa o x -So' EXo X Xw XM < Xa Q X .. hi> X 2 CaO. X OX XJa. a. x Xx X Xx XX QX MQ so OH j M j25 X XHJ M uX uX EO os H u V 0u301 iJ CO m oX Xu XE- QX X XX o CO 0 4U) rH 5) .. z < o t- 2 X XO EXh X X Q XX XJ DX CO 5X iq u eH o u 4) CJ osSHS <o {hfc* Id Eh XH< 2 XJ X X iD M X X Q Oz XX M z zM oM X2 O3 3 T5 -D 0 4) U xa oX fezM J zo X u Q r<l u0 V IsQ-. 4a1 41 O & -uH 41 au J1S0 -3l U4) H<a . 4c) 22 H IG H CONCENTRATION 3 1 0 .7 ABD00029669 3 1 0 .0 PROCESS L IN E DRYING A IR SUPPLY TO CYCLONE DRYER ( c o n t in u e d ) I>XQXd OH XM< JaaCXC(-dd 3O X {- H30 oX a 00m>) o >ja< Xu0) au DO CD Zo co0) z l-l 0ao1 TJ .. 4) ci a> C u-i <-* c 0> aov>. T<c3o 1*1 * 4oJ T30C5* a cH 001) 01 'uHU031 iH0 'HC0 Q U CJ 3 XtHn oU xa uoai x-chr> MX r 0) X<4C03H10) u c3j 0uo a o 01 a 01 Uuj 00o1) O -H A ai QH a ID ioo--*1\*i JQx oHODaXa Ms Ol V3 XC>Xd* o >< Xa zoMa X2 Cl) U If J ZH aM * zo XM cH a<O3u a30 0V01) c* -- 41 XU VOO 0 i* 1c01 z -Oc4a1 U 41 cc 3 X 8.J? O TJ CD CUxaD Q3 Ua5; CD CCXaDd pH < uaU oz XoM X H 3Qa a (J> oH o1rH*1 o m OcH s<c u az. 3 H X MX iH o r> 3 N3 z Q oo X QJ a ua 3 3 CX g Q j Cd Cd M sJ s a X o Xih CXD QW CD > HZ Oz l-t X MU XX O O IN m r iH H l-t H ri H *4 m ro m r*> None H IG H PRESSURE 3 1 1 .6 ABD00029670 3 1 1 .0 DRYER - FLASH DRYER (c o n tin u e d ) 3 1 2 .4 MISSING SV 2 3 c 4c CD *H V kk 43 4J U4 Ok 4 V Q| CE OV ZU j= <n (n 4 al 0) c to -H 4 kk V3 AU U4 0k 4 4 0. ce 04 Zo 4 e 0 z 4 51 4e m -h 4 uu 43 AU 4J 4 Ok 4 4a CE 04 Zu E 44 uC H U (Q 43 -H A e H " k A4 0) >. h k S TJ 3 9 0 k a o 4 a (0 (0 m < H QC Z QO O Q. Cd 4 -H k4 o un cu 0 3 c0 0 H 4J 4 ID C 4 o C o u kA 4O a-s 4 J4 UO -o 4k Vno 3 ABD00029671 05 c o U05 U n 3 CU l 3 1 2 .0 PROCESS L IN E - CYCLONE DRYER WATER RECIRCULATION ( c o n t in u e d ) V c zo 03 30 30 TV0J c 3 1 3 .6 HIGH TEMPERATURE None ABD00029672 3 1 3 .0 TANK VESSEL - CYCLONE SEPARATOR AND PRODUCT RECEIVERS ( c o n t in u e d )/ 0) rH Xi a0H1 I v cO ' <H T> OU>1 r4H5 H O fl 41 V5 h C o an nu3 o. m XI OS 2 J? 2 CL u CO fc 3 a o a a z o aC b as w < b. b O b O as u b CO 55 g Z o M fc u H Z M M CO u a iH H-l > <0H 45 41 jn m~ 4) <0 JZ VO 4J O O ro 45 45 c o OO Ze 4 > S' >> o a0s jo0j 45 Si M3 Z H IG H CONCENTRATION 3 1 4 .7 ABD00029673 DESIGN IN T E N T IO N : TRANSFER OF A IR TO FAN ._. iH 1H*1 A 0> 4) -H -O A0 e 41 0141 C *H >i Q OS u 3i u 6 vt oc uo z fw 0a gS CH D MQ O o H fl. CB [14 UO > M CB uW u b. C -H H t) >11 r--t A CTl H A it it n -- * 01 4) C H a 3 , 1M > C 4) U U u n 0) V CO T03 zs 0n -Vo U -H 41 > Z 3 ou O a, z J ayo b. w O CB 3 6- u 3 3 O 3 o u o v. b as z H M X a3 CO o WQ CO o M H J M X z X Z b. T U H fl fl y in IS) Lfl in in m r-* H **4 H H r> fi m <*| fi H IG H CONCENTRATION 3 1 5 .7 m TT3J Tu3 19 g 0 3 1 5 .0 PROCESS L IK E - PRODUCT FROM RECEIVER TO SCREENER ( c o n t in u e d ) ABD00029674 VU C 8 4J 2c ao vva $ 3 u H <Hs ue UuH u>0 m -UH 5 3 1 6 .9 H IG H PRESSURE ABD00029675 01 c0 eb Q> in cc H H * r4>-4> jU*a U*i> Ohi j0dj)) r(J>i\ X *0 ~ H u 0) S0h1 U T03J Si 3O i--* 4-. 30 V0<9) 03 30 3O O3 0411 0011 at <0 ns v 3 C<0 u0 O 4J 4) c o z None 3 1 7 .9 HIGHSPEED ABD00029676 30 0 c0 <30-i *JUaHJ U T3 4) 0 4> 4) OC T03 2C 8* e 41 Si M2 Q 3 CO CMXO QJCu XCMO ABD00029677 3 1 9 .0 PROCESS L IN E - PRODUCT FROM SCREENER TO STORAGE S IL O (d w g : D Y -0 9 3 1 4 4 -P ID -D ) o ca cH 4o1 - 4> <4w1 > 4) i--1 J3 -- 0 CTI a H O S. O' * s*a HOOHDMD u mri M4a) -- h o o h u id wh<e f>i a<. <*> r<H8 >. M eoo oua I U JVS V Li Li oO None 3 1 9 .1 0 LOW TEMPERATURE 3 1 9 .0 PROCESS L IN E - PRODUCT FROM SCREENER TO STORAGE S IL O ( c o n t in u e d ) HI c o z Ve o z ABD00029678 CD co 5 ne C0 T0J zc V c o z UO !"4V>> 3 n 0> 1J -H 0 C 0 00 U0 1> <0 U S' 3 2 0 .1 2 /INTERNAL LEAK RUPTURE Torn bag in v e n t 3 D u stin g o f p ro d u c t, p ro d u c t lo ss . 3 ........... P r e v e n t iv e m a in te n a n c e p ro g ra m ABD00029679 BV s-i >-t 3 Z o 3H U U V) CO a* Z U z 3 CO Q. o -v u Z oQ os y co 55 zo u a CO Q 3 hH << o u H (0 c2 q* XNX X U.23 CO 6- 3 u o3 o M XO UU Q h- X o z M X QM 2- X >* LD VO t~ CO o HH H iH rH rH iH HH <N CN (N <N (N (N fN 04 ro ro n f*1 ro Pi P> P> ABD00029680 T2JT 41 hi U3 --(N It O' 3 Q. C M U41 i-IQ4 rt T5 C H U -- IQ U u H o 73 u 0, e 3 hi at it |Q 41 -- C |Q o a 4) i aH e t4) 4J M H J-Ch5T> am>i a-- aD r-i <n 4) ul 41 > o i--"c4* r44) Ji %A c4 & O' J-- h 00 u3 o <Q IN hi 41 H a. 46> iOi' E-* -- H OH 4UJ a3 Vc4 m3 4h)i 0 rH aa h> 3 r04 6 S' T3 vn oa >o-> a Uv 5a*f7c3- c o -I fN <*> U1 fN IN IN IN rt <> IN IN IN IN IN IN <*! r*> m IN ImN U 73 iHQ QV 4) 0 S-7S & J3 *4 v -- r-i > ffV IUQ ^44 tofl c >> Oy u<0 <**i *1- C 3 c- 40 <(NN <<NN PO r> LOW INTERFACE 3 2 2 .9 ABD00029681 3 2 3 .1 1 HIGH TEMPERATURE ABD00029682 01 c0 UM 3a to a. O>1 TJ C oj 4a> UH T33 o J uz fc o H zz o 111 x Cb M as Mz <o a. M01 Cb u oQ 4-1 41 2 S2 3 M 0 u fll Q> t&*3 -oi coU 0o31t c0 e0 zz E 0) MS3i Z QS M QJ Z U. W 01H1 Z V VVV ec Cce o z 0 z o z o z o z z oM m 3 Cil fw i5 Xc w u x u p 2a a. 0) til zu z oi w M a. X Z o Q X JE u u J a, t* XXX o M X o z oM X X Q uM X rH r- <n iH * rt<N (N (N M IN 1*1 1*1 m ABD00029683 DESIG N IN T E N T IO N : STORAGE OF CENTRATE WATER 3 2 5 .1 0 HIGH INTERFACE 2Dr iu-H-i DG M3> -t3Hn O J3 e a) M3 Z -OH 0) CU J3Z 3 -H U -H V ns Z U rt 3 CH 3O --3Hl 4) 3 Z M VH 30J V0W 3 is s* . 3OCH 3hi 33 jU: --Hh 33 Z <w zo u I oH 3 2 Q J O z U ao> 3 OM 3 Cu y H 3 O z u H 3 0M s 3 QJ N o z (N n 31 in vo in <mN in n<N in C(*N! in (N m m (N n in (mN ABD00029684 4) 4) CO T0J ZC 1 > oz J Cl4 - Zo o z a: \ UZo a. a Xo u H o O u [1. u a. CzJ H-l h- X Q 3 c/1 o M C/1 O MJ VI 1H X Cl OZo a. XH <c2 uzoa. exu- zoo M H C0 DESIG N IN T E N T IO N : STORAGE OF COAGULANT FOR CENTRATE TREATMENT 3 2 7 .1 0 HIGH INTERFACE 9) CD 5 v~ --m co H xlaH;i J^J 41 O Co Go ZU UU 031 4J X gi 0c1 CH 0C) 3 M J3 -HH 30 am W 01 a v%u* G3, o 8 -S u <g O 41 4) Zu 4J 4) 4J -H a 03 Za & flu u z o u 3 o a o z o o a oM X 53 CO U a oa a. z 3 a. u \X H o z oM 3 3 Qa a. I E- X UM X (N r** in VO r N r(N fO r* r- r CmN (N m CP>4 c<N m ABD00029686 ............ 4 SOP, t r a i n i n g O perator e rro r: manual v a lv e 4 Poor f ilt e r in g system clo se d v-- jS r4OJ (mN V ,3 * T03 oc OC 01 u c0 c0 zo uH n0) <<oWui -CmH MC &3 0h <U0 U -H ID E U> UO C 0 TcJ IQ 9 U CO S' CU IQ 3 JS i-H |UQ H 0) C10 9<0 abo X oM X td tB-Ot MQW XQJ X Cu O z VwM) z b) h ZOO2. XCd OU cs r> V <mN 0r<*N0i CODJ I"1 C(ND zo0 ou xoj oXM X VD p** 04 3<roN0 H IG H PRESSURE 3 2 8 .9 ABD00029687 tj\ 3 2 8 .0 PROCESS L IN E - COAGULANT FROM TANK TO RECIRCULATION L IN E ( c o n t in u e d ) SOP e 2 2 U u aos _ r~ b. cs C_ r*> w 2 3 4) O TJ 35 -< 0 C C3 41 < 41 C O U u, --01 -H C4 1U1 o 4S1 3 JJ >* J (0 Ja. 0u 4> 0. 4i a > H oZ CO o w 3 as o o a * CO z 2 H HH OoS uJ uX < c2 o o oa H w 2X co s HM 5M CC a o >3 oOi X O a Oo cc 41 -H (J Q C3 U 41 fl Cl U4) IQ amo) *44J)i 1-1 m rH n c ou -aw> HcI J33 U J3 02 O Q, >. CT> -0H.-HC Q. M <30 O4) a0] uOo u C E 4> 2-i M3 Z ABD00029688 None o th e r (see low le v e l in node 329) DESIGN IN T E N T IO N : STORAGE OF SODIUM HYPOCHLORITE FOR CENTRATE TREATMENT Q OMa a> o >Q. c Q. OH K V1) Hm u a> -- CU <INf\ O r> 41 U a 5 05 zc 11 a0 z > ToJ 0C V --m co H M41 U(0 XU 44J* 0C 41 4U) CC 00 zu JWh3 V0fl 41 C -- 0H 4141 U(0 J45J U44 0c 4) 1) O CC 00 ZO u 10 r4 > aV sv 2 i M3 Z o o U e o z o CD CN H OOmNJ 0(N> O<NN QCMO QJ3 <CMO0 2 Cm 2 fS m v irt V0 opr*li Om r^> Oro <n O^ <*i omn onr**>> o m N O / LOW PRESSURE 3 3 0 .8 ABD00029689 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 ABD00029690 <n a. isf C o IHufl co <uHo 1ll ca 3 01 011 u a. r 5E CO C B3 41 C V c o z H CUO 0) 3 Vc o z J V 0 TJ O Vco C c Z -H 1c Vc zo If aa ll a n<o CJ H 1 C >1 J<O38 h-3Hi 4) X <** g H<0 41 H> id > 3 C S' 4) C zo c 0 4fHfJl 1>1 Q T13 3 C u C o o OX MQ >-i _J z a, M W hi z EX- Zo U CJ hi CN t*l If LA LO t"~ <N <N m <N co fh] cmi <1> nm fh> fr(NOil nrf-i1) oz A CN 5 Ed a. 5 o> CmmJ fmrN*i <nnNo ABD00029691 umu ~oto cc3t -- ua zs CO M r--* Cl] oz o C3 CL H aw a It > E a3 rH It .* U 4) U Cl] 3 ffiQ C o 0> ii u E 4) 4> n (N i3 3 --1 i i-i 3m it m flH H a0 U <*4 h i*l u jw: toj -H c u4) u<M0 t) o eo co zu uv O "D0 4) C c 0c Z -H 4) 4) C c oc Z -H 3 3 2 a .11 HIGH TEMPERATURE ABD00029692 DESIG N IN T E N T IO N : STORAGE OF FLOCCULANT FOR CENTRATE TREATMENT Oc ' -H oX 41 H 4> MC 11 c H ' Ol Cl c C -H i >0 41 c0 z X Jo 3<0 iJ u ouu 4) TJ 4> U r-t 0 r-t 4JJ -rt 4a1 o z UU 4) 4) *5 41 C o z o e i> rH <N n in * r 9 IT* H mm m mm m mm mro m r**j m ni rr>o fm*f*>> nn m f*> mm rno ABD00029693 V >3 oc 4= -O 01 0 H C MVC U<k0 ve z0 ocoo k 4J 4I3I IkQ 4) O gg zo 3 3 4 .1 1 HIG H TEMPERATURE ABD00029694 tn c0 30> 0 O3 n-i o c * r*l l O irr/nnI c o L) > o4) *1DE0) > 4> 41 4 c0u 4J E 1) C o z sz o fAH 2 w zo h-4 hA3 H z3 o U 5 w wu aac, CO 5wX CO uz o z o u o3 3 Cl] a (X u 3 o J a ol-l X o z X oM X H N n ** LH m Pi m ro ro i/i it !*> U*> pi n 41 4) C0 C o zz w fc5 2< 2< EQx.) w > JCi] JCi] U' O 0 < < Cl Cl QC XCd a, H 3 O J sCO: H X oM X 3 o o z > CJi] X Mu X Ci] M X QM ZM X oM X o ui [- <0 H Lit I/I Pi <0 u<*li rt l/l f*> ro U> n p> Lit (*> ABD00029695 j: 3oi 41 41 ~ Vi u V 3UO 01 -H mE i 41 0) M Vi C Q ana a E 3 a H c0 H JJ H c _ u0 c H 41 u 11 U flj o Uc 41 <n a0) 4c1 H 1+4 H 3 H a05 44 & i--1 0 c cH 41 0CL a H ) M 4M) i41l- 3 0} -H c o> r* H 4i m i V CH c a nj q 0 c 'H 0>0) Vi tn u u . j= a. o 0H> cH CD 0xJ 'w' C H 4) u 05 uM 4) u 15 +4 H 4J TJ rH -H a C H 4-1 u H TJ C H 3 O H &. D a M CL *22 t - 3 H c CO 0U U H c 41H H T3 4) C Vi U H 3 U <n 3 <n O 41 a- i--i Vi o u. a. DESIGN IN T E N T IO N : F IL T E R CENTRATE WATER 41 Vi 3 H Vi H Or 4) <4 41 U w u m -H rH 4-1 0 JZ flQ <Co v 3 x: > J u o H 41 41 C Vi 01 <0 3 01 SZ rH O 3 O -H mH 41 >4 XI a. >w Ol c H Vi 41 U H 4-1 4-1 0 05 05 3Q CL o uu v* 41 0 fl J Vi Vi r^i -H H Vi "O -H a 41 41 in 01 0] Vl 0 o o 0 '-l 41 41 U O 01 01 >0 01 01 Vi U 41 3 3 41 4H HH Q, 41 a. CL O rH C 0 z M IS S IN G COMPONENT 3 3 6 .4 ABD00029696 00s1 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 P re v e n tiv e m aintenance program * VU 11 3C -h -tHu rH 1) A 1-2 u tj Il O*l O O Z X2 3 i xu o33 JH M & td b. .. 8MJ-< z Mo b. 01 cH A <n .Xy y .0 U u nj -h u-t Aa 0 IXV Ji M yy 33 JJ u 2c i) & c 3 y 2 33 <N r* m eem'n ABD00029697 DESIGN IN T E N T IO N : F IL T E R BACKWASHING 0* sz -0H1 a v(a o 0) c U -H .. vQ, Uo 0u bv 01 <0 uV cc 00 zz td VI as u > QM h m aHsI Q3 WM Q3 tt. H u Z Oa O U O zHtoI <Ma m T r* r~ r> m mm & OH ffV |H H it*- <f~n mr <* 1*1 *> ABD00029698 moo 0a 0>1 --utuHHo *uuo0H1 >rs -VhC a0u 0c) 0c) zo 11 c u3 rH -cttuHHoo C0ao) m 01 a; cc oo zz 01 ID 0) 0) 0) 0) cCcC cC z0 0 O O o zzzzz 0 Id CO QC Cd z > _ z o Cd c2d CO o IH M f-j 35- Cd X2 2sCl. \ z o CL Dz Cd o t- u o o z o o' 2 H5 H < c2 2 u pc |h 2 Cd U Z CO CO Cd 02 a. 2 Cd p2 X CO CO Cd X <5 cd Cd a. X fcC <cd Cd X Z 23 Cd ac o -- z z zo O U O J ac a. E Cd Cu H *-* QX H V) <o t Q. u x H XX z 2 2 0o CO O MJ Ci. CO M z hz xo Cd O Q J 0 M X O z o M X O *3 M X 03o1 C H CN Cl U1 VO r CD 01 Oi--* .--H1 ooc CO 00 00so CO o co CD CO 9 Cl Cl cl cl m m Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl Cl ABD00029699 3 3 9 .0 PROCESS L IN E - PLANT A IR FOR SCOUR (d w g : D Y -0 9 3 1 4 9 -P ID -D ) 3 3 9 .1 1 HIQH TEMPERATURE W Q U CQ a> u OMS s ra-->* Q, J M 0E b. u c os -H o 0) oMs cp* 4u 3 > 0 0) J uc 0. & B 1*4 *JaHS 0 fl a b0 u V M >i IB o V au *3i aH a k rH (B C O 8?-Oi 0 *J cH 4J 4) D> rH -H * U 44J) *MHH c 4|HJ *4 %* 14 0M M t> 14 0 *ifJl Vo 14 B BO a"3 4J e <3 a **4 o B B s wCLlldl . in 2 O > ABD00029703 -* ABD00029704 Vv-3A * ABD00029705 9 i) ABD00029706 mi ABD00029707 ABD00029708 ABD00029709 ABD00029710 ABD00029711 ABD00029712 ABD00029713 ABD00029714 ABD00029715 ? 3i X ! 3 i li ? 2 1 ?w iU SiRiriR _ F s i2 L S vs ir u oujuoouy: t ------------------------------------------------------------------------------------------------------------------------ --------------------------------------- tow -on ABD00029716 ABD00029717 ABD00029718 ABD00029719 ABD00029720 ABD00029721 ABD00029722 ABD00029723 ABD00029724 ABD00029725 t ABD00029726 ABD00029727 ABD00029728 ABD00029729 83 S82 I S in Biii1^t'ft H ZO If t i* 7? cs: g Q B oowr>irM n ru CM ! M MB 1 J irj Bx" g> S3 f-IV II MM J W IS to t-l* M MOD M 1 j --0---- -X- '-1 Oi XV n"`'l s]w--1 rn eyrzfi | 1 :iiSm Si sfei- BH m HEi/o J tZjf B: J/^N. I=K IUV zI i::m iJ ;l>> iA J ? S;f Si9 ? i 6 t 1i 1 n| Ay A ? i & Ia ABD00029731 ABD00029732 9661 lOD LV-6V01 LZ &$ Md (HsdXl0e)*ld'Jd6Il^ S DM-001 CENTRATE FLOCCULATING TANK cu Uj u ABD00029733 9661XQO WLV-60 LZ &S !Jd >ldoid (frlsd*iioe)lld`!d8M*F ABD00029734 ABD00029735 9661100 69:8fr:60 LI daS Hdi *Hsd@jo[d (nsd7I0)*ld'!d6H*F ABD00029736 ABD00029737 C T -006 EAST C O O LIN G TOWER ABD00029738 PIPE PUMP HOUSE ABD00029739 9661 1QD 9V$S`9l 81 Jdy `ls!lld (|srtOl It)w''!d3l 1 ABD00029740