Material Control/Quality Assurance Requirements For Chemical Plants and Refineries

MaterialControl and QualityAssurance:
Amanda Stephens
August 15,2011
Regulationsand Requirements
ISP CalvertCity
INTRODUCTION
The needforamaterialcontrol/QAprogram andthe extentto whichsuch aprogram is required at ISP'sCalvertCityplant has
been questioned. This documentattemptsto bringtogetherthe relevantcodes, standards, and requirementsformaterialcontrol
and material qualityassuranceas appliesto mechanicalsystemsin onecompilationforease of understandingand readability.
Electrical and instrumentationsystem QA requirementsare notcoveredin this report.
EXECUTIVESUMMARY
Both OSHAand the EPA require aMechanical Integrityprogram, and also requireaQualityAssurance program as partofthe
Mechanical IntegrityProgram. Further, both regulations statethattheQualityAssurance program appliesto pressurevessels,
storagetanks, pipingsystemsandcomponents, reliefand ventsystems, emergencyshutdown systems, controls, and pumps.
Both regulations specifythe needforinspections and testsalong with the requirementthatinspection/testproceduresfollow
recognizedand generallyacceptedgoodengineering practices(RAGAGEP), which effectivelymakes anyRAGAGEPthe law.
In orderto adequatelycomplywith all the regulations, codes and standards that applyto pressurevessels, piping, andstorage
tanks, ISP CalvertCitymust have amaterial control/materialQA program covering newinstallations, repairs andalterations,
and general maintenance ofall vessels, tanks, and pipingsystems. In orderto accomplishthis, materialshould go through
inspection as it is received and following installation. The receipt inspection mustinclude materialverificationat aminimum-
PMI verification and comparison to MTRs/CoCs is requiredacross all materialsused in vessels, tanks, orpiping, includingweld
fillermaterial. Dimensional analysis is required on vessel parts and on piping, andthicknesstesting is required on tank plate
material. Other"suitabletests"are required on gaskets, dependingon the material, which impliesthe needfor durometertesting
of nonmetallicgasket material.
FEDERALREGULATIONS: OSHA AND EPA
Both OSHA (regulation 29, CFR 1910.119Process SafetyManagementof HighlyHazardous Chemicals) andthe EPA (rule40,
CFR 68, Chemical Accident Prevention Provisions) requireplantsthatfall underthe named regulationsto maintain Mechanical
Integrityprograms. The relevantsectionsfrom each regulation areshown below:
(j) Mechanical integrity
(1) Application.
Paragraphs 0)(2)through 0)(6)ofthissection applytothefollowingprocessequipment:
(i) Pressurevessels andstoragetanks;
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(ii) Pipingsystems(includingpipingcomponentssuchasvalves);
(iii) Reliefandventsystemsanddevices;
(iv)Emergencyshutdownsystems;
(v)Controls(includingmonitoringdevicesandsensors,alarms,andinterlocks)and,
(vi)Pumps.
OSHA 1910.119(j)(1)
(6) Qualityassurance.
(i)Intheconstructionofnewplantsand equipment,theemployershallassurethatequipmentasitis
fabricated issuitablefortheprocessapplicationforwhichtheywillbeused.
(ii)Appropriatechecksand inspectionsshallbeperformedtoassurethatequipmentisinstalledproperlyand
consistentwithdesignspecificationsandthemanufacturer'sinstructions.
(iii)Theemployershallassurethatmaintenancematerials,sparepartsandequipmentaresuitableforthe
processapplicationforwhichtheywillbe used.
OSHA 1910.119U)(6)
Sec.68.73 Mechanicalintegrity.
(a) Application. Paragraphs(b)through(f)ofthissectionapplytothefollowingprocessequipment:
(1) Pressurevesselsandstoragetanks;
(2) Pipingsystems(includingpipingcomponentssuchasvalves);
(3) Reliefandventsystemsanddevices;
(4) Emergencyshutdownsystems;
(5) Controls(includingmonitoringdevicesandsensors,alarms,andinterlocks)and,
(6) Pumps.
EPA68.73 (a)
(f) Qualityassurance.
(1) Intheconstruction ofnewplantsandequipment,theowneroroperatorshallassurethatequipmentas itis
fabricated issuitablefortheprocessapplicationforwhich theywillbe used.
(2) Appropriatechecksandinspectionsshall beperformedtoassurethatequipmentisinstalledproperlyand
consistentwithdesignspecificationsandthemanufacturer'sinstructions.
(3) Theowneroroperatorshallassurethatmaintenancematerials,sparepartsandequipmentaresuitablefor
theprocessapplicationforwhich theywillbe used.
EPA 68.73 (f)
Furthermore, the Appendix ofthe OSHA regulation states (emphasis added):
"A qualityassurance system is neededto help ensurethatthe propermaterials ofconstruction are used,
that fabrication and inspection procedures are proper, and that installation procedures recognize field
installation concerns. The quality assurance program is an essential part of the mechanical integrity
program and will help to maintain the primary and secondary lines of defense that have been designed
into the process to prevent unwanted chemical releases or those which control or mitigate arelease.
"As built" drawings, together with certifications of coded vessels and other equipment, and materials of
construction need to be verified and retained in the quality assurance documentation. Equipment
installation jobs need to be properly inspected in the field for use of proper materials and procedures
and to assure that qualified craftsmen are used to do the job. The use of appropriate gaskets, packing,
bolts, valves, lubricants and welding rods need to be verified in the field. Also procedures for installation
of safety devices need to be verified, such as the torque on the bolts on ruptured disc installations,
uniform torque on flange bolts, proper installation of pump seals, etc. Ifthe quality of parts is aproblem,
it may be appropriate to conduct audits of the equipment supplier's facilities to better assure proper
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purchases of required equipment which is suitable for its intended service. Any changes in equipment
that may become necessary will need to go through the management of change procedures."
As stated in both regulations, a quality assurance program is required and applies to pressure vessels, storage tanks, piping
systems and components, relief and vent systems, emergency shutdown systems, controls, and pumps that handle Highly
Hazardous Chemicals as specified in Appendix Ato Sec. 1910.119 of the OSHA regulation and Sec. 68.130 of the EPA
regulation. The need for quality assurance implies the need for material control, as uncontrolled material could then be installed
in any system regardless of intended application. Both regulations specify the need for inspections and tests along with the
requirement that inspection and testing procedures follow recognized and generally accepted good engineering practices
(RAGAGEP). Therefore, material control and quality assurance programs are required per OSHA regulation 29, CFR 1910.119
and EPA rule 40, CFR 68. (Complete copies of the OSHA and EPA regulations are attached in Appendices 1and 2 of this
report).
Neither the OSHA regulation nor the EPA regulation specifies how such programs are to be implemented; they simply refer to
using RAGAGEP to determine the implementation of material control and material quality assurance. This makes following
RAGAGEP the law. RAGAGEP includes codes, standards, and recommended practices, which are covered further in the
following sections.
CODES AND STANDARDS
ASME BOILER AND PRESSURE VESSEL CODE, SECTION VIII
Within the state of Kentucky, any entity that owns and operates boilers or pressure vessels is required by law to adhere to the
ASME Boiler and Pressure Vessel (BPV) Code as specified by Chapter 236.005 of the Kentucky Revised Statutes, the Boiler
and Pressure Vessel Safety Act enacted on July 15, 1980. Therefore, ISP Calvert City is required to adhere to it.
Paragraph UG-90 (c) (1) U) of the ASME Boiler and Pressure Vessel Code, Section VIII, states that the Inspector is responsible
for, "inspection of the vessel to confirm that there are no material or dimensional defects." UG-96, Dimensional Check of
Component Parts, specifies that" The Inspector shall satisfy himself that the above dimensional requirements have been met.
This shall include making such dimensional measurements as he considers necessary."
Paragraph UG-93 (a) (1) states, "For plates, the vessel Manufacturer shall obtain the material test report or certificate of
compliance as provided for in the material specification and the Inspector shall examine the Material Test Report or certificate of
compliance and shall determine that it represents the material and meets the requirements of the material specification."
Paragraph UG-93 (b) states, "... when some requirements of a material specification of Section /I have been completed by other
than the material manufacturer [see UG-84(d) and UG-85], then the vessel Manufacturer shall obtain supplementary material
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test reports or certificates of compliance and the Inspector shall examine these documents and shall determine that they
represent the material and meet the requirements of the material specification."
Paragraph UG-93 (c) states, "When requirements or provisions of this Division applicable to materials exceed or supplement the
requirements of the material specification of Section II (see UG-24, UG-84, and UG-85), then the vessel Manufacturer shall
obtain supplementary material test reports or certificates of compliance and the Inspector shall examine these documents and
shall determine that they represent the material and meet the requirements or provisions of this Division."
Taken together, these paragraphs indicate that when a new pressure vessel is installed, it should arrive with material test
reports (MTRs) or certificates of compliance (COCs) for all parts. In addition, the Inspector (in ISP Calvert City's case, a
Mechanical Integrity Engineer) is responsible for determining that the MTRs/COCs represent the material in question and for
checking the dimensions of the vessel and its parts.
Highlighted excerpts from the ASME Boiler and Pressure Vessel Code, Section VIII are included in Appendix 3.
API 510, PRESSURE VESSEL INSPECTION CODE
Section 4.2.1 of API 510 contains a number of requirements for material control and quality assurance. It states, "An owner/user
organization is responsible for developing, documenting, implementing, executing, and assessing pressure vessel/pressure
relieving device inspection systems and inspection/repair procedures that meet the requirements of this inspection code. These
systems and procedures will be contained and maintained in a quality assurance inspectionlrepair management system.. ," It
goes on to specify the important aspects that must be included, some of which are:
4.2. 1b. Documenting of inspection and quality assurance procedures.
4.2.1 c. Documenting and reporting inspection and test results,
4.2.1 p. Controls necessary so that only materials conforming to the applicable construction code are utilized for
repairs and alterations.
Section 5.9 of API 510, Material Verification and Traceability, states, "During repairs or alterations of pressure vessels, the
inspector shall verify that all new materials (including carbon steel) are consistent with the specifications.. .Material testing can
be done by the inspector or examiner using suitable methods such as optical spectrographic analyzers, or x-ray fluorescence
analyzers. API 578 has additional guidance on material verification programs."
ISP Calvert City would be considered an owner/user organization. Therefore when a vessel is repaired or altered, ISP Calvert
City is required to verify the materials used in the alteration or repair either by optical spectrographic analysis or XRF.
Highlighted excerpts from API 510 are included in Appendix 4.
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Regulations and Requirements ISP Calvert City
NATIONAL BOARD INSPECTION CODE
The National Board Inspection Code covers pressure vessels and power piping (e.g. boiler piping). Per this code, replacement
parts to be used in repairs or alterations are to meet certain requirements. Section 3.2.2 b) states, "The supplier or manufacturer
shall certify that the material and fabrication are in accordance with the original code of construction. This certification shall be
supplied in the form of bills of material and drawings with statement of certification." This demonstrates further the need for
documentation, whether in the form of material test reports or certificates of compliance.
Highlighted excerpts from the National Board Inspection Code are included in Appendix 5.
ASME B31.1, POWER PIPING AND ASME BOILER AND PRESSURE VESSEL CODE, SECTION I
Section 136.2.1 of ASME B31.1 states that, "Inspection is the responsibility of the Owner, "and "piping shall be inspected during
construction and after completion." For specific requirements, the reader is referred to Section I of the ASME Boiler and
Pressure Vessel Code, sections PG-1 04 through PG-113. Section 136.2.2 states, "Certification by stamping and Data Reports,
where required, shall be as per PG-l04, PG-l05, PG-l09, PG-ll0, PG-lll, and PG-112 of Section I of the ASME Boiler and
Pressure Vessel Code."
Section I of the BPV contains several material requirements. The ones relevant to the need for material control and quality
assurance are as follows: PG-112.6.1 states, "Certification may be supplied in the form of bills of material and drawings with a
statement of compliance or Certificate of Compliance from the Manufacturer." PG-112.6.2 states, "The Certification shall state
what materials were used including size (0.0. and wall thickness) and which edition and addenda of the Code were used to
construct the parts." Finally, PG-112.6.3 states, "The parts shall be clearly identified with markings traceable to the certification.
The markings may be in the form of labels, tags, stamping, paint, or coded identification."
These codes further underscore the importance of having a quality assurance program and making sure that the materials used
are traceable back to their certifications.
Highlighted excerpts 'from the ASME B31.1 and ASME Boiler and Pressure Vessel Code, Section I are included in Appendices 6
and 7.
ASME 631 .3, PROCESS PIPING
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Section 341.4.1 (c) of ASME 831.3 states, "The examiner shall be assured, by examination of certifications, records, and other
evidence, that the materials and components are of the specified grades and that they have been received required heat
treatment, examination, and testing. The examiner shall provide the Inspector with a certification that all the quality control
requirements of the Code and of the engineering design have been carried out." Section 341.4.1 (c) covers Normal Fluid
Service; however, sections 341.4.3 (d) for Severe Cyclic Conditions and 341.4.4 (d) for Elevated Temperature Fluid Service
both refer back to section 341.4.1 (c).
Section 341.4.3 (3) and section 341.4.4 (a) (3) state, "All piping erection shall be examined to verify dimensions and alignment."
The above-mentioned sections of ASME 831.3 state that the Inspector should be given certification that the QC requirements
have been carried out.
Highlighted excerpts from ASME 831.3 are included in Appendix 8.
API 570, PIPING INSPECTION CODE
API 570 has several material control/quality assurance requirements. Much like API 510 for pressure vessels, it states, "An
owner/user organization is responsible for developing, documenting, implementing, executing, and assessing piping inspection
systems and inspection procedures that will meet the requirements of this inspection code. These systems and procedures will
be contained and maintained in a quality assurance inspection/repair management system..." Some of the important aspects
that must be included are:
4.3.1.1 b. Documenting of inspection and quality assurance procedures.
4.3.1.1 c. Documenting and reporting inspection and test results.
4.3.1.1 o. Controls necessary so that only materials conforming to the applicable section of the ASME Code are utilized
for repairs and alterations.
Section 5.9 of API 570, Material Verification and Traceability, states, "During repairs or alterations to alloy material piping
systems, where the alloy material is required to maintain pressure containment, the inspector shall verify that all new materials
are consistent with the selected or specified construction materials. This material verification program should be consistent with
API 578.. .PMI testing can be accomplished by the inspector or examiner with the use of suitable methods as described in API
578."
As an owner/user organization, ISP Calvert City is required to verify the materials used in alteration or repair to piping systems.
API 570 goes one step further than API 510, however, noting (emphasis added) that the "material verification program should
be consistent with API 578." API 578 is a Recommended Practice put forth by API, and is titled, "Material Verification Program
for New and Existing Alloy Piping Systems." The requirements per API 578 will be covered more fully later in this report, but it
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should be noted that because of the reference to it by the API 570 Code using the word "should," it becomes mandatory and is
considered RAGAGEP.
Furthermore, the above quoted sections from API 570 require material control and quality assurance for all pressure retaining
parts in piping systems. This includes anything that creates a pressure boundary, whether in acontrol instrument, pipe, weld,
pressure gauge, etc.
API 653, TANK INSPECTION, REPAIR, ALTERATION, AND RECONSTRUCTION
API 653 covers atmospheric storage tanks. Material control/QA requirements are contained in section 7. Section 7.3.1.1 of API
653 states, "All shell plate materials and bottom plates welded to the shell shall be identified. Material identified by original
contract drawings, API nameplates, or other suitable documentation do not require further documentation." Section 7.3.1.2 then
goes on to say, "Each individual plate for which adequate identification does not exist shall be subjected to a chemical analysis
and mechanical tests as required in ASTM A6 and ASTM A370 including Charpy V-notch." Section 7.3.1.3 covers further
requirements even for "known" materials (those covered in section 7.3.1.1), stating, "For known materials, all shell plates and
bottom plates welded to the shell shall meet, as a minimum, the chemistry and mechanical properties of the material specified
for the application..." This means that even for known materials, ISP Calvert City is required to verify the chemical and
mechanical properties of the material.
Additionally, section 13.2 of API 653 covers recordkeeping and states that material test reports/certifications shall be made a
part of the owner/operator's records for the tank.
Highlighted excerpts hom API 653 are included in Appendix 10.
API 620, DESIGN AND CONSTRUCTION OF LARGE, WELDED, LOW-PRESSURE STORAGE TANKS
In section 7of API 620, which covers Inspection, Examination and Testing, paragraph 7.1.1 states, "The inspector shall ensure
that all materials used in tanks constructed according to the rules in this standard comply in all respects with the requirements of
these rules. This shall be done either by witneSSing mill tests or examining certified mill test reports supplied by the
Manufacturer." Further, section 7.8 states, "All material shall be gauged or measured to determine whether the thickness meets
the requirements." Finally, section 7.12 states, "The inspector shall check the material being assembled by the lists of the plates
from the mill, their heat numbers, chemical analyses, and mechanical properties as given on mill reports and shall see that
copies are available to be attached to the Manufacturer's report."
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Together, the above statements require ISP Calvert City's inspector to obtain mill test reports, verify their chemistry, and to
verify the mechanical properties of the material used in low-pressure storage tanks.
RECOMMENDED PRACTICES
API 578: MATERIAL VERIFICATION PROGRAM FOR NEW AND EXISTING ALLOY PIPING SYSTEMS
API 578 is referred to by both API 510 and API 570. The reference from API 510 merely says that API 578 "can" be used;
however, the reference from API 570 states that API 578 "should" be used. The use of the word "should" elevates API 578 to
mandatory and automatically indicates that it is considered RAGAGEP.
API 578 contains numerous recommendations for material control and material QA. The overarching requirement is that the
owner/operator is responsible for "the implementation and conduct of the material verification program" as well as the
documentation of the material verification program in accordance with API 578.
Section 4.1 states, "The owner/user should establish a written material verification program indicating the extent and type of PMI
testing to be conducted during the construction of new piping systems, retroactively on existing piping systems, and during the
maintenance, repair, or alteration of existing piping systems."
Section 4.2.4 states, "Mill test reports should not be considered a substitute for a PMI test. However, mill test reports are an
important part of an overall material quality assurance program."
Section 4.2.5 covers the components to be covered in a Material Verification Program:

Pipe lengths

Pipe fittings, including blinds and plugs

Special forgings

Process valves, control valves, relief valves

Pressure-containing welds

Instruments (all pressure containing parts)

Weld overlays or cladding

Bolting

Expansion jOints and bellows

Gaskets
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Section 4.3.1 requires that "alloy piping systems that are already in service where the material verification program procedures
for the construction were not in accordance with 4.2' be retroactively PMI tested (pressure containing components and their
attachment welds). Section 4.3.3 covers prioritization of retroactive PMI of existing piping, and 4.3.5 discusses extent of
retroactive PMI testing. The prioritization should depend on likelihood of material mix-ups, consequences of failure, and reason
for alloy specification, among other things. The extent of retroactive testing should be based on things such as historical
inspection and material verification program records, number of plant modifications, materials control during original
construction and during modifications, and others.
Section 4.3.3.3 covers gaskets, stating "Incorrect gasket materials in incompatible service may cause premature failings. The
main principles outlined in this document can be applied to gasket materials. The owner/user is required to ascertain the
potential material variations and select analytical methods capable of providing the required data. The actual test procedures
can be more detailed due to the geometric structure of the gasket materials."
Section 4.4 requires material control as an element of maintenance, stating, "The principles associated with materials
verification as part of a new piping installation should also be applied to provide confidence that proper materials are being used
as apart of maintenance activities." Further, section 4.4.2 states, "A material verification program should be directly applied to
activities associated with receiving alloy materials into warehouse systems," which requires ISP Calvert City to perform PMI on
incoming material upon receipt. Finally, section 4.4.2 also states, "The material verification program that is adopted should
provided for proper documentation and methods for indicating which materials have been tested and are approved for use." This
requires ISP Calvert City to maintain documentation on PMI testing and to have some way of identifying which materials have
been tested.
API 574, INSPECTION PRACTICES FOR PIPING SYSTEM COMPONENTS
This recommended practice gives advice on methods of inspection for piping. In section 10.11.2, Material Verification, it states,
"Checks should be made using material test kits or other positive identification means, such as portable X-ray fluorescence or
portable optical emission spectrometry analyzers. In addition, manufacturers' material and test data can be obtained for
review..." Section 10.11.4.1, Repairs and Alterations, gives some typical inspection activities involved with planning repairs and
alterations and specifically calls out, "Reviewing material test reports... to assure all materials of construction are per the piping
specification and/or scope of work." Finally, sections 10.11.4.2 c) and d) name as typical inspector activities, "assuring any heat
treatment is performed per the work scope," and "assuring testing requirements, like hardness andpressure testing, are
performed and acceptable."
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The above statements further support that material testing in the form of PMI and hardness testing are part of an acceptable
material QA program and are RAGAGEP.
API 577, WELDING INSPECTION AND METALLURGY
Section 9.2 of API 577 covers Materials Identification, and states, "During welding inspection, the inspector may need to verify
the conformance of the base metal and filler metal chemistries with the selected or specified alloyed materials. This may include
reviewing the cerlified mill test reporl, reviewing stamps or markings on the components, or require PMI testing. It is the
responsibility of the owner/user to establish a written material verification program indicating the extent and type of PMI to be
conducted. Guidelines for material control and verification are outlined in API 578."
API 577 underscores the importance of ensuring that weld metal material is as specified and is used in the correct application
with compatible materials. It also supports PMI testing and requiring mill test reports as good practice in a material control/QA
program.
CONCLUSIONS
Requirements for pressure vessels and piping, whether new or repairs/alterations to existing, include obtaining and maintaining
mill test reports (MTRs)/certificates of compliance (CoCs) for all parts; determining that the MTRs/CoCs represent the material
in question (typically done through Positive Material Identification-or PMI); and verifying the dimensions of the vessel and/or its
parts.
Additional requirements for piping, pipe fittings, special forgings, valves, instruments, bolts, expansion joints/bellows, and
gaskets include all the above, plus material verification upon receipt and marking to identify which parts have been verified
when being stored for maintenance and repair activities. Furthermore, existing installed before implementation of the material
control/QA program should be retroactively identified by PMI testing.
Requirements for gaskets are "analytical methods capable ofproviding the required data."
Requirements for tanks-new and repairs/alterations-include obtaining and maintaining MTRs/CoCs, verifying material
chemistry matches the MTR/CoC, verifying the mechanical properties of the material, and performing thickness checks on the
material.
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In order to adequately comply with all the regulations, codes and standards that apply to pressure vessels, piping, gaskets and
storage tanks, ISP Calvert City must have a material control/material QA program covering new installations, repairs and
alterations, and general maintenance of all vessels, tanks, and piping systems. In order to accomplish this, material should go
through inspection as it is received. The receipt inspection must include material verification at a minimum-PM I verification and
comparison to MTRs/CoCs is required across all materials used in vessels, tanks, or piping, including welding material.
Dimensional analysis is required on vessel parts and on piping, and thickness testing is required on tank plate material. Other
"suitable tests" are required on gaskets, depending on the material, which implies the need for durometer testing of nonmetallic
gasket material.
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APPENDIX 1
OSHA REGULATION 29, CFR 1910.119 AND APPENDIX
(Relevant sections highlighted)
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TITLE29--LABOR
CHAPTERXVII--OCCUPATIONALSAFETYANDHEALTHADMINISTRATION,DEPARTMENT
OFLABOR
PART1910_0CCUPATIONALSAFETYANDHEALTHSTANDARDS
SubpartH_HazardousMaterials
Sec. 1910.119 Processsafetymanagementofhighlyhazardouschemicals.
Purpose.Thissectioncontainsrequirementsforpreventingorminimizingthe consequencesof
catastrophicreleasesoftoxic,reactive,flammable, orexplosivechemicals.Thesereleasesmayresultin
toxic, fire orexplosionhazards.
(a) Application.
(1) Thissectionappliesto thefollowing:
(i) Aprocesswhichinvolvesachemicalat orabovethespecifiedthresholdquantitieslistedin
appendix Atothis section;
(ii) Aprocesswhichinvolvesaflammable liquidorgas (as definedin 1910.1200(c)ofthis part)
onsiteinonelocation,in aquantityof10,000pounds(4535.9kg) ormoreexceptfor:
(A) Hydrocarbon fuels usedsolelyfor workplaceconsumptionas afuel (e.g.,propaneused
forcomfortheating, gasolinefor vehiclerefueling),ifsuchfuels arenotapartofa
processcontaininganotherhighlyhazardouschemicalcoveredbythis standard;
(B) Flammableliquidsstoredin atmospherictanksortransferredwhich arekeptbelowtheir
normalboilingpointwithoutbenefitofchillingorrefrigeration.
(2) Thissectiondoesnotapplyto:
(i) Retailfacilities;
(ii) Oil orgaswell drillingorservicing or,
(iii) Normallyunoccupiedremotefacilities.
(b)Definitions.
Atmospherictankmeans astoragetankwhichhas beendesignedto operateatpressures from atmospheric
through0.5 p.s.i.g. (poundspersquareinchgauge, 3.45 Kpa).
Boilingpointmeans the boilingpointofaliquidatapressureof14.7poundspersquareinchabsolute
(psia) (760mm.). Forthe purposesofthis section, where an accurateboilingpointis unavailablefor the
materialinquestion,orfor mixtureswhichdonothaveaconstantboilingpoint, the 10percentpointofa
distillationperformedin accordancewith theStandardMethodofTestfor DistillationofPetroleum
Products,ASTMD-86-62,whichisincorporatedbyreferenceas specifiedinSec. 1910.6,maybeused as
theboilingpointofthe liquid.
Catastrophicreleasemeansamajoruncontrolledemission,fire, orexplosion,involvi,ng oneormore
highlyhazardouschemicals, thatpresentsserious dangerto employeesin theworkplace.
Facilitymeans thebuildings,containersorequipmentwhichcontainaprocess.
Highlyhazardouschemicalmeansasubstancepossessingtoxic, reactive, flammable, orexplosive
propertiesand specifiedbyparagraph(a)(1) ofthis section.
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Hot work means work involving electric or gas welding, cutting, brazing, or similar flame or spark-
producing operations.
Normally unoccupied remote facility means a facility which is operated, maintained or serviced by
employees who visit the facility only periodically to check its operation and to perform necessary
operating or maintenance tasks. No employees are permanently stationed at the facility.
Facilities meeting this definition are not contiguous with, and must be geographically remote from all
other buildings, processes or persons.
Process means any activity involving a highly hazardous chemical including any use, storage,
manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities.
For purposes of this definition, any group of vessels which are interconnected and separate vessels which
are located such that a highly hazardous chemical could be involved in a potential release shall be
considered a single process.
Replacement in kind means a replacement which satisfies the design specification.
Trade secret means any confidential formula, pattern, process, device, information or compilation of
information that is used in an employer's business, and that gives the employer an opportunity to obtain an
advantage over competitors who do not know or use it. Appendix
D contained in Sec. 1910.1200 sets out the criteria to be used in evaluating trade secrets.
(c) Employee participation.
(1) Employers shall develop a written plan of action regarding the implementation of the employee
participation required by this paragraph.
(2) Employers shall consult with employees and their representatives on the conduct and development
of process hazards analyses and on the development of the other elements of process safety
n1anagement in this standard.
(3) Employers shall provide to employees and their representatives access to process hazard analyses
and to all other information required to be developed under this standard.
(d) Process safety information.
In accordance with the schedule set forth in paragraph (e)(1) of this section, the employer shall
complete a compilation of written process safety information before conducting any process hazard
analysis required by the standard. The compilation of written process safety information is to enable
the employer and the employees involved in operating the process to identify and understand the
hazards posed by those processes involving highly hazardous chemicals. This process safety
information shall include inforn1ation pertaining to the hazards of the highly hazardous chemicals
used or produced by the process, information pertaining to the technology of the process, and
information pertaining to the equipment in the process.
(1) Information pertaining to the hazards of the highly hazardous chemicals in the process. This
information shall consist of at least the following:
(i) Toxicity information;
(ii) Permissible exposure limits;
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(iii) Physical
(iv) Reactivity data:
(v) Corrosivity data;
(vi) Thermal and chemical stability and
(vii) Hazardous effects of inadvertent mixing of different materials that could foreseeably occur.
Note: Material Safety Data Sheets meeting the requirements of29 CFR 1910.1200(g) may be used to
comply with this requirement to the extent they contain the information required by this subparagraph.
(2) Information pertaining to the technology of the process.
(i) Information concerning the technology of the process shall include at least the following:
(A) A block flow diagram or simplified process flow diagranl (see appendix B to this section);
(B) Process
(C) Maximum intended
(D) Safe upper and lower limits for such items as temperatures, pressures, flows or
compositions; and,
(E) An evaluation of the consequences of deviations, including those affecting the safety and
health of employees.
(ii) Where the original technical information no longer exists, such information may be developed
in conjunction with the process hazard analysis in sufficient detail to support the analysis.
(3) Information pertaining to the equipment in the process.
(i) Information pertaining to the equipment in the process shall include:
(A) Materials of construction;
(B) Piping and instrument diagrams (P&ID's);
(C) Electrical classification;
(D) Relief system design and design basis;
(E) Ventilation system design;
(F) Design codes and standards employed;
(G) Material and energy balances for processes built after May 26, 1992; and,
(H) Safety systems (e.g. interlocks, detection or suppression systems).
(ii) The employer shall document that equipment complies with recognized and generally accepted
good engineering practices.
(iii) For existing equipment designed and constructed in accordance with codes, standards, or
practices that are no longer in general use, the employer shall determine and document that the
equipment is designed, maintained, inspected, tested, and operating in a safe manner.
(e) Process hazard analysis.
(1) The employer shall perform an initial process hazard analysis (hazard evaluation) on processes
covered by this standard. The process hazard analysis shall be appropriate to the complexity of the
process and shall identify, evaluate, and control the hazards involved in the process. Employers
shall determine and document the priority order for conducting process hazard analyses based on a
rationale which includes such considerations as extent of the process hazards, number of
potentially affected employees, age of the process, and operating history of the process. The
process hazard analysis shall be conducted as soon as possible, but not later than the following
schedule:
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(i) Noless than25 percentoftheinitialprocesshazardsanalysesshallbecompletedbyMay26,
1994;
(ii) Noless than 50percentoftheinitialprocesshazardsanalysesshallbecompletedbyMay26,
1995;
(iii)Nolessthan75percentoftheinitialprocesshazardsanalysesshallbecompletedbyMay26,
1996;
(iv)Allinitialprocess hazardsanalysesshallbecompletedbyMay26, 1997.
(v) ProcesshazardsanalysescompletedafterMay26, 1987which meettherequirementsofthis
paragraphareacceptableas initialprocesshazards analyses. Theseprocesshazardanalyses
shallbeupdatedandrevalidated, basedontheircompletiondate,inaccordancewithparagraph
(e)(6) ofthis section.
(2) Theemployershall useoneormoreofthefollowing methodologiesthatareappropriateto
determineandevaluatethehazardsoftheprocessbeinganalyzed.
(i) What-If;
(ii) Checklist;
(iii) What-If/Checklist;
(iv) Hazard and OperabilityStudy(HAZOP):
(v) FailureModeandEffectsAnalysis (FMEA);
(vi) FaultTreeAnalysis;or
(vi) Anappropriateequivalentlllethodology.
(3)Theprocesshazard analysisshalladdress:
(i) Thehazardsofthe process;
(ii) Theidentificationofanypreviousincidentwhichhad alikelypotentialforcatastrophic
consequencesin the workplace;
(iii) Engineeringand administrativecontrolsapplicabletothe hazards and theirinterrelationships
such as appropriateapplicationofdetection methodologiestoprovideearlywarningof
releases. (Acceptabledetectionmethodsmightincludeprocessmonitoringandcontrol
instrumentationwithalarms, anddetection hardwaresuchas hydrocarbonsensors.);
(iv) Consequencesoffailureofengineeringand administrativecontrols;
(v) Facilitysiting;
(vi) Humanfactors; and
(vii) Aqualitativeevaluationofarangeofthepossiblesafetyand healtheffectsoffailureof
controlsonemployeesin the workplace.
(4) Theprocesshazard analysisshallbeperformedbyateamwithexpertiseinengineeringand
processoperations,andtheteamshallincludeat leastoneemployeewhohasexperienceand
knowledgespecificto the processbeingevaluated. Also, onememberofthe teammustbe
knowledgeablein the specificprocesshazardanalysis methodologybeingused.
(5) Theemployershallestablishasystemto promptlyaddressthe team'sfindings and
recommendations; assurethattherecommendationsare resolvedin atimelyll1annerand that the
resolution is documented; documentwhatactions are to betaken; cOlllplete actions as soon as
possible;developawrittenscheduleofwhen theseactions are tobecompleted;communicatethe
actions to operating,maintenanceandotheremployeeswhoseworkassignmentsare in theprocess
and whomaybe affectedbytherecommendationsoractions.
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(6) Atleasteveryfive (5) years afterthecompletionoftheinitialprocesshazardanalysis,theprocess
hazardanalysis shallbeupdatedandrevalidatedbyateammeetingtherequirementsin paragraph
(e)(4)ofthis section,to assurethattheprocesshazardanalysisis consistentwiththecurrent
process.
(7) Employers shallretainprocesshazards analyses and updates orrevalidations foreachprocess
coveredbythis section, as well as the documentedresolutionofrecommendationsdescribedin
paragraph(e)(5) ofthis sectionforthelifeoftheprocess.
(f) Operatingprocedures
(1)Theemployershalldevelopandimplementwrittenoperatingprocedures thatprovideclear
instructionsfor safelyconductingactivitiesinvolvedin eachcoveredprocessconsistentwiththe
process safetyinformationand shalladdress atleastthefollowingelements.
(i) Stepsforeachoperatingphase:
(A) Initialstartup;
(B) Normaloperations;
(C) Temporaryoperations;
(D)Emergencyshutdownincludingtheconditionsunderwhichemergencyshutdownis
required, and the assignmentofshutdownresponsibilitytoqualifiedoperatorsto ensure
thatemergencyshutdownisexecutedin asafeandtimelymanner.
(E)EmergencyOperations;
(F) Normalshutdown; and,
(G) Startupfollowingaturnaround, orafteran emergencyshutdown.
(ii) Operatinglimits:
(A) Consequencesofdeviation; and
(B)Stepsrequiredtocorrectoravoiddeviation.
(iii) Safetyand healthconsiderations:
(A) Properties of, andhazardspresentedby, the chemicalsusedin theprocess;
(B) Precautionsnecessaryto preventexposure,includingengineeringcontrols,
administrativecontrols, andpersonalprotectiveequipment;
(C) Control measuresto betakenifphysicalcontactorairborneexposureoccurs;
CD) Qualitycontrolforrawmaterials andcontrol ofhazardouschemicalinventorylevels;
and,
(E) Anyspecialoruniquehazards.
(iv) Safetysystemsand theirfunctions .
(2) Operatingproceduresshall bereadilyaccessibletoemployeeswho workin ormaintain aprocess.
(3)Theoperatingproceduresshallbereviewedas oftenas necessaryto assurethattheyreflectcurrent
operatingpractice,includingchangesthatresultfrom changesin processchemicals, technology,
andequipn1ent, andchangestofacilities. TheemployershaH certifyannuallythattheseoperating
procedures arecurrentandaccurate.
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(4) Theemployershalldevelopandimplementsafeworkpracticesto providefor thecontrolof
hazardsduringoperationssuchas lockout/tagout;confinedspaceentry; openingprocess
equipmentorpiping; andcontroloverentranceintoafacilitybymaintenance,contractor,
laboratory,orothersupportpersonnel. Thesesafeworkpracticesshall applyto employeesand
contractoremployees.
(g)Training
(l)Initial training.
(i) Eachemployeepresentlyinvolvedin operatingaprocess, andeachemployeebeforebeing
involvedinoperatinganewlyassigned process,shallbetrainedin an overviewoftheprocess
andin theoperatingproceduresas specifiedinparagraph(f) ofthis section.Thetrainingshall
includeemphasison the specificsafetyand healthhazards,emergencyoperationsincluding
shutdown, and safeworkpracticesapplicableto theemployee'sjobtasks.
(ii)In lieu ofinitial trainingfor thoseen1ployees alreadyinvolvedin operatingaprocessonMay
26, 1992,an employermaycertifyin writingthattheemployeehas therequiredknowledge,
skills,andabilities to safelycarryoutthedutiesandresponsibilitiesas specifiedin the
operatingprocedures.
(2)Refreshertraining.
Refreshertrainingshallbeprovidedatleasteverythreeyears,andmoreoftenifnecessary, to each
employeeinvolvedin operatingaprocessto assurethattheemployeeunderstands and adheresto
thecurrentoperatingproceduresoftheprocess.Theemployer,in consultationwiththeemployees
involvedin operatingthe process, shalldeterminetheappropriatefrequencyofrefreshertraining.
(3)Trainingdocumentation.
Theemployershall ascertainthateachemployeeinvolvedinoperatingaprocesshasreceivedand
understood thetrainingrequiredbythis paragraph. Theemployershall preparearecordwhich
contains theidentityoftheemployee,thedateoftraining,and themeansusedto verifythatthe
employeeunderstoodthe training.
(h) Contractors
(l)Application.
Thisparagraphapplies to contractorsperformingmaintenanceorrepair, turnaround,major
renovation,orspecialtyworkon oradjacentto acoveredprocess. Itdoes notapplyto contractors
providingincidentalserviceswhichdonotinfluenceprocesssafety, suchasjanitorialwork, food
anddrinkservices,laundry,deliveryorothersupplyservices.
(2) Employerresponsibilities.
(i) Theemployer,whenselectingacontractor,shall obtainandevaluateinformationregarding
thecontractemployer'ssafetyperformanceandprograms.
(ii) Theemployershallinformcontractemployersoftheknownpotentialfire, explosion,ortoxic
releasehazardsrelatedto thecontractor'sworkand theprocess.
(iii) Theemployershall explain to contractemployerstheapplicableprovisionsoftheemergency
actionplanrequiredbyparagraph(n) ofthissection.
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(iv) Theemployershalldevelopandimplementsafeworkpracticesconsistentwithparagraph
(f)(4)ofthissection, tocontroltheentrance,presenceand exitofcontractemployersand
contractemployeesincoveredprocessareas.
(v) Theemployershallperiodicallyevaluatetheperformanceofcontractemployersin fulfilling
theirobligationsas specifiedin paragraph(h)(3)ofthissection.
(vi) Theemployershallmaintainacontractemployeeinjuryandillnesslogrelatedto the
contractor'sworkinprocessareas.
(3) Contractemployerresponsibilities.
(i) Thecontractemployershall assurethateachcontractemployeeis trainedinthework
practicesnecessaryto safelyperformhis/herjob.
(ii) Thecontractemployershall assurethateachcontractemployeeis instructedin theknown
potentialfire, explosion,ortoxicreleasehazardsrelatedto his/herjobandtheprocess, and
theapplicableprovisionsoftheemergencyactionplan.
(iii)Thecontractemployershalldocumentthateachcontractemployeehasreceivedand
understoodthetrainingrequiredbythisparagraph.Thecontractemployershallpreparea
recordwhichcontains theidentityofthecontractemployee,thedateoftraining, andthe
meansusedto verifythattheemployeeunderstoodthetraining.
(iv) Thecontractemployershall assurethateachcontractemployeefollows the safetyrulesofthe
facilityincludingthesafeworkpracticesrequiredbyparagraph(f)(4) ofthis section.
(v) Thecontractemployershalladvisetheemployerofanyuniquehazardspresentedbythe
contractemployer'swork, orofanyhazardsfound bythecontractemployer'swork.
(i) Pre-startupsafetyreview.
(1) Theemployershallperformapre-startupsafetyreviewfornewfacilities andfor modified
facilities whenthemodificationissignificantenoughtorequireachangein theprocesssafety
information.
(2) Thepre-startupsafetyreviewshallconfirmthatpriortotheintroductionofhighlyhazardous
chemicalstoaprocess:
(i) Constructionandequipmentisinaccordancewithdesign
(ii) Safety,operating, maintenance,andemergencyproceduresareinplaceandare
(iii) Fornewfacilities, aprocesshazardanalysis hasbeenperformedandrecomnlendationshave
beenresolvedorimplementedbefore and modifiedfacilities meettherequirements
containedinmanagementofchange,paragraph(1).
(iv)Trainingofeachemployeeinvolvedinoperatingaprocesshasbeencompleted.
(j) Mechanical integrity
(l)Application.
Paragraph U(2) throll bh (j)(6) ofthi section applyto the followingprocessequipnlent:
(i) Pre ureve sel' and toragetank ;
(ii Piping y tern (includingpipingcomponent uch as valve );
(iii Reliefand vent y tern andde ice .
(iv) Emergency hutdown ystem ;
(v) Control Oncludingmonitori ngdevices and en or.,alarm,and interlock)and,
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(vi)Pumps.
(2)Writtenprocedures.Theemployershallestablishandimplementwrittenproceduresto maintain
theon-goingintegrityofprocessequipment.
(3) Trainingfor processmaintenanceactivities.Theemployershall train eachemployeeinvolvedin
maintainingtheon- goingintegrityofprocessequipmentin an overviewofthatprocessandits
hazardsandintheproceduresapplicabletotheemployee'sjobtasksto assurethattheemployee
canperformthejobtasks in asafemanner.
(4)Inspect jonand te ti ng.
(i)Inspectionsand te tsshall beperfornlecionprocessequjpment.
(ii)]11 pectionandtestingprocedures hallfollowrecognizedand generallyaccepted good
engineeringpractices.
(iii)Thefrequencyofin pectionsandtests ofprocessequipmentshal1 beconsistentwith
appli cable manufact urers'recomluendation andgoodengi neering practices and nlore
frequentlyif deternlinedto be nece arybyprioroperatingexperience.
(iv) Theemployershall documenteach in pectionand testthathasbeenperformedonprocess
equiplnent. Thedocumentation hall identifythedateofthein pectionortest, the nameoftbe
personwhoperformed theinspectionortest,the erialnUlnberorotheridenti fjerofthe
equipment on which theinspectionorte twa performed, adescri ptionoftheinspection or
te tperformed,and theresul t ofthe inspectionorte t.
(5) Equipmentdeficiencies.Theemployershallcorrectdeficienciesin equipmentthatareoutside
acceptablelimits (definedbytheprocesssafetyinformationin paragraph(d) ofthis section)before
furtheruseorin asafeandtimelymannerwhennecessarymeansaretaken to assuresafeoperation.
(6) Qualityas Ul'ance.
0) Tn theconhtructionofnewplantsand equipnlent,theenlp]oyer halla ure thatequipmentas it
i fabricated i uitableforthe proces applicationforwhichtheywill be used.
(1i) Appropriatechecksand inspections hall beperformedto a ure thatequipment isinstalled
properlyand con i tentwithde ign pecification and the manufacturer' n ~ truction .
(ii i)Theemployer hall a ure thatmaintenancematerial,sparepart andequipmentare uitable
forth proce appli cationfor which theywi1J beused.
(k) Hotworkpermit.
(1) Theemployershallissueahotworkpermitforhotwork operationsconductedonorneara
coveredprocess.
(2) Thepermitshalldocumentthatthe fire preventionandprotectionrequirementsin 29CFR
1910.252(a)havebeenimplementedpriorto beginningthehotworkoperations;itshallindicate
the date(s) authorizedfor hotwork; andidentifythe objecton whichhot workis tobe
performed. Thepermitshall bekepton file untilcompletionofthehotwork operations.
(1) Managementofchange.
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(1) The employer shall establish and implement written procedures to n1anage changes (except for
"replacements in kind") to process chemicals, technology, equipment, and procedures; and,
changes to facilities that affect a covered process.
(2) The procedures shall assure that the following considerations are addressed prior to any change:
(i) The technical basis for the proposed change;
(ii) Impact of change on safety and health;
(iii) Modifications to operating procedures;
(iv) Necessary time period for the change; and,
(v) Authorization requirements for the proposed change.
(3) Employees involved in operating a process and maintenance and contract employees whose job
tasks will be affected by a change in the process shall be informed of, and trained in, the change
prior to start -up of the process or affected part of the process.
(4) If a change covered by this paragraph results in a change in the process safety information
required by paragraph (d) of this section, such information shall be updated accordingly.
(5) If a change covered by this paragraph results in a change in the operating procedures or
practices required by paragraph (f) of this section, such procedures or practices shall be updated
accordingly.
(m) Incident investigation.
(1) The employer shall investigate each incident which resulted in, or could reasonably have
resulted in a catastrophic release of highl y hazardous chemical in the workplace.
(2) An incident investigation shall be initiated as promptly as possible, but not later than 48 hours
following the incident.
(3) An incident investigation team shall be established and consist of at least one person
knowledgeable in the process involved, including a contract employee if the incident involved
work of the contractor, and other persons with appropriate knowledge and experience to
thoroughly investigate and analyze the incident.
(4) A report shall be prepared at the conclusion of the investigation which includes at a minimum:
(i) Date of incident;
(ii) Date investigation began;
(iii) A description of the incident;
(iv) The factors that contributed to the incident; and,
(v) Any recommendations resulting from the investigation.
(5) The employer shall establish a system to promptly address and resolve the incident report
findings and recommendations. Resolutions and corrective actions shall be documented.
(6) The report shall be reviewed with all affected personnel whose job tasks are relevant to the
incident findings including contract employees where applicable.
(7) Incident investigation reports shall be retained for five years.
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(n) Emergency planning and response.
The employer shall establish and in1plen1ent an emergency action plan for the entire plant in
accordance with the provisions of 29 CFR 1910.38. In addition, the emergency action plan shall
include procedures for handling smaIl releases. Employers covered under this standard n1ay also be
subject to the hazardous waste and emergency response provisions contained in 29 CFR 1910.120 (a),
(p) and (q).
(0) Compliance Audits.
(1) Employers shall celiify that they have evaluated compliance with the provisions of this section
at least every three years to verify that the procedures and practices developed under the
standard are adequate and are being foIlowed.
(2) The compliance audit shall be conducted by at least one person knowledgeable in the process.
(3) A report of the findings of the audit shaIl be developed.
(4) The employer shall promptly determine and document an appropriate response to each of the
findings of the compliance audit, and document that deficiencies have been corrected.
(5) Employers shall retain the two (2) most recent compliance audit reports.
(p) Trade secrets.
(1) Employers shall make all information necessary to comply with the section available to those
persons responsible for compiling the process safety information (required by paragraph (d) of
this section), those assisting in the development of the process hazard analysis (required by
paragraph (e) of this section), those responsible for developing the operating procedures
(required by paragraph (f) of this section), and those involved in incident investigations (required
by paragraph (m) of this section), emergency planning and response (paragraph (n) of this
section) and compliance audits (paragraph (0) of this section) without regard to possible trade
secret status of such information.
(2) Nothing in this paragraph shall preclude the employer from requiring the persons to whom the
information is made available under paragraph (p)( 1) of this section to enter into confidentiality
agreements not to disclose the information as set forth in 29 CFR 1910.1200.
(3) Subject to the rules and procedures set forth in 29 CFR 1910.1200(i)(1) through
1910. 1200(i)(12), employees and their designated representatives shall have access to trade
secret information contained within the process hazard analysis and other documents required to
be developed by this standard.
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Material Control and Quality Assura.nce:
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August 15, 2011
ISP Calvert City
Appendix A to Sec. 1910.119--List of Highly Hazardous Chemicals, Toxics and Reactives (Mandatory)
This appendix contains a listing of toxic and reactive highly hazardous chemicals which present a
potential for a catastrophic event at or above the threshold quantity.
CHEMICAL name CAS* TQ**
Acetaldehyde 75-07-0 2500
Acrolein (2-Progenal) 107-02-8 150
Acrylyl Chloride 814-68-6 250
Allyl Chloride 107-05-1 1000
Allylamine 107-11-9 1000
Alkylaluminllms Varies 5000
Ammonia, Anhydrous 7664-41-7 10000
Ammonia solutions (44%
amn10nia by weight)
7664-41-7 15000
Ammonium Perchlorate 7790-98-9 7500
An1monium Permanganate 7787-36-2 7500
Arsine (also called Arsenic
Hydride)
7784-42-1 100
Bis(Chloromethyl) Ether 542-88-1 100
Boron Trichloride 10294-34-5 2500
Boron Trifluoride 7637-07-2 250
Bromine 7726-95-6 1500
Bromine Chloride 13863-41-7 1500
Bromine Pentafluoride 7789-30-2 2500
Bromine Trifluoride 7787-71-5 15000
3-Bromopropyne (also called
Propargyl Bromide)
106-96-7 100
Butyl Hydroperoxide
(Tertiary)
75-91-2 5000
Butyl Perbenzoate (Tertiary) 614-45-9 7500
Carbonyl Chloride (see
Phosgene)
75-44-5 100
Carbonyl Fluoride 353-50-4 2500
Cellulose Nitrate
(concentration 12.6%
nitrogen)
9004-70-0 2500
Chlorine 7782-50-5 1500
Chlorine Dioxide 10049-04-4 1000
Chlorine Pentrafluoride 13637-63-3 1000
Chlorine Trifluoride 7790-91-2 1000
Chlorodiethylaluminum (also
called Diethylaillminum
Chloride)
96-10-6 5000
l-Chloro-2,4-Dini trobenzene 97-00-7 5000
Chloromethyl Methyl Ether 107-30-2 500
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Chloro}2icrin 76-06-2 500
ChloropicrinandMethyl None 1500
Bromidemixture
ChloropicrinandMethyl None 1500
Chloridemixture
CumeneHydroperoxide 80-15-9 5000
Cyanogen 460-19-5 2500
CyanogenChloride 506-77-4 500
CyanuricFluoride 675-14-9 100
DiacetylPeroxide 110-22-5 5000
(Concentration70%)
Diazomethane 334-88-3 500
DibenzoylPeroxide 94-36-0 7500
Diborane 19287-45-7 100
DibutylPeroxide(Tertiary) 110-05-4 5000
DichloroAcetylene 7572-29-4 250
Dichlorosilane 4109-96-0 2500
Diethylzinc 557-20-0 10000
Diisopropyl 105-64-6 7500
Peroxydicarbonate
Dilaluroyl Peroxide 105-74-8 7500
Dimethyldichlorosilane 75-78-5 1000
Dimethylhydrazine, 1,1- 57-14-7 1000
Dimethylarnine, Anhydrous 124-40-3 2500
2,4-Dinitroaniline................................. 97-02-9 5000
EthylMethyl KetonePeroxide(alsoMethylEthyl 1338-23-4 5000
Ketone concentration60%)....
EthylNitrite...................................... 109-95-5 5000
Ethylamine......................................... 75-04-7 7500
EthyleneFluorohydrin.............................. 371-62-0 100
EthyleneOxide..................................... 75-21-8 5000
Ethyleneimine...................................... 151-56-4 1000
Fluorine........................................... 7782-41-4 1000
Formaldehyde(Formalin)............................ 50-00-0 1000
Furan.............................................. 110-00-9 500
Hexafluoroacetone.................................. 684-16-2 5000
HydrochloricAcid, Anhydrous....................... 7647-01-0 5000
HydrofluoricAcid, Anhydrous....................... 7664-39-3 1000
HydrogenBromide................................... 10035-10-6 5000
HydrogenChloride.................................. 7647-01-0 5000
HydrogenCyanide, Anhydrous........................ 74-90-8 1000
HydrogenFluoride.................................. 7664-39-3 1000
HydrogenPeroxide(52% byweightorgreater)....... 7722-84-1 7500
HydrogenSelenide.................................. 7783-07-5 150
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Hydrogen Sulfide................................... 7783-06-4 1500
MethylEthyl KetonePeroxide(concentration 60%)...........................................
SulfuricAcid)....................................
Acid; alsocalledPeroxyaceticAcid)..............
weight)...........................................
Acetic Acid; alsocalledPeraceticAcid)..........
Hydroxylamine...................................... 7803-49-8 2500
Iron, PentacarbonyI................................ 13463-40-6 250
Isopropylamine..................................... 75-31-0 5000
Ketene............................................. 463-51-4 100
Methacrylaldehyde.................................. 78-85-3 1000
MethacryloylChloride.............................. 920-46-7 150
MethacryloyloxyethylIsocyanate.................... 30674-80-7 100
Methyl Acrylonitrile............................... 126-98-7 250
Methylamine,Anhydrous............................. 74-89-5 1000
MethylBromide..................................... 74-83-9 2500
MethylChloride.................................... 74-87-3 15000
MethylChloroformate............................... 79-22-1 500
MethylFluoroacetate............................... 453-18-9 100
MethylFluorosulfate............................... 421-20-5 100
Methyl Hydrazine................................... 60-34-4 100
Methyl Iodide...................................... 74-88-4 7500
Methyl Isocyanate.................................. 624-83-9 250
MethylMercaptan................................... 74-93-1 5000
MethylVinyl Ketone................................ 79-84-4 100
Methyltrichlorosilane.............................. 75-79-6 500
NickelCarbonly(NickelTetracarbonyl)............. 13463-39-3 150
Nitric Acid (94.5% byweightorgreater)........... 7697-37-2 500
Nitric Oxide....................................... 10102-43-9 250
Nitroaniline(paraNitroaniline.................... 100-01-6 5000
Nitromethane....................................... 75-52-5 2500
Nitrogen Dioxide................................... 10102-44-0 250
Nitrogen Oxides(NO; N02;N204;N203).............. 10102-44-0 250
NitrogenTetroxide(alsocalledNitrogen Peroxide). 10544-72-6 250
Nitrogen Trifluoride........'" .................... 7783-54-2 5000
NitrogenTrioxide.................................. 10544-73-7 250
Oleum(65% to 80% byweight; alsocalledFuming 8014-94-7 1000
OsmiumTetroxide................................... 20816-12-0 100
OxygenDifluoride(FluorineMonoxide).............. 7783-41-7 100
Ozone.............................................. 10028-15-6 100
Pentaborane........................................ 19624-22-7 100
Peracetic Acid (concentration60% Acetic 79-21-0 1000
PerchloricAcid(concentration 60% by 7601-90-3 5000
PerchloromethylMercaptan.......................... 594-42-3 150
PerchlorylFluoride................................ 7616-94-6 5000
PeroxyaceticAcid (concentration 60% 79-21-0 1000
Phosgene(alsocalledCarbonylChloride)........... 75-44-5 100
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Phosphine(HydrogenPhosphide)..................... 7803-51-2 100
PhosphorusOxychloride(alsocalledPhosphoryl 10025-87-3 1000
Chloride).........................................
PhosphorusTrichloride............................. 7719-12-2 1000
PhosphorylChloride(alsocalledPhosphorus 10025-87-3 1000
Oxychloride)......................................
PropargylBromide.................................. 106-96-7 100
PropylNitrate..................................... 627-3-4 2500
Sarin.............................................. 107-44-8 100
SeleniumHexafluoride.............................. 7783-79-1 1000
Stibine(AntimonyHydride)......................... 7803-52-3 500
SulfurDioxide(liquid)............................ 7446-09-5 1000
SulfurPentafluoride............................... 5714-22-7 250
SulfurTetrafluoride............................... 7783-60-0 250
SulfurTrioxide(alsocalledSulfuricAnhydride)... 7446-11-9 1000
SulfuricAnhydride (alsocalledSulfurTrioxide)... 7446-11-9 1000
TelluriumHexafluoride............................. 7783-80-4 250
Tetrafluoroethylene................................ 116-14-3 5000
Tetrafluorohydrazine............................... 10036-47-2 5000
TetramethylLead................................... 75-74-1 1000
ThionylChloride................................... 7719-09-7 250
Trichloro(chloromethyl) Silane.................... 1558-25-4 100
Trichloro(dichlorophenyl)Silane.................. 27137-85-5 2500
Trichlorosilane.................................... 10025-78-2 5000
Trifluorochloroethylene............................ 79-38-9 10000
Trimethyoxysilane.................................. 2487-90-3 1500
*ChernicalAbstractServiceNumber.
**ThresholdQuantityin Pounds(Amountnecessaryto becoveredbythis
standard).
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Appendix B to Sec. 1910.119--Block Flow Diagram and Simplified Process Flow Diagram
(Nonmandatory)
[GRAPHIC] [TIFF OMITTED] TC270C91.026
[GRAPHIC] [TIFF OMITTED] TC270C91.027
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AppendixC to Sec. 1910.119--ComplianceGuidelinesand Recommendationsfor ProcessSafety
Management(Nonmandatory)
This appendixservesas anonmandatoryguidelinetoassistemployersandemployeesincomplyingwith
therequirementsofthis section, as well as providesotherhelpfulrecommendationsandinformation.
Examplespresentedin this appendixare nottheonlymeansofachievingtheperformancegoalsinthe
standard.Thisappendix neitheradds nordetractsfrom therequirenlentsofthestandard.
1. IntroductiontoProcessSafetyManagenlent.
Themajorobjectiveofprocesssafetymanagementofhighlyhazardouschemicalsis to prevent
unwantedreleasesofhazardouschemicalsespeciallyintolocations whichcouldexposeemployees
andothersto serioushazards. An effectiveprocesssafetymanagenlentprogramrequires a
systematicapproachtoevaluatingthe wholeprocess. Usingthis approach theprocessdesign,
processtechnology,operationaland maintenanceactivitiesandprocedures, nonroutineactivities
andprocedures,emergencypreparednessplansandprocedures,trainingprograms,andother
elementswhichimpacttheprocessare all consideredin theevaluation. Thevariouslinesof
defensethathavebeen incorporatedinto thedesignandoperationofthe processtopreventor
n1itigatethereleaseofhazardouschemicalsneedto beevaluatedand strengthenedto assuretheir
effectiveness ateachlevel. Processsafetymanagementis theproactiveidentification,evaluation
andmitigationorpreventionofchemicalreleasesthatcouldoccuras aresultoffailures in process,
proceduresorequipment. Theprocesssafetymanagementstandardtargets highlyhazardous
chemicalsthathavethe potentialtocauseacatastrophicincident.Thisstandardas awholeis to
aidemployersin theireffortsto preventormitigateepisodicchemicalreleasesthatcouldleadto a
catastrophein the workplaceandpossiblyto thesurroundingcommunity.Tocontrolthesetypes of
hazards, employersneed to developthe necessaryexpertise,experiences,judgementandproactive
initiativewithintheirworkforceto properlyimplementand maintain an effectiveprocesssafety
managementprogramas envisionedin theOSHAstandard.ThisOSHAstandardis requiredby
theCleanAirActAmendmentsas is theEnvironmentalProtection Agency'sRiskManagement
Plan. Employers,whomergethe twosetsofrequirementsintotheirprocesssafetymanagement
program,willbetterassurefull compliancewitheachas wellas enhancingtheirrelationshipwith
thelocalcommunity.
WhileOSHAbelievesprocesssafetymanagementwill haveapositiveeffecton thesafetyof
employeesin workplaces and alsooffersotherpotentialbenefitsto employers(increased
productivity),smallerbusinesseswhichmayhave limitedresources availableto themat this time,
mightconsideralternativeavenuesofdecreasingtherisks associated withhighlyhazardous
chemicalsat theirworkplaces. Onemethod which mightbeconsideredis thereductionin the
inventoryofthehighlyhazardouschemical. Thisreduction in inventorywillresultin areduction
oftheriskorpotentialfor acatastrophicincident. Also,employersincludingsmallemployers may
beableto establishmoreefficientinventorycontrolbyreducingthequantitiesofhighlyhazardous
chemicalsonsitebelowtheestablishedthresholdquantities.Thisreductioncanbeaccomplished
byorderingsmallershipmentsandmaintainingthenlinimuminventorynecessaryforefficientand
safeoperation. Whenreducedinventoryis notfeasible, then theemployermightconsider
dispersinginventoryto severallocationson site. Dispersingstorageintolocationswherearelease
in onelocationwill notcauseareleasein anotherlocation is apracticalmethodto alsoreducethe
riskorportentialforcatastrophicincidents.
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2. EmployeeInvolven1entinProcessSafetyManagement.
Section 304oftheCleanAirActAmendmentsstatesthatemployersaretoconsultwith their
employeesandtheirrepresentativesregardingtheemployerseffortsin thedevelopmentand
implementationoftheprocesssafetyrnanagementprogramelementsandhazardassessments.
Section304alsorequiresemployersto train andeducatetheiremployeesand to informaffected
employeesofthefindings fromincidentinvestigationsrequiredbytheprocesssafetymanagement
program.Manyell1ployers, undertheirsafetyand healthprograms,havealreadyestablished
meansandll1ethods tokeepemployeesandtheirrepresentativesinformed aboutrelevantsafety
andhealthissuesandemployersmaybeable to adaptthesepracticesandproceduresto meettheir
obligationsunderthis standard.Employerswhohavenotimplementedan occupationalsafetyand
healthprogrammaywishto formasafetyand healthcommitteeofemployeesandmanagement
representatives to helptheemployermeettheobligationsspecifiedbythis standard. These
committeescanbecomeasignificantallyin helpingtheemployerto implementand maintainan
effectiveprocesssafetymanagementprogramfor all employees.
3. ProcessSafetyInformation.
Completeandaccurate writteninformationconcerningprocesschemicals,processtechnology, and
processequipmentis essentialto an effectiveprocesssafetymanagementprogramandtoaprocess
hazardsanalysis.Thecompiledinformation willbeanecessaryresourceto avarietyofusers
includingtheteamthatwillperformtheprocesshazardsanalysisas requiredunderparagraph(e);
thosedevelopingthetrainingprogramsand theoperatingprocedures; contractorswhose
employeeswillbeworkingwiththeprocess;thoseconductingthepre-startupreviews; local
emergencypreparednessplanners; andinsuranceandenforcementofficials.
Theinformationtobecompiledaboutthechemicals,includingprocessintermediates, needs tobe
comprehensiveenoughfor an accurateassessmentofthefire andexplosioncharacteristics,
reactivityhazards, thesafetyandhealthhazardsto workers, andthecorrosionanderosioneffects
on theprocessequipmentand monitoringtools. Currentmaterialsafetydatasheet(MSDS)
informationcanbe usedtohelpmeetthis requirementwhichmustbesupplementedwithprocess
chemistryinformationincludingrunawayreaction andoverpressurehazardsifapplicable.
Processtechnologyinformationwillbeapartoftheprocesssafetyinformationpackageand itis
expectedthatit willincludediagramsofthetypeshownin appendixBofthis section as well as
employerestablishedcriteriafor n1aximuminventorylevelsfor processchemicals;limitsbeyond
which wouldbeconsideredupsetconditions;and aqualitativeestimateoftheconsequencesor
results ofdeviation thatcouldoccurifoperatingbeyondtheestablishedprocesslimits.Employers
areencouragedto usediagramswhichwill helpusers understandtheprocess.
Ablockflow diagramis used toshowthe majorprocessequipmentandinterconnectingprocess
flow linesand showflow rates, streamcomposition,tell1peratures, andpressureswhen necessary
for clarity.Theblockflow diagramisasimplifieddiagram.
Processflow diagramsare morecomplexand will showall mainflow streamsincludingvalvesto
enhancetheunderstandingoftheprocess, as well as pressuresandtemperatureson all feed and
productlineswithinall majorvessels,in and outofheadersandheatexchangers,andpointsof
pressureandtemperaturecontrol. Also,materialsofconstructioninformation,pumpcapacitiesand
pressureheads,compressorhorsepowerand vessel designpressuresandtemperatures areshown
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whennecessaryforclarity. In addition, majorcomponentsofcontrolloopsare usuaIIyshown
alongwithkeyutilitieson processflow diagrams.
Pipingandinstrumentdiagrams (P&IDs)maybethemoreappropriatetypeofdiagramstoshow
someoftheabovedetailsand todisplaytheinformationforthepipingdesignerandengineering
staff. TheP&IDsareto beusedto describetherelationshipsbetweenequipmentand
instrumentationas weII as otherrelevantinformationthatwillenhanceclarity. Computersoftware
programswhichdo P&IDsorotherdiagrams usefultotheinformationpackage,maybeused to
helpmeetthisrequirement.
Theinformationpertainingtoprocessequipmentdesignmustbedocumented. In otherwords,
whatwerethecodesand standardsreliedontoestablishgoodengineeringpractice. Thesecodes
andstandards arepublishedbysuchorganizationsas theAmericanSocietyofMechanical
Engineers,AmericanPetroleumInstitute,AmericanNationalStandardsInstitute,NationalFire
ProtectionAssociation, AmericanSocietyforTestingandMaterials,NationalBoardofBoilerand
PressureVesselInspectors,NationalAssociationofCorrosionEngineers, AmericanSocietyof
ExchangeManufacturersAssociation,and model buildingcodegroups.
In addition, variousengineeringsocietiesissuetechnical reports which impactprocessdesign. For
example,theAmericanInstituteofChemicalEngineershaspublishedtechnical reports ontopics
suchas twophaseflow for ventingdevices. Thistypeoftechnicallyrecognizedreportwould
constitutegoodengineeringpractice. Forexistingequipmentdesignedandconstructedmany
years agoin accordancewiththecodes and standards availableatthattimeand no longerin
generalusetoday, theemployermustdocumentwhichcodes and standardswereusedandthatthe
design andconstructionalongwiththe testing, inspectionandoperationarestiII suitableforthe
intendeduse. Wheretheprocesstechnologyrequires adesign whichdepartsfromtheapplicable
codes and standards, the employermustdocumentthatthedesignand constructionis suitablefor
theintendedpurpose.
4. ProcessHazardAnalysis.
Aprocesshazard analysis (PHA), sometimescaIIedaprocesshazardevaluation,is oneofthemost
importantelementsoftheprocesssafetymanagementprogram. A PHAis an organizedand
systematiceffortto identifyandanalyzethe significanceofpotentialhazardsassociatedwiththe
processingorhandlingofhighlyhazardouschemicals. APHAprovidesinformation whichwiII
assistemployersandemployeesin makingdecisionsforimprovingsafetyand reducingthe
consequencesofunwantedorunplannedreleasesofhazardouschemicals. A PHAisdirected
towardanalyzingpotentialcausesandconsequencesoffires, explosions,releasesoftoxicor
flammablechemicalsandmajorspiIIs ofhazardouschemicals.ThePHAfocuses onequipment,
instrumentation,utilities, humanactions (routineandnonroutine),andexternal factors thatmight
impacttheprocess. Theseconsiderationsassistin determiningthe hazardsandpotentialfailure
pointsorfailurenlodes in aprocess.
TheselectionofaPHAmethodologyortechnique will beinfluencedbymanyfactors including
the amountofexistingknowledgeabouttheprocess. Is itaprocessthathas beenoperatedfor a
longperiodoftime withlittleornoinnovationandextensiveexperiencehas beengeneratedwith
its use? Or,is itanewprocessoronewhichhasbeenchangedfrequentlybytheinclusionof
innovativefeatures? Also, thesizeandcomplexityofthe processwiII influencethedecisionas to
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the appropriate PHA methodology to use. All PHA methodologies are subject to certain
limitations. For example, the checklist methodology works well when the process is very stable
and no changes are made, but it is not as effective when the process has undergone extensive
change. The checklist may miss the most recent changes and consequently the changes would not
be evaluated. Another limitation to be considered concerns the assumptions made by the team or
analyst. The PHA is dependent on good judgment and the assumptions made during the study
need to be documented and understood by the team and reviewer and kept for a future PHA.
The team conducting the PHA need to understand the n1ethodology that is going to be used. A
PHA team can vary in size from two people to a number of people with varied operational and
technical backgrounds. Some team n1embers may only be a part of the team for a limited time. The
team leader needs to be fully knowledgeable in the proper implementation of the PHA
n1ethodology that is to be used and should be impartial in the evaluation. The other full or part
time team members need to provide the team with expertise in areas such as process technology,
process design, operating procedures and practices, including how the work is actually performed,
alarms, emergency procedures, instrumentation, maintenance procedures, both routine and
nonroutine tasks, including how the tasks are authorized, procurement of parts and supplies, safety
and health, and any other relevant subject as the need dictates. At least one team member must be
familiar with the process.
The ideal team will have an intimate knowledge of the standards, codes, specifications and
regulations applicable to the process being studied. The selected team members need to be
compatible and the team leader needs to be able to manage the team, and the PHA study. The team
needs to be able to work together while benefiting from the expertise of others on the team or
outside the team, to resolve issues, and to forge a consensus on the findings of the study and
recommendations.
The application of a PHA to a process may involve the use of different methodologies for various
parts of the process. For example, a process involving a series of unit operation of varying sizes,
complexities, and ages may use different methodologies and team mernbers for each operation.
Then the conclusions can be integrated into one final study and evaluation. A more specific
example is the use of a checklist PHA for a standard boiler or heat exchanger and the use of a
Hazard and Operability PHA for the overall process. Also, for batch type processes like custom
batch operations, a generic PHA of a representative batch may be used where there are only small
changes of monomer or other ingredient ratios and the chemistry is documented for the full range
and ratio of batch ingredients. Another process that might consider using a generic type of PHA is
a gas plant. Often these plants are simply moved from site to site and therefore, a generic PHA
may be used for these movable plants. Also, when an employer has several similar size gas plants
and no sour gas is being processed at the site, then a generic PHA is feasible as long as the
variations of the individual sites are accounted for in the PHA. Finally, when an employer has a
large continuous process which has several control rooms for different portions of the process
such as for a distillation tower and a blending operation, the employer may wish to do each
segment separately and then integrate the final results.
Additionally, small businesses which are covered by this rule, will often have processes that have
less storage volume, less capacity, and less complicated than processes at a large facility.
Therefore, OSHA would anticipate that the less complex methodologies would be used to meet the
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processhazard analysiscriteriain the standard.Theseprocesshazardanalysescanbedonein less
tinleandwith afew peoplebeinginvolved. Alesscomplexprocessgenerallymeansthatlessdata,
P&IDs, and processinformationis neededtoperformaprocesshazard analysis. Manysmall
businesseshaveprocessesthatarenotunique, suchascoldstoragelockersorwatertreatment
facilities. Whereemployerassociationshaveanumberofnlembers withsuchfacilities, ageneric
PHA,evolvedfromachecklistorwhat-ifquestions,couldbedevelopedandusedbyeach
employereffectivelytoreflecthis/herparticularprocess;thiswouldsimplifycompliancefor them.
Whentheenlployerhas anumberofprocesseswhichrequireaPHA,theemployermustsetup a
prioritysystemofwhichPHAsto conductfirst. A preliminaryorgrosshazardanalysismaybe
useful in prioritizingthe processesthattheemployerhas determined are subjectto coveragebythe
processsafetymanagementstandard. Considerationshouldfirst begivento thoseprocesseswith
thepotentialofadverselyaffectingthelargestnumberofemployees.Thisprioritizingshould
considerthepotentialseverityofachemicalrelease, the numberofpotentiallyaffectedemployees,
the operatinghistoryoftheprocesssuchas thefrequencyofchemicalreleases,theageofthe
processandanyotherrelevantfactors. Thesefactors wouldsuggestarankingorderand would
suggesteitherusingaweighingfactorsystemorasystematicrankingmethod. Theuseofa
preliminaryhazardanalysis wouldassistan employerindeterminingwhichprocessshouldbeof
thehighestpriorityandtherebytheemployerwouldobtain the greatestimprovementin safetyat
thefacility.
Detailedguidanceonthecontentandapplicationofprocesshazardanalysis nlethodologiesis
availablefrom the AmericanInstituteofChemicalEngineers'CenterforChemicalProcessSafety
(seeappendixD).
5. OperatingProceduresandPractices.
Operatingproceduresdescribetasks tobeperformed,datato berecorded,operatingconditionsto
bemaintained, samplesto becollected, and safetyand healthprecautions to betaken. The
proceduresneedto betechnicallyaccurate, understandableto employees,andrevisedperiodically
to ensurethattheyreflectcurrentoperations. Theprocess safetyinformationpackageis tobeused
as aresourcetobetterassurethattheoperatingprocedures andpracticesare consistentwiththe
knownhazardsofthechemicalsin theprocess and thattheoperatingparametersareaccurate.
Operatingproceduresshouldbe reviewed byengineeringstaffand operatingpersonnelto ensure
thatthey are accurateand providepracticalinstructionsonhow to actuallycarryoutjobduties
safely. Operatingprocedures willincludespecificinstructionsordetails onwhatstepsaretobe
takenorfollowed in carryingoutthestatedprocedures. Theseoperatinginstructionsforeach
procedureshouldincludetheapplicablesafetyprecautionsand shouldcontainappropriate
infornlationon safetyimplications. Forexample, theoperatingproceduresaddressingoperating
parameterswillcontainoperatinginstructionsaboutpressurelimits, temperatureranges,flow
rates, whatto do when an upsetconditionoccurs,whatalarmsand instrumentsarepertinentifan
upsetconditionoccurs, and othersubjects. Anotherexampleofusingoperatinginstructionsto
properlyimplementoperatingproceduresis in startingup orshuttingdown the process. In these
cases,differentparameterswill berequired from those ofnormaloperation. Theseoperating
instructionsneed to clearlyindicatethe distinctionsbetweenstartupandnormaloperationssuchas
theappropriateallowancesfor heatingup aunittoreach the normaloperatingparameters. Alsothe
operatinginstructionsneedto describe the propermethodfor increasingthe temperatureofthe
unituntilthe normaloperatingtemperatureparametersareachieved.
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Computerizedprocesscontrolsystemsaddcomplexityto operatinginstructions.Theseoperating
instructionsneedto describethelogicofthe softwareas well as therelationshipbetween the
equipmentandthecontrolsystem; otherwise,itmaynotbeapparentto theoperator.
Operatingproceduresandinstructionsareimportantfor trainingoperatingpersonnel.The
operatingproceduresareoftenviewedas thestandardoperatingpractices (SOPs)foroperations.
Controlroompersonnelandoperatingstaff,ingeneral, needto haveafull understandingof
operatingprocedures.If workers are notfluent inEnglishthenproceduresandinstructionsneedto
bepreparedinasecondlanguageunderstoodbythe workers. In addition,operatingprocedures
needto bechangedwhenthereis achangein theprocessas aresultofthe managementofchange
procedures.Theconsequencesofoperatingprocedurechangesneedto befullyevaluatedandthe
informationconveyedto thepersonnel. Forexample,mechanicalchangesto theprocessmadeby
the maintenancedepartment(likechangingavalvefrom steel to brassorothersubtlechanges)
need to beevaluatedto determineifoperatingprocedures andpracticesalso need to bechanged.
Allmanagementofchangeactionsn1ustbecoordinatedandintegratedwithcurrentoperating
procedures andoperatingpersonnelmustbeorientedto thechangesinproceduresbeforethe
changeis made. Whentheprocessis shutdowninorderto makeachange, thentheoperating
proceduresmustbeupdatedbeforestartupofthe process.
Trainingin howto handleupsetconditionsmustbeaccomplishedas well as whatoperating
personnelare to do inemergenciessuchas whenapumpsealfails orapipelineruptures.
Conununicationbetweenoperatingpersonnel andworkersperformingworkwithintheprocess
area, suchas nonroutinetasks, alsomustbemaintained. Thehazardsofthetasksare to be
conveyedto operatingpersonnelin accordancewithestablishedproceduresand to those
performingthe actual tasks. Whenthe workis completed,operatingpersonnel shouldbeinformed
to provideclosureonthejob.
6. EmployeeTraining.
Allemployees,includingmaintenanceandcontractoremployees,involvedwithhighlyhazardous
chemicalsneedtofullyunderstandthe safetyand healthhazardsofthechemicalsandprocesses
theyworkwithfortheprotectionofthemselves, theirfellowemployeesandthecitizensofnearby
communities.Trainingconductedin compliancewithSec. 1910.1200,theHazardCommunication
standard, will helpemployeesto bemoreknowledgeableaboutthe chemicalstheywork withas
well as familiarize themwithreadingandunderstandingMSDS.
However, additional trainingin subjectssuchas operatingproceduresand safetyworkpractices,
emergencyevacuationandresponse, safetyprocedures,routineand nonroutineworkauthorization
activities, and otherareaspertinentto processsafetyand healthwill needto becoveredbyan
employer'strainingprogram.
In establishingtheirtrainingprograms,employersmustclearlydefinetheemployeestobetrained
and whatsubjects are to becoveredin theirtraining. Employersinsettingup theirtraining
programwill needtoclearlyestablishthegoals and objectivestheywishto achieve withthe
trainingthattheyprovideto theiremployees.Thelearninggoalsorobjectivesshouldbewrittenin
clearmeasurabletermsbeforethe trainingbegins. Thesegoalsandobjectivesneedto betailored
toeachofthespecifictrainingmodulesorsegments.Employersshoulddescribetheimportant
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actionsandconditionsunderwhichtheemployeewill demonstratecompetenceorknowledgeas
well as whatis acceptableperformance.
Hands-on-trainingwhereemployeesareableto usetheirsensesbeyondlistening, willenhance
learning. Forexample,operatingpersonnel, who will workin acontrolroomoratcontrolpanels,
wouldbenefitbybeingtrainedatasimulatedcontrolpanelorpanels. Upsetconditionsofvarious
typescouldbedisplayedonthesimulator,andthentheemployeecouldgo throughtheproper
operatingprocedurestobringthe simulatorpanel backto thenormaloperatingparanleters. A
trainingenvironmentcouldbecreated to helpthe traineefeel the full realityofthesituationbut,of
course,undercontrolledconditions. Thisrealistic typeoftrainingcanbeveryeffectiveinteaching
employeescorrectprocedures whileallowingthemto also seetheconsequencesofwhatmight
happeniftheydonotfollowestablishedoperatingprocedures. Othertrainingtechniques using
videosoron-the-job trainingcanalsobeveryeffectivefor teachingotherjobtasks, duties,orother
importantinformation. An effectivetrainingprogramwill allow theemployeeto fully participate
in the trainingprocess and to practicetheirskill orknowledge.
Employersneedto periodicallyevaluatetheirtrainingprogramsto seeifthenecessaryskills,
knowledge, and routinesarebeingproperlyunderstoodandimplementedbytheirtrained
employees.Themeansormethodsforevaluatingthetrainingshouldbedeveloped alongwiththe
trainingprogramgoals and objectives. Trainingprogranlevaluation will helpemployersto
determinethe amountoftrainingtheiremployeesunderstood, and whetherthedesiredresults were
obtained. If, aftertheevaluation,itappears thatthe trainedemployeesarenotat the level of
knowledgeandskill thatwasexpected,the employerwill need torevisethe trainingprogram,
provideretraining,orprovidemorefrequentrefreshertrainingsessionsuntil thedeficiencyis
resolved. Thosewhoconductedthe trainingand thosewhoreceivedthe trainingshouldalsobe
consultedas tohowbestto improvethe trainingprocess.If thereis alanguagebarrier,the
languageknown to the trainees shouldbeusedto reinforce the trainingmessagesandinformation.
Careful considerationmustbegivento assure thatemployeesincludingmaintenanceandcontract
employeesreceivecurrentand updated training. Forexample,ifchangesare madetoaprocess,
impactedemployeesmustbe trainedin thechangesandunderstand the effectsofthechangeson
theirjobtasks (e.g., anynew operatingprocedurespertinenttotheirtasks). Additionally,as
alreadydiscussedthe evaluationoftheemployee'sabsorptionoftrainingwillcertainlyinfluence
the needfor training.
7. Contractors.
Employers whousecontractorstoperformworkin and aroundprocessesthatinvolvehighly
hazardouschemicals, will need to establishascreeningprocesssothattheyhireanduse
contractorswhoaccomplishthe desiredjobtaskswithoutcompromisingthe safetyandhealthof
employeesatafacility. Forcontractors, whosesafetyperformanceonthejobis notknownto the
hiringemployer, theemployerwill needtoobtain informationoninjuryandillnessratesand
experienceand shouldobtaincontractorreferences. Additionally, the employernlustassure that
thecontractorhasthe appropriatejobskills,knowledgeandcertifications(suchas forpressure
vessel welders). Contractorworkmethods andexperiencesshouldbeevaluated. Forexample,does
thecontractorconductingdemolitionworkswingloadsoveroperatingprocessesordoes the
contractoravoidsuch hazards?
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Maintainingasite injuryandillnesslogforcontractorsis anothermethoden1ployers mustuseto
trackandmaintaincurrentknowledgeofworkactivitiesinvolvingcontractemployeesworkingon
oradjacenttocoveredprocesses. Injuryandillnesslogsofboththeemployer'semployeesand
contractemployeesallowan employerto havefull knowledgeofprocessinjuryandillness
experience. Thislog will alsocontaininformation whichwillbeofuse to thoseauditingprocess
safetymanagementcomplianceand thoseinvolvedinincidentinvestigations.
Contractemployeesmustperformtheirworksafely. Consideringthatcontractorsoftenperform
veryspecializedandpotentiallyhazardoustasks suchas confinedspaceentryactivitiesand
nonroutinerepairactivitiesitisquiteimportantthattheiractivitiesbecontrolledwhilethey are
workingon ornearacoveredprocess. Apermitsystemorworkauthorizationsystemforthese
activities wouldalsobehelpfulto all affectedemployers. Theuseofa work authorization systen1
keepsan employerinformedofcontractemployeeactivities,and as abenefittheemployerwill
havebettercoordinationandmoremanagementcontrolovertheworkbeingperformedin the
processarea. Awellrun andwell maintainedprocesswhereenlployeesafetyis fullyrecognized
willbenefitall ofthose whoworkinthefacility whethertheybecontractemployeesoremployees
oftheowner.
8. Pre-StartupSafety.
Fornewprocesses,theemployerwill find aPHAhelpfulin improvingthedesign andconstruction
oftheprocessfrom areliabilityandqualitypointofview. Thesafeoperationofthe newprocess
willbeenhancedbymakinguseofthePHArecommendationsbeforefinal installationsare
completed.P&IDsare tobecompletedalongwith havingtheoperatingproceduresin placeand
theoperatingstafftrained torun theprocessbeforestartup.Theinitialstartupproceduresand
normaloperatingproceduresneedto befullyevaluatedas partofthepre-startupreviewto assurea
safetransferintothe normaloperatingmodefor meetingtheprocessparameters.
Forexistingprocessesthathavebeenshutdownfor turnaround,ormodification,etc., theemployer
mustassurethatanychangesotherthan "replacementin kind" madeto theprocessduring
shutdowngothroughthe managementofchangeprocedures. P&IDswill needtobeupdatedas
necessary, as well as operatingproceduresandinstructions. If thechangesmade to theprocess
duringshutdownare significantand impactthe trainingprogram,then operatingpersonnel as well
asemployeesengagedin routineand nonroutineworkintheprocess areamayneedsomerefresher
oradditionaltraininginlightofthechanges. Anyincidentinvestigationrecommendations,
con1pliance audits orPHArecommendationsneed to bereviewedas well to seewhatimpactsthey
n1ay haveontheprocessbeforebeginningthe startup.
9. MechanicalIntegrity.
Employers will needtoreviewtheirmaintenanceprogramsand schedulesto seeifthere areareas
where"breakdown"maintenanceis usedratherthan an on-goingmechanicalintegrityprogram.
Equipn1entused to process,store,orhandlehighlyhazardouschemicalsneedstobedesigned,
constructed,installedand maintainedto minimizethe riskofreleasesofsuchchemicals. This
requires thatamechanicalintegrityprogrambein placeto assurethecontinuedintegrityof
processequipment. Elementsofamechanical integrityprogramincludetheidentificationand
categorizationofequipmentand instrumentation,inspections and tests, testingand inspection
frequencies, developmentofmaintenanceprocedures, trainingofmaintenancepersonnel, the
establishmentofcriteriafor acceptabletestresults, documentationoftestand inspectionresults,
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and documentation of manufacturer recommendations as to meantime to failure for equipment and
instrumentation.
The first line of defense an employer has available is to operate and maintain the process as
designed, and to keep the chemicals contained. This line of defense is backed up by the next line
of defense which is the controlled release of chemicals through venting to scrubbers or flares, or to
surge or overflow tanks which are designed to receive such chemicals, etc. These lines of defense
are the primary lines of defense or means to prevent unwanted releases. The secondary lines of
defense would include fixed fire protection systems like sprinklers, water spray, or deluge
systems, monitor guns, etc., dikes, designed drainage systems, and other systems which would
control or mitigate hazardous chemicals once an unwanted release occurs. These primary and
secondary lines of defense are what the mechanical integrity program needs to protect and
strengthen these primary and secondary lines of defenses where appropriate.
The first step of an effective mechanical integrity program is to compile and categorize a list of
process equipment and instrumentation for inclusion in the program. This list would include
pressure vessels, storage tanks, process piping, relief and vent systems, fire protection system
components, emergency shutdown systems and alarms and interlocks and pumps. For the
categorization of instrumentation and the listed equipment the employer would prioritize which
pieces of equipment require closer scrutiny than others. Meantime to failure of various
instrumentation and equipment parts would be known from the manufacturer's data or the
employer's experience with the parts, which would then influence the inspection and testing
frequency and associated procedures. Also, applicable codes and standards such as the National
Board Inspection Code, or those from the American Society for Testing and Material, An1erican
Petroleum Institute, National Fire Protection Association, American National Standards Institute,
American Society of Mechanical Engineers, and other groups, provide information to help
establish an effective testing-and inspection frequency, as well as appropriate methodologies.
The applicable codes and standards provide criteria for external inspections for such items as
foundation and supports, anchor bolts, concrete or steel supports, guy wires, nozzles and
sprinklers, pipe hangers, grounding connections, protective coatings and insulation, and external
metal surfaces of piping and vessels, etc. These codes and standards also provide information on
methodologies for internal inspection, and a frequency formula based on the corrosion rate of the
materials of construction. Also, erosion both internal and external needs to be considered along
with corrosion effects for piping and valves. Where the corrosion rate is not known, a maxin1um
inspection frequency is recommended, and methods of developing the corrosion rate are available
in the codes. Internal inspections need to cover items such as vessel shell, bottom and head;
metallic linings; nonmetallic linings; thickness measurements for vessels and piping; inspection
for erosion, corrosion, cracking and bulges; internal equipment like trays, baffles, sensors and
screens for erosion, corrosion or cracking and other deficiencies. Some of these inspections may
be performed by state of local government inspectors under state and local statutes. However, each
employer needs to develop procedures to ensure that tests and inspections are conducted properly
and that consistency is maintained even where different employees may be involved. Appropriate
training is to be provided to maintenance personnel to ensure that they understand the preventive
maintenance program procedures, safe practices, and the proper use amd application of special
equipment or unique tools that may be required. This training is part of the overall training
program called for in the standard.
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Aqualitya surancesy't.em isneeded to helpensurethatthepropern1aterialsofconstruction are
used,thatfabricationand inspectionprocedure areproper,andthat in lallation procedures
recognizefieldinstallationconcern .Thequalityassuranceprogramisane senti alpartofthe
mechanical integrityprogramandwill helpto maintai ntheprimaryand secondaryline ofdefense
thathavebeendesignedintotheproce stopreventunwantedchemicalrelea es or tho e which
contra] orrnitigate arelea e. As built" drawings togetherwith certi fication ofcoded vessels and
otherequipment,andmaterialsofconstructionneed tobe veri fied and retainedin the quali ty
as urance docUJnentati on. Equipment in tallati onj obs need to beproperl yinspected in thefield
for useofpropern1ateri a] andprocedures and to assurethatqualifiedcraft men areu ed todo the
job.The useofappropri ate gaskets,packing, bolts, valves lubricants and welcling rodsneed to be
verifiedin the field. Al 0 proceduresforinst.allati onofsafety devices need to be veri fied,suchas
the torqueonthe bolts onruptureddi scin ta11a1'ions, uniformtorqueonfl angebolts, proper
installationofplunpseals, etc. If the qualityofpartsisa problem, it may be appropriateto conduct
audjtsoftheequipment upplier' facilitjestobettera sureproperpurchases ofrequired
equipmentwhi chi ui tableforits intended service.Anychange in equipmentthatnl aybecolne
nece ary will need togothroughthe management ofchangeprocedure .
10. NonroutineWorkAuthorizations.
Nonroutineworkwhichis conductedinprocessareas needs to becontrolledbythe
employerin aconsistentmanner.Thehazardsidentifiedinvolvingthe workthatis to be
accomplishedmustbecommunicatedto thosedoingthe work,butalso to thoseoperating
personnelwhoseworkcouldaffectthe safetyofthe process. A workauthorizationnoticeorperu1it
nlusthaveaprocedurethatdescribes thestepsthe maintenancesupervisor,contractor
representativeorotherpersonneeds to follow to obtainthe necessaryclearanceto getthejob
started.Theworkauthorizationproceduresneedtoreferenceandcoordinate,as applicable,
lockout/tagoutprocedures,linebreakingprocedures,confinedspaceentryprocedures and hot
workauthorizations. Thisprocedurealsoneeds to provideclearstepsto followoncethejobis
conlpletedin ordertoprovideclosurefor thosethatneed toknowthejobis nowcompletedand
equipmentcanbereturnedtonormal.
11. ManagingChange.
To properlymanagechangesto processchemicals,technology, equipmentandfacilities, onemust
define whatis n1eantbychange. In this processsafetymanagementstandard,changeincludesall
nl0dificationstoequipment,procedures,rawmaterialsandprocessingconditionsotherthan
"replacementinkind". Thesechanges needto be properlymanagedbyidentifyingandreviewing
thempriortoimplementationofthechange.Forexample,theoperatingprocedurescontainthe
operatingparameters (pressurelimits, temperatureranges, flow rates,etc.) andthe importanceof
operatingwithin theselin1its. Whilethe operatormusthave theflexibilityto maintainsafe
operationwithin theestablishedparameters,anyoperationoutsideoftheseparametersrequires
reviewandapproval bya writtenmanagementofchangeprocedure.
Managementofchangecoverssuchas changesin process technologyandchangestoequipment
andinstrumentation. Changesinprocess technologycanresultfromchangesinproductionrates,
raw materials,experimentation,equjpmentunavailability, newequipn1ent, new product
development,changeincatalystandchangesinoperatingconditionstoin1prove yieldorquality.
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Equipment changes include among others change in materials of construction, equipment
specifications, piping pre-arrangements, experimental equipment, computer program revisions and
changes in alarms and interlocks. Employers need to establish means and n1ethods to detect both
technical changes and mechanical changes. Temporary changes have caused a number of
catastrophes over the years, and employers need to establish ways to detect temporary changes as
well as those that are permanent. Itis important that a time limit for temporary changes be
established and monitored since, without control, these changes may tend to become permanent.
Temporary changes are subject to the management of change provisions. In addition, the
management of change procedures are used to insure that the equipment and procedures are
returned to their original or designed conditions at the end of the temporary change. Proper
documentation and review of these changes is invaluable in assuring that the safety and health
considerations are being incorporated into the operating procedures and the process.
Employers may wish to develop a form or clearance sheet to facilitate the processing of changes
through the management of change procedures. A typical change form may include a description
and the purpose of the change, the technical basis for the change, safety and health considerations,
documentation of changes for the operating procedures, maintenance procedures, inspection and
testing, P&IDs, electrical classification, training and communications, pre-startup inspection,
duration if a temporary change, approvals and authorization.
Where the impact of the change is minor and well understood, a check list reviewed by an
authorized person with proper communication to others who are affected may be sufficient.
However, for a more complex or significant design change, a hazard evaluation procedure with
approvals by operations, maintenance, and safety departments may be appropriate. Changes in
documents such as P&IDs, raw materials, operating procedures, mechanical integrity programs,
electrical classifications, etc., need to be noted so that these revisions can be made permanent
when the drawings and procedure manuals are updated.
Copies of process changes need to be kept in an accessible location to ensure that design changes
are available to operating personnel as well as to PHA team members when a PHA is being done
or one is being updated.
12. Investigation of Incidents.
Incident investigation is the process of identifying the underlying causes of incidents and
implementing steps to prevent similar events from occurring. The intent of an incident
investigation is for employers to learn from past experiences and thus avoid repeating
pastmistakes. The incidents for whicn OSHA expects employers to becon1e aware and to
investigate are the types of events which result in or could reasonably have resulted in a
catastrophic release. Some of the events are sometimes referred to as "near misses," meaning that
a serious consequence did not occur, but could have.
Employers need to develop in-house capability to investigate incidents that occur in their facilities.
A team needs to be assembled by the employer and trained in the techniques of investigation
including how to conduct interviews of witnesses, needed documentation and report writing. A
multi-disciplinary team is better able to gather the facts of the event and to analyze them and
develop plausible scenarios as to what happened, and why. Team men1bers should be selected on
the basis of their training, knowledge and ability to contribute to a team effort to fully investigate
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the incident. Employeesin the processareawherethe incidentoccurredshouldbeconsulted,
interviewedormadeamemberoftheteam. Theirknowledgeoftheeventsform asignificantset
offacts abouttheincidentwhichoccurred. Thereport,its findings andrecommendationsare to be
sharedwiththosewhocanbenefitfrom theinformation.Thecooperationofemployeesisessential
to aneffectiveincidentinvestigation.Thefocus oftheinvestigationshouldbe to obtainfacts, and
notto placeblame.Theteamand theinvestigationprocessshouldclearlydealwithall involved
individualsin afair, openandconsistentmanner.
13. EmergencyPreparedness.
Eachemployermustaddress whatactionsemployeesare to takewhen thereis an unwanted
releaseofhighlyhazardouschemicals.Emergencypreparednessortheemployer'stertiary(third)
linesofdefensearethosethatwill bereliedonalongwith thesecondarylinesofdefensewhen the
primarylinesofdefensewhichare usedto preventan unwantedreleasefail to stoptherelease.
Employerswill needto decideiftheywantemployees to handle and stopsmallorminor
incidentalreleases. Whethertheywishto mobilizetheavailableresourcesattheplantandhave
thembroughtto bearonamoresignificantrelease. Orwhetheremployerswanttheiremployeesto
evacuatethedangerareaandpromptlyescapeto apreplannedsafezonearea, and allow thelocal
communityemergencyresponseorganizationsto handletherelease. Orwhetherthe employer
wants to use somecombinationofthese actions. Employerswillneedto selecthowmanydifferent
emergencypreparednessortertiarylinesofdefensetheyplanto haveandthendevelopthe
necessaryplans andprocedures, and appropriatelytrainemployeesin theiremergencydutiesand
responsibilitiesandthenimplementtheselinesofdefense.
Employersataminimummusthaveanemergencyaction planwhichwill facilitate theprompt
evacuationofemployeesdueto an unwantedreleaseofahighlyhazardouschemical.Thismeans
thatthe employerwill haveaplanthatwill beactivatedbyan alarmsystemto ale11 employees
whento evacuateand, thatemployeeswho arephysicallyimpaired,will have the necessary
supportand assistance to getthemto the safezoneas well. Theintentoftheserequirementsis to
alertand moveemployeesto asafezonequickly. Delayingalarmsorconfusingalarmsare to be
avoided. Theuseofprocesscontrolcentersorsimilarprocessbuildingsin theprocess areaas safe
areasis discouraged. Recentcatastropheshaveshown thatalargelifelosshasoccurredin these
structuresbecauseofwheretheyhavebeensitedandbecausetheyare notnecessarilydesignedto
withstandover-pressuresfrom shockwavesresultingfromexplosionsin theprocessarea.
Unwantedincidentalreleasesofhighlyhazardouschemicalsin theprocessareamustbeaddressed
bytheemployeras to whatactionsemployees are to take. If the employerwantsemployeesto
evacuatethe area, then theemergencyactionplan will beactivated. Foroutdoorprocesses where
winddirectionis importantfor selectingthesaferoute to arefugearea, theemployershouldplace
awind directionindicatorsuchas a windsockorpennantat thehighestpointthatcanbeseen
throughouttheprocess area. Employeescan movein thedirectionofcross windtoupwindto gain
safeaccess to the refugeareabyknowingthe winddirection.
If theemployerwants specificemployeesin thereleaseareato controlorstopthe minor
emergencyorincidentalrelease, these actions mustbeplannedforinadvanceandprocedures
developedandin1plemented. Preplanningfor handlingincidentalreleases forminoremergencies
in the processareaneeds tobedone, appropriateequipmentfor thehazardsmustbeprovided,and
trainingconductedfor thoseemployeeswhowill performtheemergencyworkbeforethey
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respond to handle an actual release. The employer's training program, including the Hazard
Communication standard training is to address the training needs for employees who are expected
to handle incidental or minor releases. Preplanning for releases that are more serious than
incidental releases is another important line of defense to be used by the employer. When a serious
release of a highly hazardous chemical occurs, the employer through preplanning will have
determined in advance what actions employees are to take. The evacuation of the immediate
release area and other areas as necessary would be accomplished under the en1ergency action plan.
Ifthe employer wishes to use plant personnel such as a fire brigade, spill control team, a
hazardous materials team, or use employees to render aid to those in the immediate release area
and control or mitigate the incident, these actions are covered by Sec. 1910.120,the Hazardous
Waste Operations and Emergency Response (HAZWOPER) standard. Ifoutside assistance is
necessary, such as through mutual aid agreements between employers or local government
emergency response organizations, these emergency responders are also covered by HAZWOPER.
The safety and health protections required for en1ergency responders are the responsibility of their
employers and of the on-scene incident commander.
Responders may be_ working under very hazardous conditions and therefore the objective is to
have them competently led by an on-scene incident commander and the commander's staff,
properly equipped to do their assigned work safely, and fully trained to carry out their duties
safely before they respond to an emergency. Drills, training exercises, or simulations with the
local community emergency response planners and responder organizations is one means to obtain
better preparedness. This close cooperation and coordination between plant and local community
emergency preparedness managers will also aid the employer in complying with the
Environmental Protection Agency's Risk Management Plan criteria.
One effective way for medium to large facilities to enhance coordination and communication
during emergencies for on plant operations and with local community organizations is for
employers to establish and equip an emergency control center. The emergency control center
would be sited in a safe zone area so that it could be occupied throughout the duration of an
emergency. The center would serve as the major comn1unication link between the on-scene
incident commander and plant or corporate management as well as with the local community
officials. The communication equipment in the emergency control center should include a network
to receive and transmit information by telephone, radio or other means. It is important to have a
backup communication network in case of power failure or one communication means fails. The
center should also be equipped with the plant layout and community maps, utility drawings
including fire water, emergency lighting, appropriate reference materials such as a government
agency notification list, company personnel phone list, SARA Title III reports and material safety
data sheets, emergency plans and procedures manual, a listing with the location of emergency
response equipment, mutual aid information, and access to meteorological or weather condition
data and any dispersion modeling data.
14. Compliance Audits.
Employers need to select a trained individual or assemble a trained team of people to audit the
process safety management system and program. A small process or plant may need only one
knowledgeable person to conduct an audit. The audit is to include an evaluation of the design and
effectiveness of the process safety management system and a field inspection of the safety and
health conditions and practices to verify that the employer's systems are effectively implemented.
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The audit should be conducted or lead by a person knowledgeable in audit techniques and who is
impartial towards the facility or area being audited. The essential elements of an audit program
include planning, staffing, conduting the audit, evaluation and corrective action, follow-up and
documentation.
Planning in advance is essential to the success of the auditing process. Each employer needs to
establish the format, staffing, scheduling and verification methods prior to conducting the audit.
The format should be designed to provide the lead auditor with a procedure or checklist which
details the requirements of each section of the standard. The names of the audit team members
should be listed as part of the format as well. The checklist, if properly designed, could serve as
the verification sheet which provides the auditor with the necessary infornlation to expedite the
review and assure that no requirements of the standard are omitted. This verification sheet format
could also identify those elements that will require evaluation or a response to correct deficiencies.
This sheet could also be used for developing the follow-up and documentation requirements.
The selection of effective audit team members is critical to the success of the program. Teanl
members should be chosen for their experience, knowledge, and training and should be familiar
with the processes and with auditing techniques, practices and procedures. The size of the team
will vary depending on the size and complexity of the process under consideration. For a large,
complex, highly instrumented plant, it may be desirable to have team members with expertise in
process engineering and design, process chemistry, instrumentation and computer controls,
electrical hazards and classifications, safety and health disciplines, maintenance, enlergency
preparedness, warehousing or shipping, and process safety auditing. The team may use part-time
members to provide for the depth of expertise required as well as for what is actually done or
followed, conlpared to what is written. An effective audit includes a review of the relevant
documentation and process safety information, inspection of the physical facilities, and interviews
with all levels of plant personnel. Utilizing the audit procedure and checklist developed in the
preplanning stage, the audit team can systematically analyze compliance with the provisions of the
standard and any other corporate policies that are relevant. For example, the audit team will
review all aspects of the training program as part of the overall audit. The team will review the
written training program for adequacy of content, frequency of training, effectiveness of training
in terms of its goals and objectives as well as to how it fits into meeting the standard's
requirements, documentation, etc. Through interviews, the team can determine the employee's
knowledge and awareness of the safety procedures, duties, rules, emergency response
assignments, etc. During the inspection, the team can observe actual practices such as safety and
health policies, procedures, and work authorization practices. This approach enables the team to
identify deficiencies and determine where corrective actions or improvements are necessary.
An audit is a technique used to gather sufficient facts and information, including statistical
information, to verify compliance with standards. Auditors should select as part of their
preplanning a sample size sufficient to give a degree of confidence that the audit reflects the level
of cOlllpliance with the standard. The audit team, through this systematic analysis, should
document areas which require corrective action as well as those areas where the process safety
management systelll is effective and working in an effective manner. This provides a record of the
audit procedures and findings, and serves as a baseline of operation data for future audits. It will
assist future auditors in determining changes or trends from previous audits.
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Corrective action is one of the most important parts of the audit. It includes not only addressing
the identified deficiencies, but also planning, followup, and documentation. The corrective action
process normally begins with a management review of the audit findings. The purpose of this
review is to determine what actions are appropriate, and to establish priorities, timetables, resource
allocations and requirements and responsibilities. In some cases, corrective action may involve a
simple change in procedure or minor maintenance effort to remedy the concern. Management of
change procedures need to be used, as appropriate, even for what may seem to be a minor change.
Many of the deficiencies can be acted on promptly, while some may require engineering studies or
indepth review of actual procedures and practices. There may be instances where no action is
necessary and this is a valid response to an audit finding. All actions taken, including an
explanation where no action is taken on a finding, needs to be documented as to what was done
and why.
It is important to assure that each deficiency identified is addressed, the corrective action to be
taken noted, and the audit person or team responsible be properly documented by the employer.
To control the corrective action process, the employer should consider the use of a tracking
system. This tracking system might include periodic status reports shared with affected levels of
management, specific reports such as completion of an engineering study, and a final
implementation report to provide closure for audit findings that have been through management of
change, if appropriate, and then shared with affected employees and managenlent. This type of
tracking system provides the employer with the status of the corrective action. It also provides the
documentation required to verify that appropriate corrective actions were taken on deficiencies
identified in the audit.
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AppendixDto Sec. 1910.119- SourcesofFurtherInformation
(Nonmandatory)
1. CenterforChemicalProcessSafety, AmericanInstituteofChemicalEngineers, 345East47thStreet,
New York, NY 10017,(212)705-7319.
2. "GuidelinesforHazardEvaluationProcedures,"AmericanInstituteofChemicalEngineers; 345East
47thStreet,New York, NY 10017.
3. "GuidelinesforTechnicalManagementofChemicalProcessSafety,"CenterforChemicalProcess
Safetyofthe American InstituteofChemicalEngineers; 345 East47thStreet,New York, NY 10017.
4. "EvaluatingProcessSafetyin theChemicalIndustry,"ChemicalManufacturersAssociation; 2501 M
StreetNW, Washington,DC 20037.
5. "SafeWarehousingofChemicals,"Chen1icalManufacturersAssociation; 2501 MStreetNW,
Washington,DC 20037.
6. "ManagementofProcessHazards,"AmericanPetroleumInstitute(APIRecommendedPractice750);
1220LStreet,N.W.,Washington,D.C. 20005.
7. "ImprovingOwnerand ContractorSafetyPerformance,"AmericanPetroleumInstitute(API
RecommendedPractice2220); API, 1220LStreetN.W.,Washington,D.C. 20005.
8. Chen1icalManufacturers Association(CMA'sManagerGuide),FirstEdition,Septelnber 1991;CMA,
2501 MStreet,N.W.,Washington,D.C. 20037.
9. "ImprovingConstructionSafetyPerformance,"ReportA-3,TheBusinessRoundtable;TheBusiness
Roundtable,200ParkAvenue,New York, NY10166. (Reportincludescriteriatoevaluatecontractor
safetyperformanceandcriteriatoenhancecontractorsafetyperformance).
10. "Recon1mendedGuidelinesfor ContractorSafetyand Health,"TexasChemicalCouncil;Texas
ChemicalCouncil, 1402NuecesStreet, Austin,TX78701-1534.
11. "LossPreventioninthe ProcessIndustries,"Volumes IandII; FrankP. Lees,Butterworth;London
1983.
12. "Safetyand HealthProgramManagementGuidelines," 1989; U.S. DepartmentofLabor,
OccupationalSafetyandHealthAdministration.
13. "Safetyand HealthGuidefor theChen1ical Industry," 1986,(OSHA3091); U.S. Departmentof
Labor, OccupationalSafetyandHealthAdministration; 200ConstitutionAvenue,N.W.,Washington,
D.C. 20210.
14. "ReviewofEmergencySystems,"June 1988;U.S. EnvironmentalProtectionAgency(EPA), Office
ofSolidWasteandEmergencyResponse,Washington,DC 20460.
15. "TechnicalGuidancefor HazardsAnalysis,EmergencyPlanningforExtremelyHazardous
Substances,"December 1987; U.S. EnvironmentalProtectionAgency(EPA),FederalEmergency
ManagementAdministration(FEMA) and U.S. DepartmentofTransportation(DOT), Washington,
DC 20460.
16. "AccidentInvestigation * * * ANew Approach," 1983,NationalSafetyCouncil;444NorthMichigan
Avenue, Chicago, IL60611-3991.
17. "Fire& ExplosionIndex HazardClassificationGuide,"6thEdition,May 1987,DowChemical
Company;Midland,Michigan48674.
18. "ChemicalExposureIndex,"May 1988,DowChemicalCompany;Midland,Michigan48674.
Page 43 of 132
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APPENDIX 2
EPA RULE 40, CFR 68, CHEMICAL ACCIDENT PREVENTION PROVISIONS
. (Relevant sections highlighted)
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+Title 40--Protection of Environment
CHAPTER I--ENVIRONMENTAL PROTECTION AGENCY
PART 68--CHEMICAL ACCIDENT PREVENTION PROVISIONS
68.1
Scope.

68.2
Stayed provisions.

ta 68.3
Definitions.

t8 68.10
Applicability.

ra 68.12
General requirements .

L@
rJ;l 68.15
Management.
68.20
Applicability.

m
68.22
Offsite consequence analysis parameters.

68.25
Worst-case release scenario analysis.

68.28
Alternative release scenario analysis.

68.30
Defining offsite impacts--population.

'fa 68.33
Defining offsite impacts--environment.

iJ8 68.36
Review and update.

m68.39
Documentation.

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mJ 68.42
Five-year accident history.

m
Safety information.
68.48

Hazard review.
68.50

68.52
Operating procedures.

68.54
Training.

68.56
Maintenance.

fa 68.58
Compliance audits.

ta 68.60
Incident investigation.

ra 68.65
Process safety information.

68.67
Process hazard analysis.

m68.69
Operating procedures.

68.71
Training.

m1
68
.
73 Mechanical integrity.

68.75
Management of change.

ta 68.77
Pre-startup review.

il8 68.79
Compliance audits.

ta 68.81
I ncident investigation.

ta 68.83
Employee participation.

fa 68.85
Hot work permit.

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!I 68.87 Contractors.
68.90 Applicability.
68.95 Emergencyresponse program.
m68.100 Purpose.
68.115 Thresholddetermination.
68.120 Petitionprocess.
m68.125 Exemptions.
tg 68.126 Exclusion.
68.130 Listofsubstances. m
68.150 Submission. m
68.151 Assertionofclaimsofconfidential business information. m
68.152 Substantiatingclaims ofconfidential business information.
68.155 Executivesummary.
68.160 Registration.
68.165 Offsiteconsequenceanalysis.
68.168 Five-yearaccidenthistory.
m68.170 Prevention program/Program2.
tl;] 68.175 Prevention program/Program3.
68.180 Emergencyresponse program.
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la 68.185 Certification.
68.190 Updates.
68.200 Recordkeeping.
68.210 Availability of information to the public.
m68.215 Permit content and air permitting authority or designated agency requirements.
68.220 Audits.
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TITLE40- PROTECTIONOFENVIRONMENT
CHAPTERI- ENVIRONMENTALPROTECTIONAGENCY(CONTINUED)
PART68 - CHEMICALACCIDENTPREVENTIONPROVISIONS--TableofContents
Subpart A - General
Sec. 68.1 Scope.
Thispartsetsforth thelistofregulatedsubstancesand thresholds,thepetitionprocessfor addingor
deletingsubstancesto thelistofregulatedsubstances,therequirementsfor ownersoroperatorsof
stationarysourcesconcerningthepreventionofaccidentalreleases,andtheStateaccidentalrelease
preventionprogramsapprovedundersection 112(r).Thelistofsubstances,thresholdquantities,and
accidentpreventionregulationspromulgatedunderthispartdo notlimitinanywaythegeneralduty
provisionsundersection 112(r)(1).
Sec. 68.2 Stayedprovisions.
(a) Notwithstandinganyotherprovisionofthis part, theeffectivenessofthefollowingprovisionsis
stayedfrom March2, 1994to December22, 1997.
(1) In Sec. 68.3, thedefinitionof" stationarysource," to theextentthatsuchdefinitionincludes
naturallyoccurringhydrocarbonreservoirsortransportationsubjectto oversightorregulation
underastatenatural gas orhazardousliquidprogramfor whichthestatehasin effecta
certificationtoDOTunder49U.S.C. 60105;
(2) Section68.115(b)(2) ofthis part,to theextentthatsuchprovisionrequires an owneror
operatorto treatas aregulatedflammablesubstance:
(i) Gasoline,whenin distributionorrelatedstorageforuseas fuel for internalcombustion
engInes;
(ii) Naturallyoccurringhydrocarbon mixturespriorto entryintoapetroleumrefining
processunitoranatural gasprocessingplant. Naturallyoccurringhydrocarbon
mixturesincludeanyofthefollowing: condensate,crudeoil, field gas, and produced
water,each as definedin paragraph(b) ofthis section;
(iii) Othermixturesthatcontainaregulatedflammable substanceand thatdo nothavea
NationalFireProtection Associationflammabilityhazardratingof4, thedefinitionof
whichis in theNFPA704,StandardSystemfor the IdentificationoftheFireHazards
ofMaterials,NationalFireProtectionAssociation, Quincy,MA, 1990,availablefrom
theNationalFireProtection Association, 1BatterymarchPark,Quincy,MA02269-
9101;and
(3) Section68.130(a).
(b) FromMarch2, 1994to December22, 1997,thefollowing definitions shall applyto thestayed
provisionsdescribedin paragraph(a) ofthis section:
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Condensatemeans hydrocarbonliquidseparatedfrom naturalgas thatcondensesbecauseof
changesintemperature, pressure,orboth,andremainsliquidatstandardconditions.
Crudeoilmeansanynaturallyoccurring,unrefinedpetroleumliquid.
Fieldgasmeansgasextractedfromaproduction wellbeforethe gasentersanaturalgas
processingplant.
Natural gasprocessingplantmeans anyprocessingsiteengagedin theextractionofnaturalgas
liquidsfromfield gas, fractionation ofnatural gasliquidsto naturalgasproducts,orboth. A
separator,dehydrationunit, heatertreater, sweeteningunit,compressor,orsimilarequipmentshall
notbeconsidereda"processingsite"unlesssuchequipmentisphysicallylocatedwithin anatural
gas processingplant(gasplant) site.
Petroleumrefiningprocessunitmeansaprocessunitusedin an establishmentprin1arilyengaged
inpetroleumrefiningas definedin theStandardIndustrialClassificationcodeforpetroleum
refining(2911) andusedforthefollowing: Producingtransportationfuels (suchas gasoline,diesel
fuels, andjetfuels), heatingfuels (suchas kerosene,fuel gasdistillate,and fuel oils),orlubricants;
separatingpetroleum;orseparating,cracking,reacting,orreformingintermediatepetroleum
streams. Examplesofsuchunitsinclude,butare notlimitedto, petroleumbasedsolventunits,
alkylation units, catalytic hydrotreating,catalytichydrorefining,catalytichydrocracking,catalytic
reforming,catalyticcracking,crudedistillation,lubeoil processing, hydrogenproduction,
isomerization,polymerization,thermalprocesses,andblending,sweetening,andtreating
processes. Petroleumrefiningprocessunitsincludesulfurplants.
Producedwatermeanswaterextractedfrom theearthfrom an oilornaturalgas productionwell,
orthatis separatedfrom oilornatural gas afterextraction.
(c) Notwithstandinganyotherprovisionofthis part, theeffectivenessofpart68 is stayedfrom June21,
1999 to December21, 1999 withrespecttoregulatedflammable hydrocarbonsubstanceswhenthe
substanceis intendedfor use as afuel anddoes notexceed67,000 poundsin aprocessthatis not
manufacturingthe fuel, doesnotcontaingreaterthan athresholdquantityofanotherregulated
substance, andis notcollocatedorinterconnectedto anothercoveredprocess.
Sec. 68.3 Definitions.
Forthepurposesofthispart:
Accidental releasemeans an unanticipatedemissionofaregulatedsubstanceorotherextremely
hazardoussubstanceinto theambientairfrom astationarysource.
Actmeans the Clean AirActas amended(42 U.S.C. 7401 etseq.)
Administrativecontrolsmeanwrittenproceduralmechanismsusedfor hazardcontrol.
Adnlinistratormeans theadministratoroftheU.S. EnvironmentalProtection Agency.
AIChE/CCPS meanstheAmericanInstituteofChemicalEngineers/Centerfor ChemicalProcessSafety.
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API n1eans the American Petroleum Institute.
Article means a manufactured item, as defined under 29 CFR 1910.1200(b), that is formed to a specific
shape or design during manufacture, that has end use functions dependent in whole or in part upon the
shape or design during end use, and that does not release or otherwise result in exposure to a regulated
substance under normal conditions of processing and use.
ASME means the American Society of Mechanical Engineers.
CAS means the Chemical Abstracts Service.
Catastrophic release means a major uncontrolled emission, fire, or explosion, involving one or more
regulated substances that presents imminent and substantial endangern1ent to public health and the
en vironmen t.
Classified information means "classified information" as defined in the Classified Information Procedures
Act, 18 U.S.C. App. 3, section l(a) as "any information or material that has been determined by the
United States Government pursuant to an executive order, statute, or regulation, to require protection
against unauthorized disclosure for reasons of national security."
Condensate means hydrocarbon liquid separated from natural gas that condenses due to changes in
temperature, pressure, or both, and remains liquid at standard conditions.
Covered process means a process that has a regulated substance present in more than a threshold quantity
as determined under Sec. 68.115.
Crude oil means any naturally occurring, unrefined petroleum liquid.
Designated agency means the state, local, or Federal agency designated by the state under the provisions
of Sec. 68.215(d).
DOT means the United States Department of Transportation.
Environmental receptor means natural areas such as national or state parks, forests, or monuments;
officially designated wildlife sanctuaries, preserves, refuges, or areas; and Federal wilderness areas, that
could be exposed at any time to toxic concentrations, radiant heat, or overpressure greater than or equal to
the endpoints provided in Sec. 68.22(a) , as a result of an accidental release and that can be identified on
local U. S. Geological Survey maps.
Field gas means gas extracted from a production well before the gas enters a natural gas processing plant.
Hot work means work involving electric or gas welding, cutting, brazing, or similar flame or spark-
producing operations.
Implementing agency means the state or local agency that obtains delegation for an accidental release
prevention program under subpart E, 40 CFR part 63. The implen1enting agency may, but is not required
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to, be the state or local air permitting agency. If no state or local agency is granted delegation, EPA will
be the implementing agency for that state.
Injury means any effect on a human that results either from direct exposure to toxic concentrations;
radiant heat; or overpressures from accidental releases or from the direct consequences of a vapor cloud
explosion (such as flying glass, debris, and other projectiles) from an accidental release and that requires
medical treatment or hospitalization.
Major change means introduction of a new process, process equipment, or regulated substance, an
alteration of process chemistry that results in any change to safe operating limits, or other alteration that
introduces a new hazard.
Mechanical integrity means the process of ensuring that process equipment is fabricated from the proper
materials of construction and is properly installed, maintained, and replaced to prevent failures and
accidental releases.
Medical treatment means treatment, other than first aid, administered by a physician or registered
professional personnel under standing orders from a physician.
Mitigation or mitigation system means specific activities, technologies, or equipment designed or
deployed to capture or control substances upon loss of containment to minimize exposure of the public or
the environment. Passive mitigation means equipment, devices, or technologies that function without
human, mechanical, or other energy input. Active mitigation means equipment, devices, or technologies
that need human, mechanical, or other energy input to function.
NAICS means North American Industry Classification System.
NFPA means the National Fire Protection Association.
Natural gas processing plant (gas plant) means any processing site engaged in the extraction of natural gas
liquids from field gas, fractionation of mixed natural gas liquids to natural gas products, or both, classified
as North American Industrial Classification System (NAICS) code 211112 (previously Standard
Industrial Classification (SIC) code 1321).
Offsite means areas beyond the property boundary of the stationary source, and areas within the property
boundary to which the public has routine and unrestricted access during or outside business hours.
OSHA means the U.S. Occupational Safety and Health Administration.
Owner or operator means any person who owns, leases, operates, controls, or supervises a stationary
source.
Petroleum refining process unit means a process unit used in an establishment primarily engaged in
petroleum refining as defined in NAICS code 32411 for petroleum refining (formerly SIC code 2911) and
used for the fOllowing: Producing transportation fuels (such as gasoline, diesel fuels, and jet fuels),
heating fuels (such as kerosene, fuel gas distillate, and fuel oils), or Separating or
Separating, cracking, reacting, or reforming intern1ediate petroleum streams. Examples of such units
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include, but are not limited to, petroleum based solvent units, alkylation units, catalytic hydrotreating,
catalytic hydrorefining, catalytic hydrocracking, catalytic reforming, catalytic cracking, crude distiIIation,
lube oil processing, hydrogen production, isomerization, polymerization, thermal processes, and blending,
sweetening, and treating processes. Petroleum refining process units include sulfur plants.
Population means the public.
Process means any activity involving a regulated substance including any use, storage, manufacturing,
handling, or on-site movement of such substances, or combination of these activities. For the purposes of
this definition, any group of vessels that are interconnected, or separate vessels that are located such that a
regulated substance could be involved in a potential release, shaII be considered a single process.
Produced water means water extracted from the earth from an oil or natural gas production weII, or that is
separated from oil or natural gas after extraction.
Public means any person except employees or contractors at the stationary source.
Public receptor means offsite residences, institutions (e.g., schools, hospitals), industrial, commercial, and
office buildings, parks, or recreational areas inhabited or occupied by the public at any time without
restriction by the stationary source where members of the public could be exposed to toxic concentrations,
radiant heat, or overpressure, as a result of an accidental release.
Regulated substance is any substance listed pursuant to section l12(r)(3) of the Clean Air Act as
amended, in Sec. 68.130.
Replacement in kind means a replacement that satisfies the design specifications.
Retail facility means a stationary source at which more than one-half of the incon1e is obtained from
direct sales to end users or at which more than one-half of the fuel sold, by volun1e, is sold through a
cylinder exchange program.
RMP means the risk management plan required under subpart G of this part.
Stationary source means any buildings, structures, equipment, installations, or substance emitting
stationary activities which belong to the same industrial group, which are located on one or more
contiguous properties, which are under the control of the same person (or persons under common control),
and from which an accidental release may occur. The term stationary source does not apply to
transportation, including storage incident to transportation, of any regulated substance or any other
extremely hazardous substance under the provisions of this part. A stationary source includes
transportation containers used for storage not incident to transportation and transportation containers
connected to equipment at a stationary source for loading or unloading. Transportation includes, but is not
limited to, transportation subject to oversight or regulation under 49 CFR parts 192, 193, or 195, or a state
natural gas or hazardous liquid program for which the state has in effect a certification to DOT under 49
U.S.C. section 60105. A stationary source does not include naturally occurring hydrocarbon reservoirs.
Properties shall not be considered contiguous solely because of a railroad or pipeline right-of-way.
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Thresholdquantitymeansthequantityspecifiedforregulatedsubstancespursuantto section 112(r)(5)of
theCleanAirActas amended,listedin Sec. 68.130anddeterminedto bepresentatastationarysourceas
specifiedin Sec. 68.115 ofthis part.
Typicalmeteorologicalconditionsmeansthetemperature, wind speed,cloudcover,and atmospheric
stabilityclass,prevailingatthesitebasedondatagatheredatornearthesiteorfrom alocal
meteorologicalstation.
Vesselmeans anyreactor, tank, drum, barrel,cylinder,vat, kettle, boiler, pipe, hose, orothercontainer.
Worst-casereleasemeansthereleaseofthelargestquantityofaregulatedsubstancefrom avessel or
processlinefailure thatresultsin thegreatestdistanceto an endpointdefinedin Sec. 68.22(a).
Sec. 68.10 Applicability.
(a) An owneroroperatorofastationarysourcethathas morethanathresholdquantityofaregulated
substancein aprocess,as determinedunderSec. 68.115,shallcomplywiththerequirementsofthis
partno laterthan thelatestofthefollowingdates:
(1) June21, 1999;
(2) Threeyears afterthedateon whicharegulatedsubstanceis first listed underSec. 68.130; or
(3) Thedateon whicharegulatedsubstanceis first presentaboveathresholdquantityin aprocess.
(b) Program 1eligibilityrequirements. Acoveredprocessiseligiblefor Program 1requirementsas
providedinSec. 68.12(b) ifitmeets all ofthefollowingrequirements:
(1) Forthefive years priortothesubmissionofan RMP, theprocesshas nothad an accidental
releaseofaregulatedsubstancewhereexposureto thesubstance,itsreactionproducts,
overpressuregeneratedbyan explosioninvolvingthe substance,orradiantheatgeneratedbya
fire involvingthesubstanceledto anyofthefollowing offsite:
(i) Death;
(ii) Injury; or
(iii) Responseorrestorationactivitiesfor an exposureofan environmentalreceptor;
(2) Thedistanceto atoxicorflammableendpointfor aworst-caserelease assessmentconducted
underSubpartB andSec. 68.25islessthan the distanceto anypublicreceptor, as definedin
Sec. 68.30; and
(3) Emergencyresponseprocedureshavebeencoordinatedbetweenthe stationarysourceandlocal
emergencyplanningand responseorganizations.
(c) Program2eligibilityrequirements. Acoveredprocessis subjectto Program2requirementsifit
doesnotp1eettheeligibilityrequirementsofeitherparagraph(b) orparagraph(d) ofthis section.
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(d) Program3eligibilityrequirements. Acoveredprocessis subjectto Program3iftheprocessdoes
notmeettherequirementsofparagraph(b) ofthissection, andifeitherofthefollowing conditions
is met:
(1) Theprocessis in NAICS code32211,32411, 32511,325181,325188,325192,325199,325211,
325311,or32532;or
(2) Theprocessis subjectto theOSHAprocesssafetymanagementstandard,29CFR 1910.119.
(e) If atanytin1e acoveredprocessno longermeets theeligibilitycriteriaofits Programlevel, the
owneroroperatorshallcomplywiththerequirementsofthenewProgramlevel thatapplies to the
processandupdatetheRMPas providedin Sec. 68.190.
(f) Theprovisionsofthispartshall notapplytoan OuterContinentalShelf("OCS")source, as defined
in40CFR55.2.
Sec. 68.12 Generalrequirements.
(a) Generalrequirements.Theowneroroperatorofastationarysourcesubjectto thispartshall submita
singleRMP, as providedin Sec. 68.150to68.185.TheRMPshallincludearegistrationthatreflects
allcoveredprocesses.
(b) Program 1requirements.
In additionto111eeting therequirementsofparagraph(a) ofthis section,theowneroroperatorofa
stationarysourcewithaprocesseligiblefor Program 1, as providedin Sec. 68.10(b), shall:
(1) Analyzethe worst-casereleasescenariofor theprocess(es), as providedin Sec. 68.25; document
thatthenearestpublic receptoris beyondthedistanceto atoxic orflammableendpointdefined
in Sec. 68.22(a);andsubmitin theRMPtheworst-case releasescenarioas providedin Sec.
68.165;
(2) Completethe five-yearaccidenthistoryfor theprocessas providedin Sec. 68.42ofthis partand
submititintheRMPas providedin Sec. 68.168;
(3) Ensurethatresponseactionshavebeencoordinatedwithlocalemergencyplanningand response
agencies;and
(4) Certifyin theRMPthefollowing: "Basedon the criteriain40CFR68.10, thedistanceto the
specifiedendpointfor the worst-caseaccidentalreleasescenarioforthe followingprocess(es)
is less than thedistanceto the nearestpublicreceptor: [listprocess(es)]. Withinthepastfive
years, theprocess(es)has (have) hadno accidentalreleasethatcausedoffsiteimpactsprovided
in theriskD1anagementprogramrule (40CFR68.10(b)(1)). Noadditional measuresare
necessaryto preventoffsiteimpactsfromaccidentalreleases. In theeventoffire, explosion,or
areleaseofaregulatedsubstancefrom the process(es),entrywithin thedistanceto the
specifiedendpointsmayposeadangertopublicemergencyresponders. Therefore,public
emergencyresponders shouldnotenterthisareaexceptas arrangedwiththeemergencycontact
indicatedin theRMP. Theundersignedcertifiesthat, to thebestofmyknowledge,
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information,andbelief,formed afterreasonableinquiry,theinformationsubmittedis true,
accurate,andcomplete. [Signature, title, date signed]."
(c) Program2requirements.
In additiontomeetingtherequirementsofparagraph(a) ofthis section,theowneroroperatorofa
stationarysourcewithaprocesssubjectto Program2, as providedin Sec. 68.10(c), shall:
(1) Developand implementamanagementsystemas providedin Sec. 68.15;
(2) ConductahazardassessmentasprovidedinSec. 68.20through68.42;
(3) Implementthe Program2preventionstepsprovidedin Sec. 68.48 through68.60orimplement
theProgram3preventionstepsprovidedin Sec. 68.65 through 68.87;
(4) Developandimplementan emergencyresponseprogramas providedin Sec. 68.90to 68.95;
and
(5) Submitas partoftheRMPthedataonpreventionprogramelementsfor Program2processes
as providedinSec. 68.170.
(d) Program3requirements.
In addition to meetingtherequiren1entsofparagraph(a) ofthis section,theowneroroperatorofa
stationarysourcewithaprocesssubjecttoProgram3, as providedin Sec. 68.10(d) shall:
(1) Developandimplementamanagementsystemas providedin Sec. 68.15;
(2) Conductahazardassessmentas providedin Sec. 68.20through68.42;
(3) ImplementthepreventionrequirementsofSec. 68.65 through 68.87;
(4) Developandimplementan emergencyresponseprogramas providedin Sec. 68.90to 68.95 of
thispart; and
(5) Submitas partoftheRMPthedataonpreventionprogramelementsforProgram3processes
as providedinSec. 68.175.
Sec. 68.15 Management.
(a) Theowneroroperatorofastationarysourcewithprocessessubjectto Program2orProgram3shall
developamanagementsysten1to overseetheimplementationoftherisk managementprogram
elements.
(b) Theowneroroperatorshall assignaqualifiedpersonorposition thathas theoverallresponsibility
for thedevelopment,implementation,andintegrationoftheriskn1anagementprogramelements.
(c) Whenresponsibilityfor implementingindividual requirementsofthis partis assignedto persons
otherthan thepersonidentifiedunderparagraph(b) ofthis section, the namesorpositionsofthese
peopleshallbedocumentedand the lines ofauthoritydefined through an organizationchartor
similardocument.
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SubpartB - HazardAssessment
Theowneroroperatorofastationarysourcesubjectto thispartshallprepareaworst-caserelease
scenarioanalysisas providedin Sec.68.25 ofthispartandcompletethefive-yearaccidenthistoryas
providedinSec. 68.42.TheowneroroperatorofaProgram2and3process mustcomplywithall
sectionsinthissubpartfor theseprocesses.
Sec. 68.22 Offsiteconsequenceanalysisparameters.
(a) Endpoints.Foranalyses ofoffsiteconsequences,the following endpointsshallbeused:
(a) Toxics. Thetoxicendpointsprovidedin appendix Aofthispart.
(b) Flammables.Theendpointsforflammables varyaccordingto thescenariosstudied:
(i) Explosion. An overpressureof1 psi.
(ii) Radiantheat/exposuretime. Aradiantheatof5kw/m2for40seconds.
(iii)Lowerflan1mability lin1it. Alowerflammabilitylimitas providedinNFPAdocumentsor
othergenerallyrecognizedsources.
(b) Windspeed/atmosphericstabilityclass. Fortheworst-casereleaseanalysis, theowneroroperator
shall use awindspeedof1.5 meterspersecondandF atmosphericstabilityclass.If theowneror
operatorcandemonstratethatlocaln1eteorological dataapplicableto thestationarysourceshowa
higherminimumwindspeedorlessstableatmosphereatall timesduringtheprevious threeyears,
theseminimumsmaybeused. Foranalysisofalternativescenarios, theowneroroperatormayuse
thetypical meteorologicalconditionsfor thestationarysource.
(c) Ambienttemperaturelhumidity. Forworst-casereleaseanalysisofaregulatedtoxicsubstance, the
owneroroperatorshalluse thehighestdailymaximumtemperatureinthepreviousthreeyearsand
averagehun1idityforthesite,basedontemperature/humiditydatagatheredat the stationarysource
oratalocal meteorologicalstation; an owneroroperatorusingtheRMPOffsiteConsequence
AnalysisGuidancemayuse 25 C and50percenthumidityas valuesfor thesevariables. Foranalysis
ofalternativescenarios,theowneroroperatormayusetypical ten1perature/humiditydatagathered
at the stationarysourceoratalocal n1eteorological station.
(d) Heightofrelease. Theworst-casereleaseofaregulatedtoxicsubstanceshallbeanalyzedassuming
agroundlevel (0 feet) release. Foran alternativescenarioanalysisofaregulatedtoxic substance,
releaseheightmaybedeterminedbythereleasescenario.
(e) Surfaceroughness. Theowneroroperatorshalluseeitherurbanorrural topography, as appropriate.
Urbanmeansthatthere are manyobstaclesin theimmediatearea; obstaclesincludebuildingsor
trees. Rural means there are nobuildingsintheimmediateareaand the terrainis generallyflat and
unobstructed.
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(f) Denseorneutrallybuoyantgases. Theowneroroperatorshallensurethattablesormodelsusedfor
dispersionanalysisofregulatedtoxicubstancesappropriatelyaccountforgas density.
(g) Temperatureofreleasedsubstance.Forworstcase,liquidsotherthangasesliquifiedbyrefrigeration
onlyshall beconsideredtobereleasedatthe highestdailymaximumtemperature,basedondatafor
thepreviousthree yearsappropriatefor the stationarysource,oratprocesstemperature, whichever
is higher. Foralternativescenarios,substancesmaybeconsideredto bereleasedataprocessor
ambientten1perature thatis appropriatefor thescenario.
Sec. 68.25 Worst-casereleasescenarioanalysis.
(a) Theowneroroperatorshall analyzeandreportin theRMP:
(1) ForProgram 1processes,oneworst-casereleasescenarioforeachProgram 1 r o e s s ~
(2) ForProgram2and 3processes:
(i) Oneworst-casereleasescenariothatisestimatedto createthegreatestdistanceinany
direction to an endpointprovidedin appendix Aofthis partresultingfrom an accidental
releaseofregulated toxic substancesfrom covered processesunderworst-case
conditionsdefinedin Sec. 68.22;
(ii) Oneworst-casereleasescenariothat isestimatedtocreatethegreatestdistanceinany
directionto anendpointdefinedin Sec. 68.22(a)resultingfrom an accidentalreleaseof
regulatedflammablesubstancesfrom coveredprocessesunderworst-caseconditions
definedin Sec. 68.22; and
(iii) Additional worst-casereleasescenariosforahazardclassifaworst-casereleasefrom
anothercoveredprocess at the stationarysourcepotentiallyaffectspublicreceptors
differentfrom thosepotentiallyaffectedbytheworst-casereleasescenariodeveloped
underparagraphs(a)(2)(i)or(a)(2)(ii)ofthis section.
(b) Determinationofworst-casereleasequantity. Theworst-casereleasequantityshallbethe greaterof
thefollowing:
(1) Forsubstancesin avessel, the greatestamountheldin asinglevessel, takingintoaccount
administrativecontrolsthatlimitthemaximumquantity; or
(2) Forsubstancesinpipes,the greatestamountin apipe, takingintoaccountadministrative
controlsthatlimitthemaximumquantity.
(c) Worst-casereleasescenario- toxic gases.
(1) Forregulatedtoxicsubstancesthatarenormallygases atambienttemperatureand handledas a
gasoras aliquidunderpressure,theowneroroperatorshall assumethat thequantityin the
vessel orpipe,as determinedunderparagraph(b) ofthis section,is releasedas agas over10
minutes. Thereleaserate shallbeassumedtobethe totalquantitydividedby 10unlesspassive
n1itigation systemsarein place.
(2) Forgaseshandledas refrigeratedliquidsatambientpressure.
(i) Ifthereleasedsubstanceis notcontainedbypassivemitigationsystemsorifthe
containedpool would haveadepthof1cmorless, theowneroroperatorshall assume
thatthe substanceisreleasedas agasin 10minutes;
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(ii) Ifthereleasedsubstanceis containedbypassivemitigationsystemsin apoolwitha
depthgreaterthan 1cm,theowneroroperatormayassumethatthequantityin the
vesselorpipe,as determinedunderparagraph(b) ofthissection,isspilled
instantaneouslytoforma liquidpool. Thevolatilizationrate(releaserate) shallbe
calculatedattheboilingpointofthesubstanceandattheconditionsspecifiedin
paragraph(d) ofthis section.
(d) Worst-casereleasescenario- toxicliquids.
(1) Forregulatedtoxicsubstancesthatare normallyliquidsatambienttemperature,theowneror
operatorshall assumethatthe quantityin thevesselorpipe,asdeterminedunderparagraph
(b)ofthissection,isspilledinstantaneouslyto formaliquidpool.
(i) Thesurfaceareaofthepoolshallbedeterminedbyassumingthattheliquidspreads to 1
centimeterdeepunlesspassivemitigationsystemsareinplacethatservetocontainthe
spillandlimitthesurfacearea. Wherepassivemitigationis in place,thesurfaceareaofthe
containedliquidshallbeusedtocalculatethevolatilizationrate.
(ii) If thereleasewouldoccurontoasurfacethatisnotpavedorsmooth,the owneror
operatormaytakeintoaccounttheactual surfacecharacteristics.
(2) Thevolatilizationrateshall accountforthehighestdailymaximumtemperatureoccurringin
thepastthree years, thetemperatureofthesubstancein the vessel, andtheconcentrationof
thesubstanceiftheliquidspilledis amixtureorsolution.
(3) Therateofreleaseto airshallbedeterminedfromthe volatilizationrateoftheliquidpool.The
owneroroperatormayusethemethodologyin the RMPOffsiteConsequenceAnalysis
Guidanceoranyotherpubliclyavailabletechniquesthataccountforthemodelingconditions
and arerecognizedbyindustryasapplicableas partofcurrentpractices. Proprietarymodels
thataccountfor themodelingconditionsmaybeusedprovidedtheowneroroperatorallows
theimplementingagencyaccess to then10del and describes modelfeatures anddifferences
frompubliclyavailablemodels to localemergencyplannersupon request.
(e) Worst-casereleasescenario- flammablegases. Theowneroroperatorshallassumethatthequantity
ofthesubstance,asdeterminedunderparagraph(b) ofthissectionandtheprovisionsbelow,
vaporizesresultinginavaporcloudexplosion. A yieldfactorof10percentoftheavailableenergy
releasedin theexplosionshallbeused to determinethedistanceto theexplosionendpointifthe
modelusedis basedonTNTequivalentmethods.
(1) Forregulatedflammable substances thatare normallygasesatambienttemperatureand
handledas a gasoras aliquidunderpressure, theowneroroperatorshallassumethatthe
quantityin thevessel orpipe, as detern1inedunderparagraph(b) ofthis section,isreleasedas
a gasover10minutes. Thetotal quantityshall beassumedtobeinvolvedinthevaporcloud
explosion.
(2) Forflammable gaseshandledas refrigeratedliquidsatambientpressure:
(i) If thereleasedsubstanceis notcontainedbypassivemitigationsystemsorifthe
containedpoolwouldhavea depthofonecentimeterorless,the owneroroperatorshall
assumethatthetotal quantityofthesubstanceis releasedas a gasin 10minutes, andthe
totalquantitywill beinvolvedin thevaporcloudexplosion.
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(ii) Ifthereleasedsubstanceiscontainedbypassivemitigationsystemsinapoolwitha depth
greaterthan 1centimeter,theowneroroperatormayassumethatthequantityin thevessel
orpipe,asdeterminedunderparagraph(b) ofthis section,is spilledinstantaneouslyto
form aliquidpool.Thevolatilizationrate(releaserate) shallbecalculatedattheboiling
pointofthesubstanceandattheconditionsspecifiedinparagraph(d)ofthissection. The
owneroroperatorshallassumethatthequantitywhichbecomesvaporinthefirst 10
minutesis involvedin thevaporcloudexplosion.
(f) Worst-casereleasescenario- flammableliquids. Theowneroroperatorshallassumethatthe
quantityofthesubstance, as determinedunderparagraph(b)ofthis sectionand the provisionsbelow,
vaporizesreSUlting ina vaporcloudexplosion. A yieldfactorof10percentoftheavailableenergy
releasedintheexplosionshallbeusedtodeterminethedistancetotheexplosionendpointifthe
modelusedisbasedonTNTequivalentmethods.
(1) Forregulatedflammablesubstancesthatarenormallyliquidsatambienttemperature,theowner
oroperatorshallassumethattheentirequantityin thevesselorpipe,asdeterminedunder
paragraph(b) ofthissection,is spilledinstantaneouslytoformaliquidpool.Forliquidsat
temperaturesbelowtheiratmosphericboilingpoint, thevolatilizationrateshallbecalculatedat
theconditionsspecifiedinparagraph(d) ofthis section.
(2) Theowneroroperatorshallassumethatthequantitywhichbecomesvaporin thefirst 10minutes
is involvedinthevaporcloudexplosion.
(g) Parameterstobeapplied. TheowneroroperatorshallusetheparametersdefinedinSec. 68.22to
determinedistancetotheendpoints. Theowneroroperatormayusethemethodologyprovidedinthe
RMPOffsiteConsequenceAnalysisGuidanceoranycommerciallyorpubliclyavailableair
dispersionmodelingtechniques,providedthetechniques accountforthemodelingconditionsandare
recognizedbyindustryas applicableas partofcurrentpractices. Proprietarymodelsthataccountfor
the modelingconditionsmaybeusedprovidedtheowneroroperatorallowstheimplementing
agencyaccesstothen10del anddescribesmodelfeatures anddifferencesfrompubliclyavailable
modelstolocalemergencyplannersuponrequest.
(h) Considerationofpassivemitigation. Passivemitigationsystemsmaybeconsideredfortheanalysisof
worstcaseprovidedthatthemitigation systemiscapableofwithstandingthereleaseeventtriggering
the scenarioandwouldstillfunction asintended.
(i) Factorsin selectinga worst-casescenario.Notwithstandingtheprovisionsofparagraph(b)ofthis
section,theowneroroperatorshallselectastheworstcaseforflammable regulatedsubstancesorthe
worstcaseforregulatedtoxicsubstances,a scenariobasedonthefollowing factorsifsuchascenario
wouldresultin agreaterdistanceto anendpointdefinedinSec. 68.22(a)beyondthestationary
sourceboundarythan the scenarioprovidedunderparagraph(b) ofthissection:
(1) Smallerquantitieshandledathigherprocesstemperatureorpressure; and
(2) Proximitytotheboundaryofthestationarysource.
Sec. 68.28 Alternativereleasescenarioanalysis.
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(a) Thenumberofscenarios.Theowneroroperatorshallidentifyandanalyzeatleastonealternative
releasescenarioforeachregulatedtoxicsubstanceheld in acoveredprocess(es)and atleastone
alternativereleasescenariotorepresentallflamn1able substances heldincoveredprocesses.
(b) Scenarios to consider.
(1) Foreachscenariorequired underparagraph(a) ofthis section, theowneroroperatorshallselecta
scenario:
(i) Thatis morelikelyto occurthanthe worst-casereleasescenariounderSec. 68.25;and
(ii) Thatwillreach anendpointoffsite, unless nosuchscenarioexists.
(2) Releasescenariosconsideredshouldinclude,butare notlimitedto, the following, where
applicable:
(i) Transferhosereleasesdueto splitsorsuddenhoseuncoupling;
(ii) Processpipingreleasesfromfailures atflanges,joints,welds, valves andvalveseals,and
drains orbleeds;
(iii) Processvessel orpumpreleases dueto cracks,sealfailure, ordrain,bleed,orplugfailure;
(iv) Vesseloverfillingand spill,oroverpressurizationand ventingthroughreliefvalves orrupture
disks; and
(v) Shippingcontainermishandlingandbreakageorpuncturingleadingto aspill.
(c) Parameterstobeapplied. Theowneroroperatorshall use theappropriateparametersdefinedin Sec.
68.22to determinedistanceto theendpoints. Theowneroroperatormayuseeitherthemethodology
providedin theRMPOffsiteConsequenceAnalysisGuidanceoranycommerciallyorpublicly
availableairdispersion modelingtechniques,provided thetechniques accountfor thespecified
modelingconditionsand arerecognizedbyindustryas applicableas partofcurrentpractices.
Proprietarymodelsthataccountfor the modelingconditionsmaybeusedprovidedthe owneror
operatorallowstheimplementingagencyaccess to themodeland describes modelfeatures and
differencesfrompubliclyavailablemodelstolocalemergencyplannersuponrequest.
(d) Considerationofmitigation. Activeandpassivemitigationsystemsmaybeconsideredprovidedthey
arecapableofwithstandingtheeventthattriggeredthereleaseand wouldstillbefunctional.
(e) Factorsin selectingscenarios. Theowneroroperatorshallconsiderthefollowing in selecting
alternativereleasescenarios:
(1) Thefive-yearaccidenthistoryprovidedinSec. 68.42; and
(2) FailurescenariosidentifiedunderSec. 68.50orSec. 68.67.
Sec. 68.30 Definingoffsiteimpacts- population.
(a) TheowneroroperatorshallestimateintheRNIP thepopulation within acirclewithitscenteratthe
pointofthe releaseand aradius determinedbythedistanceto theendpointdefinedin Sec. 68.22(a).
(b) Populationto bedefined. Populationshallincluderesidentialpopulation. Thepresenceofinstitutions
(schools, hospitals, prisons), parks and recreationalareas, andmajorcon1mercial, office, and
industrial buildingsshall benotedin the RMP.
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(c) Datasourcesacceptable. Theowneroroperatormayusethe mostrecentCensusdata, orother
updatedinformation,to estimatethepopulationpotentiallyaffected.
(d) Levelofaccuracy. Populationshallbeestimatedto two significantdigits.
Sec. 68.33 Definingoffsiteimpacts- environnlent.
(a) Theowneroroperatorshall listin theRMPenvironmentalreceptors withinacirclewithitscenterat
thepointofthereleaseandaradius determinedbythedistanceto theendpointdefinedin Sec.
68.22(a)ofthis part.
(b) Datasources acceptable. Theowneroroperatormayrelyoninformationprovidedonlocal U.S.
GeologicalSurveymapsoronanydatasourcecontainingU.S.G.S. datato identifyenvironmental
receptors.
Sec. 68.36 Reviewand update.
(a) Theowneroroperatorshallreviewandupdatetheoffsiteconsequenceanalyses atleastonceevery
five years.
(b) Ifchangesin processes, quantities storedorhandled,oranyotheraspectofthestationarysource
mightreasonablybeexpectedtoincreaseordecreasethedistancetotheendpointbyafactoroftwo
ormore, theowneroroperatorshallcompletearevisedanalysis within six monthsofthechangeand
submitarevisedriskmanagementplanas providedin Sec. 68.190.
Sec. 68.39 Documentation.
Theowneroroperatorshallmaintain thefollowingrecordsontheoffsiteconsequenceanalyses:
(a) Forworst-casescenarios,adescriptionofthe vessel orpipelineand substanceselectedas worstcase,
assumptionsandparametersused, andtherationalefor selection; assumptions shallincludeuseof
anyadministrativecontrolsandanypassivemitigationthatwere assumedto limitthequantitythat
couldbereleased. Documentationshallincludethe anticipatedeffectofthecontrolsandmitigation
onthe releasequantityandrate.
(b) Foralternativereleasescenarios,adescriptionofthe scenariosidentified,assumptionsand
parametersused, and the rationalefor the selectionofspecificscenarios;assumptionsshallinclude
use ofanyadministrativecontrolsandanymitigationthatwereassumedto limitthe quantitythat
couldbereleased. Documentationshallincludethe effectofthecontrols andmitigationonthe
releasequantityand rate.
(c) Docunlentationofestimatedquantityreleased, releaserate, and durationofrelease.
(d) Methodologyused to determinedistancetoendpoints.
(e) Datausedto estimatepopulationandenvironmentalreceptorspotentiallyaffected.
Sec. 68.42 Five-yearaccidenthistory.
(a) Theowneroroperatorshall includein the five-yearaccidenthistoryall accidentalreleases from
coveredprocesses thatresultedin deaths, injuries,orsignificantpropertydamageon site, orknown
offsitedeaths,injuries,evacuations,shelteringin place,propertydamage,orenvironmentaldamage.
(b) Datarequired. Foreachaccidentalreleaseincluded, the owneroroperatorshallreportthefollowing
information:
(1) Date, time, and approximatedurationoftherelease;
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(2) Chemical(s)released;
(3) Estimatedquantityreleasedin poundsand, for mixturescontainingregulatedtoxicsubstances,
percentageconcentrationbyweightofthereleasedregulated toxicsubstancein theliquid
mixture;
(4) Five- orsix-digitNArCScodethatmostcloselycorrespondsto theprocess;
(5) Thetypeofreleaseeventandits source;
(6) Weatherconditions, ifknown;
(7) On-siteimpacts;
(8) Knownoffsiteimpacts;
(9) Initiatingeventand contributingfactors ifknown;
(10)Whetheroffsiteresponderswerenotifiedifknown; and
(11) Operationalorprocesschangesthatresultedfrom investigationofthe release.
(c) Levelofaccuracy. Numericalestimatesmaybeprovidedto two significantdigits.
SubpartC- Program2PreventionProgran1
Sec. 68.48 Safetyinformation.
Source: 61 FR31721,June20, 1996,unlessotherwisenoted.
(a) Theowneroroperatorshallcompileand maintain thefollowingup-to-datesafetyinformationrelated
to theregulated substances,processes,andequipment:
(1) MaterialSafetyDataSheetsthatmeettherequirementsof29CFR 1910.1200(g);
(2) Maximumintendedinventoryofequipmentin whichtheregulatedsubstancesarestoredor
processed;
(3) Safeupperand lowertemperatures,pressures, flows, andcon1positions;
(4) Equipmentspecifications;and
(5) Codesand standards used todesign, build, andoperatetheprocess.
(b) Theowneroroperatorshall ensurethattheprocessis designedin compliancewithrecognizedand
generallyacceptedgoodengineeringpractices. CompliancewithFederalorstateregulations that
address industry-specific safedesignorwithindustry-specificdesign codes andstandardsmay
beused todemonstratecompliancewiththis paragraph.
(c) Theowneroroperatorshallupdatethesafetyinformationifamajorchangeoccursthatmakesthe
informationinaccurate.
Sec. 68.50 Hazardreview.
(a) Theowneroroperatorshallconductareview ofthe hazards associated withtheregulated substances,
process, and procedures. Thereview shallidentifythefollowing:
(1) Thehazardsassociated withtheprocessandregulated substances;
(2) Opportunitiesfor equipmentmalfunctionsorhumanerrors thatcouldcausean accidental
release;
(3) Thesafeguardsused orneeded to control the hazardsorpreventequipmentmalfunctionorhuman
error; and
(4) Anystepsused orneededtodetectormonitorreleases.
(b) Theowneroroperatormayusechecklistsdevelopedbypersonsororganizationsknowledgeable
abouttheprocessandequipmentas aguidetoconductingthe review. Forprocessesdesigned to meet
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industrystandardsorFederalorstatedesignrules, the hazardreview shall, byinspectingall
equipment,determinewhethertheprocessis designed,fabricated, andoperatedin accordancewith
theapplicablestandardsorrules.
(c) Theowneroroperatorshall documenttheresultsofthereviewandensurethatproblemsidentified
areresolvedin atimelymanner.
(d) Thereviewshallbeupdatedatleastonceeveryfive years. Theowneroroperatorshallalsoconduct
reviewswheneveran1ajorchangeintheprocessoccurs; all issuesidentifiedin thereview shallbe
resolvedbeforestartupofthechangedprocess.
Sec. 68.52 Operatingprocedures.
(a) Theowneroroperatorshallpreparewrittenoperatingproceduresthatprovideclearinstructionsor
stepsfor safelyconductingactivitiesassociated witheachcoveredprocessconsistentwiththe safety
informationforthatprocess. Operatingproceduresorinstructionsprovidedbyequipment
manufacturersordevelopedbypersonsororganizationsknowledgeableabouttheprocessand
equipmentmaybeusedas abasisforastationarysource'soperatingprocedures.
(b) Theproceduresshall address thefollowing:
(1) Initial startup;
(2) Normaloperations;
(3) Temporaryoperations;
(4) Emergencyshutdownandoperations;
(5) Normalshutdown;
(6) Startupfollowinganormaloremergencyshutdownoramajorchangethatrequiresahazard
review;
(7) Consequencesofdeviations and stepsrequired to correctoravoiddeviations; and
(8) Equipmentinspections.
(c) Theowneroroperatorshallensurethattheoperatingproceduresare updated,ifnecessary, whenever
amajorchangeoccursandpriortostartupofthechangedprocess.
Sec. 68.54 Training.
(a) Theowneroroperatorshallensurethateachemployeepresentlyoperatingaprocess, andeach
employeenewlyassignedto acoveredprocesshavebeentrainedortested competentintheoperating
proceduresprovidedin Sec. 68.52 thatpertaintotheirduties. Forthoseemployeesalreadyoperating
aprocessonJune21, 1999,theowneroroperatormaycertifyin writingthattheemployeehas the
requiredknowledge, skills, andabilitiesto safelycarryouttheduties andresponsibilitiesas provided
in theoperatingprocedures.
(b) Refreshertraining. Refreshertrainingshallbeprovidedatleasteverythree years, andmoreoftenif
necessary,to eachemployeeoperatingaprocesstoensurethattheemployeeunderstandsand adheres
tothecurrentoperatingproceduresoftheprocess. Theowneroroperator,inconsultationwith the
employeesoperatingthe process, shall determinetheappropriatefrequencyofrefreshertraining.
(c) TheowneroroperatormayusetrainingconductedunderFederalorstateregulationsorunder
industry-specificstandardsorcodesortrainingconductedbycoveredprocessequipmentvendors to
demonstratecompliancewiththissectiontotheextentthatthetrainingmeets therequirementsofthis
section.
(d) Theowneroroperatorshallensurethatoperatorsaretrainedin anyupdatedornewproceduresprior
tostartupofaprocessafteramajorchange.
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Sec. 68.56 Maintenance.
(a) Theowneroroperatorshall prepareandimplementprocedurestomaintaintheon-goingmechanical
integrityoftheprocessequipment.Theowneroroperatormayuseproceduresorinstructions
providedbycoveredprocessequipmentvendorsorproceduresinFederalorstateregulationsor
industrycodesas thebasisfor stationarysourcemaintenanceprocedures.
(b) Theowneroroperatorshalltrain orcauseto betrainedeachemployeeinvolvedin maintainingthe
on-goingmechanicalintegrityoftheprocess.Toensurethattheemployeecanperformthejobtasks
in asafemanner,eachsuchemployeeshallbetrainedin thehazardsofthe process,in howto avoid
orcorrectunsafeconditions,andin theproceduresapplicableto theemployee'sjobtasks.
(c) Anymaintenancecontractorshallensurethateachcontractmaintenanceemployeeis trainedto
perfornlthe maintenanceproceduresdevelopedunderparagraph(a) ofthis section.
(d) Theowneroroperatorshallperformorcausetobeperformedinspectionsand tests on'process
equipment. Inspectionand testingproceduresshall follow recognizedandgenerallyacceptedgood
engineeringpractices. Thefrequencyofinspectionsandtestsofprocessequipmentshallbe
consistentwith applicable11lanufacturers'recommendations,industrystandardsorcodes,good
engineeringpractices, andprioroperatingexperience.
Sec. 68.58 Complianceaudits.
(a) Theowneroroperatorshallcertifythattheyhaveevaluatedcompliancewith theprovisionsofthis
subpartatleasteverythreeyears to verifythattheproceduresandpracticesdevelopedundertherule
areadequateand arebeingfollowed.
(b) Thecomplianceauditshall beconductedbyatleastonepersonknowledgeablein theprocess.
(c) Theowneroroperatorshalldevelopareportoftheauditfindings.
(d) Theowneroroperatorshallpromptlydetermineanddocumentan appropriateresponsetoeachofthe
findings ofthecomplianceauditanddocumentthatdeficiencieshavebeen corrected.
(e) Theowneroroperatorshallretain thetwo(2) mostrecentcomplianceauditreports. Thisrequirement
doesnotapplyto anycomplianceauditreportthatis morethan five years old.
Sec. 68.60 Incidentinvestigation.
(a) Theowneroroperatorshallinvestigateeachincidentwhichresultedin,orcouldreasonablyhave
resultedin acatastrophicrelease.
(b) Anincidentinvestigationshallbeinitiatedas promptlyas possible,butnotlaterthan48hours
following theincident.
(c) Asummaryshallbepreparedattheconclusionoftheinvestigationwhichincludesataminimum:
(1) Dateofincident;
(2) Dateinvestigationbegan;
(3) Adescriptionoftheincident;
(4) Thefactors thatcontributedto theincident; and,
(5) Anyrecommendationsresultingfrom theinvestigation.
(d) Theowneroroperatorshall promptlyaddress andresolvetheinvestigationfindings and
recommendations. Resolutionsandcorrectiveactionsshallbedoculllented.
(e) Thefindings shallbereviewedwith all affectedpersonnelwhosejobtasks are affectedbythe
findings.
(f) Investigationsummariesshallberetainedfor five years.
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SubpartD - Program3PreventionProgram
Sec. 68.65 Processsafetyinformation.
(a) In accordancewiththeschedulesetforth in Sec. 68.67, theowneroroperatorshallcompletea
compilationofwrittenprocesssafetyinformationbeforeconductinganyprocess hazardanalysis
requiredbythe rule. Thecompilationofwrittenprocesssafetyinformationis toenabletheowneror
operatorandtheemployeesinvolvedinoperatingthe processtoidentifyandunderstandthehazards
posedbythoseprocessesinvolvingregulatedsubstances.Thisprocesssafetyinformationshall
includeinformationpertainingto thehazardsoftheregulatedsubstancesusedorproducedbythe
process,informationpertainingtothetechnologyoftheprocess,andinformationpertainingto the
equipmentintheprocess.
(b) Informationpertainingto thehazardsoftheregulatedsubstancesintheprocess.Thisinformation
shallconsistofatleastthefollowing:
(1) Toxicityinformation;
(2) Permissibleexposurelimits;
(3) Physicaldata;
(4) Reactivitydata:
(5) Corrosivitydata;
(6) Thermalandchemicalstabilitydata; and
(7) Hazardouseffectsofinadvertentmixingofdifferentmaterialsthatcouldforeseeablyoccur.
Noteto paragraph(b): MaterialSafetyDataSheetsmeetingtherequirementsof29 CFR
1910.1200(g)maybeused to complywiththis requirementtotheextenttheycontaintheinformation
requiredbythis subparagraph.
(c) Inforn1ation pertainingto thetechnologyofthe process.
(1) Informationconcerningthe technologyofthe processshallincludeatleastthefollowing:
(i) Ablockflow diagramorsimplifiedprocessflow diagram;
(ii) Processchemistry;
(iii) Maximumintendedinventory;
(iv) Safeupperandlowerlimitsfor suchitems as temperatures,pressures, flows or
compositions;and,
(v) An evaluationoftheconsequencesofdeviations.
(2) Wheretheoriginaltechnicalinformationnolongerexists, suchinformationmaybedevelopedin
conjunctionwith theprocesshazardanalysisin sufficientdetail to supporttheanalysis.
(d) Informationpertainingto theequipmentin theprocess.
(1) Informationpertainingtotheequipmentin theprocessshallinclude.
(i) Materialsofconstruction;
(ii) Pipingandinstrumentdiagrams(P&ID's);
(iii)Electricalclassification;
(iv) Reliefsystemdesignanddesignbasis;
(v) Ventilationsystemdesign;
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(vi) Designcodesand standardsemployed;
(vii)MaterialandenergybalancesforprocessesbuiltafterJune21, 1999; and
(viii) Safetysystems(e.g. interlocks,detectionorsuppressionsystems).
(2) Theowneroroperatorshalldocun1entthatequipmentcomplies withrecognizedandgenerally
acceptedgoodengineeringpractices.
(3) Forexistingequipmentdesigned andconstructedin accordancewithcodes,standards,or
practicesthatarenolongerin generaluse, theowneroroperatorshalldetermineanddocument
thattheequipmentis designed, maintained,inspected,tested, andoperatingin asafemanner.
Sec. 68.67 Processhazardanalysis.
(a) Theowneroroperatorshallperforman initialprocesshazardanalysis(hazardevaluation)on
processescoveredbythispart. Theprocesshazardanalysisshallbeappropriateto thecomplexityof
the process and shallidentify,evaluate, and control the hazardsinvolvedin the process. Theowneror
operatorshalldetermineanddocumentthepriorityorderforconductingprocesshazardanalyses
basedonarationalewhichincludessuchconsiderationsas extentoftheprocesshazards, numberof
potentiallyaffectedemployees,ageoftheprocess, andoperatinghistoryoftheprocess.Theprocess
hazardanalysis shallbeconductedas soonas possible,butnotlaterthanJune21, 1999. Process
hazards analysescompletedtocomplywith 29CFR 1910.119(e)areacceptableas initialprocess
hazardsanalyses. Theseprocesshazard analysesshallbeupdatedand revalidated, basedon their
completiondate.
(b) Theowneroroperatorshall useoneormoreofthefollowing methodologiesthatareappropriateto
determineandevaluatethehazardsoftheprocessbeinganalyzed.
(1) What-If;
(2) Checklist;
(3) What-If/Checklist;
(4) Hazard and OperabilityStudy(HAZOP);
(5) FailureModeandEffectsAnalysis (FMEA);
(6) FaultTreeAnalysis; or
(7) An appropriateequivalentmethodology.
(c) Theprocesshazardanalysisshall address:
(1) Thehazardsoftheprocess;
(2) Theidentificationofanypreviousincidentwhichhadalikelypotentialfor catastrophic
consequences.
(3) Engineeringand administrativecontrolsapplicabletothe hazardsand theirinterrelationships
suchasappropriateapplicationofdetection methodologiestoprovideearlywarningofreleases.
(Acceptabledetection methodsmightincludeprocessmonitoringandcontrolinstrumentation
with alarms, anddetection hardwaresuch as hydrocarbonsensors.);
(4) Consequencesoffailureofengineeringand administrativecontrols;
(5) Stationarysourcesiting;
(6) Humanfactors; and
(7) Aqualitativeevaluationofarangeofthe possiblesafetyand healtheffectsoffailureofcontrols.
(d) Theprocesshazardanalysis shallbeperformedby ateam withexpertisein engineeringandprocess
operations,andthe teamshallincludeatleastoneemployeewhohasexperienceandknowledge
specificto theprocessbeingevaluated. Also, onememberofthe teammustbe knowledgeablein the
specificprocesshazardanalysismethodology beingused.
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(e) Theowneroroperatorshallestablishasystemtopromptlyaddresstheteam'sfindings and
recommendations; assurethattherecommendationsareresolvedin atimelymannerand thatthe
resolutionisdocumented; documentwhatactions aretobetaken;completeactionsas soonas
possible;developawrittenscheduleofwhentheseactions areto becompleted;communicatethe
actionsto operating,maintenanceandotheremployees whoseworkassignmentsarein theprocess
and whomaybeaffected bythe recomn1endations oractions.
(f) Atleasteveryfive (5) years afterthecompletionoftheinitialprocesshazardanalysis, the process
hazardanalysisshallbeupdatedand revalidatedbyateammeetingtherequirementsinparagraph(d)
ofthis section, to assurethattheprocesshazardanalysisisconsistentwiththecurrentprocess.
Updatedandrevalidatedprocesshazardanalysescompletedto complywith29 CFR 1910.119(e)are
acceptableto meet the requirementsofthis paragraph.
(g) Theowneroroperatorshallretainprocesshazards analyses and updatesorrevalidationsforeach
processcoveredbythis section,as well as the documentedresolutionofrecommendationsdescribed
in paragraph(e) ofthissectionforthelifeoftheprocess.
Sec. 68.69 Operatingprocedures.
(a) Theowneroroperatorshalldevelopandimplementwrittenoperatingproceduresthatprovideclear
instructionsfor safelyconductingactivitiesinvolvedin eachcoveredprocessconsistentwiththe
processsafetyinformationand shalladdressatleastthefollowingelements.
(1) Stepsforeachoperatingphase:
(i) Initial startup;
(ii) Normaloperations;
(iii)Temporaryoperations;
(iv)Emergencyshutdownincludingtheconditionsunderwhichemergencyshutdownis
required, and theassignmentofshutdownresponsibilitytoqualifiedoperatorsto ensurethat
emergencyshutdownis executedin asafeandtin1ely manner.
(v) Emergencyoperations;
(vi) Normal shutdown;and,
(vii) Startupfollowingaturnaround,orafteran emergencyshutdown.
(2) Operatinglimits:
(i) Consequencesofdeviation; and
(ii) Stepsrequiredto correctoravoiddeviation.
(3) Safetyand healthconsiderations:
(i) Propertiesof, and hazardspresentedby, thechemicalsusedin theprocess;
(ii) Precautionsnecessarytopreventexposure,includingengineeringcontrols, administrative
controls,andpersonalprotectiveequipment;
(iii) Controlmeasurestobetakenifphysicalcontactorairborneexposureoccurs;
(iv) Qualitycontrolforrawmaterials andcontrolofhazardouschemicalinventorylevels; and,
(v) Anyspecial oruniquehazards.
(4) Safetysystemsandtheirfunctions.
(b) Operatingproceduresshallbereadilyaccessibleto employeeswho workin ormaintain aprocess.
(c) Theoperatingproceduresshallbereviewedasoftenas necessaryto assurethattheyreflectcurrent
operatingpractice,includingchangesthatresultfromchangesinprocesschemicals,technology, and
equipment,andchangesto stationarysources.Theowneroroperatorshallcertifyannuallythatthese
operatingproceduresarecurrentandaccurate.
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(d) Theowneroroperatorshalldevelopandimplementsafeworkpracticesto providefor thecontrolof
hazardsduringoperationssuchas lockout/tagout;confinedspaceentry; openingprocessequipment
orpiping; andcontrol overentranceintoastationarysourcebymaintenance,contractor,laboratory,
orothersupportpersonnel.Thesesafeworkpracticesshallapplytoemployeesandcontractor
employees.
Sec. 68.71 Training.
(a) Initial training.
(1) Eachemployeepresentlyinvolvedinoperatingaprocess, andeachemployeebeforebeing
involvedin operatinganewlyassignedprocess,shallbetrainedin an overviewoftheprocess
andin the operatingproceduresas specifiedin Sec. 68.69.Thetrainingshall includeemphasis
onthespecificsafetyand healthhazards,emergencyoperationsincludingshutdown,and safe
workpracticesapplicableto theemployee'sjobtasks.
(2) Inlieu ofinitial trainingfor thoseemployeesalreadyinvolved in operatingaprocess on June21,
1999an owneroroperatormaycertifyin writingthattheemployeehas therequiredknowledge,
skills, and abilitiestosafelycarryoutthedutiesand responsibilitiesas specifiedin theoperating
procedures.
(b) Refreshertraining. Refreshertrainingshall beprovidedatleasteverythreeyears, andmoreoftenif
necessary,toeachemployeeinvolvedinoperatingaprocess to assurethattheemployeeunderstands
andadheres to thecurrentoperatingproceduresoftheprocess.Theowneroroperator,in consultation
with theemployeesinvolvedinoperatingtheprocess,shalldeterminethe appropriatefrequency of
refreshertraining.
(c) Trainingdocumentation. Theowneroroperatorshall ascertain thateachemployeeinvolvedin
operatingaprocesshas receivedandunderstoodthe trainingrequiredbythis paragraph. Theowner
oroperatorshallpreparearecord whichcontainstheidentityoftheemployee,thedateoftraining,
and themeans usedto verifythattheemployeeunderstoodthe training.
Sec. 68.73 Mechanicalintegrity.
(a) Application. Paragraph (b)through(f) ofthis ectionapplyto thefoHowi ngproces eqLlipm.ent:
(L) Pre ure yes el and toragetanks;
(2) Piping y terns (inc1uding pipingcomponent uch a vaJve);
(3) Reliefand ventsy ternsand device ;
(4) Emergencyshutdown ystem ;
(5) Control (incJuding l11orritoringdevke and en or ,alarm,and interlocks) and
(6) Punlps.
(b) Writtenprocedures. Theowneroroperatorshallestablishand implementwrittenproceduresto
maintaintheon-goingintegrityofprocessequipment.
(c) Trainingforprocessmaintenanceactivities.Theowneroroperatorshalltraineachemployee
involvedin maintainingtheon-goingintegrityofprocessequipmentin an overviewofthatprocess
and its hazards and in theproceduresapplicableto theemployee'sjobtasks to assurethatthe
enlployeecanperformthejobtasksin asafemanner.
d Inspectionand testing.
(]) In pecti 11. and test haJJ beperformed onproce equipment.
(2) Inspection andte tingprocedureLshallfollow recognizedandgenerallyaccepted good
engineeringpractice .
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(3) Thefrequencyofin pection andtest ofprocessequipmentsha11 beconsistent withapplkable
manufacturers' recommendationsand goodengineeringpractice ,andlnorefrequentlyif
detennined to benecessarybyprior operatingexperi ence.
(4) Theowneroroperator hall documenteachinspecti onand testthathas beenperformedon
proce equipment. Thedocumentation shall identify thedateoftheinspection ortest,thenanle
oftheper on whoperformedthe inspection ortest,theseri alnumberorother identifierofthe
equipn1entonwhichtheinspectionortestwasperformed,ade cri pti onofthein pection ortest
performed,andthe resultsof the in pectionor test.
(e) Equipmentdeficiencies. Theowneroroperatorshallcorrectdeficienciesinequipmentthatare
outsideacceptablelimits(definedbytheprocesssafetyinformationin Sec. 68.65)beforefurther use
orin asafeandtimelymannerwhennecessarymeansare takento assuresafeoperation.
() Quali tyassurance.
(1) In the construction ofnewpl ants andequipment, theowneroroperatorsha11 assure that
equipmentas iti fabricatedi sui t.ablefortheprocessapplicati on forwhi chtheywillbe used.
(2) Appropri atecheck and in pectionssball beperformedto assurethat equipn1ent j in taIled
properl yand consistent with designspecificationsand the manufacturer' in tructi ons.
(3) Theowneroroperator shall as ure that maintenancemateri als, sparepartsand equipmentare
suitable fortheproces applicationfor whichtheywillbe used.
Sec. 68.75 Managementofchange.
(a) Theowneroroperatorshallestablishand implementwrittenproceduresto managechanges(except
for"replacementsin kind") to processchemicals, technology,equipment,andprocedures;and,
changesto stationarysourcesthataffectacoveredprocess.
(b) Theproceduresshallassurethatthefollowingconsiderationsareaddressedpriorto anychange:
(1) Thetechnicalbasisfortheproposedchange;
(2) Impactofchangeon safetyand health;
(3) Modificationsto operatingprocedures;
(4) Necessarytimeperiodfor thechange;and,
(5) Authorizationrequirementsfor theproposedchange.
(c) Employeesinvolvedin operatingaprocessand maintenanceandcontractemployeeswhosejobtasks
willbeaffectedbyachangein theprocessshallbeinformedof, andtrainedin, thechangepriorto
start-upofthe processoraffectedpartofthe process.
(d) Ifachangecoveredbythis paragraphresultsin achangein theprocesssafetyinformationrequired
bySec. 68.65ofthis part, suchinformationshallbeupdatedaccordingly.
(e) Ifachangecoveredbythis paragraphresults in achangein theoperatingproceduresorpractices
requiredbySec. 68.69, suchproceduresorpracticesshallbeupdatedaccordingly.
Sec. 68.77 Pre-startupreview.
(a) Theowneroroperatorshallperformapre-startupsafetyreview for new stationarysourcesand for
modifiedstationarysourceswhen themodificationissignificantenoughto requireachangein the
processsafetyinformation.
(b) Thepre-startupsafetyreview shallconfirmthatpriorto theintroductionofregulatedsubstancesto a
process:
(1) Constructionandequipmentis in accordance with design
(2) Safety, operating,maintenance,andemergencyproceduresarein placeandareadequate;
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(3) Fornew stationarysources,aprocesshazardanalysis hasbeenperformedandrecommendations
havebeenresolvedorimplementedbeforestartup; andn10dified stationarysourcesmeetthe
requirementscontainedinmanagementofchange, Sec. 68.75.
(4) Trainingofeachemployeeinvolvedin operatingaprocesshas beencompleted.
Sec. 68.79 Complianceaudits.
(a) Theowneroroperatorshallcertifythattheyhaveevaluatedcompliancewiththeprovisionsofthis
subpartatleasteverythree yearsto verifythatproceduresandpracticesdevelopedunderthis subpart
are adequateand arebeingfollowed.
(b) Thecomplianceauditshallbeconductedbyatleastonepersonknowledgeableintheprocess.
(c) Areportofthefindings ofthe auditshallbedeveloped.
(d) Theowneroroperatorshallpromptlydetermineand documentan appropriateresponseto eachofthe
findings ofthecomplianceaudit, and documentthatdeficiencies havebeencorrected.
(e) Theowneroroperatorshallretainthe two(2) mostrecentcomplianceauditreports.
Sec. 68.81 Incidentinvestigation.
(a) Theowneroroperatorshallinvestigateeachincidentwhichresultedin, orcouldreasonablyhave
resultedin acatastrophicreleaseofaregulatedsubstance.
(b) An incidentinvestigationshallbeinitiatedas promptlyas possible,butnotlaterthan48hours
following theincident.
(c) Anincidentinvestigationteamshallbeestablishedandconsistofatleastonepersonknowledgeable
in theprocessinvolved,includingacontractemployeeiftheincidentinvolvedworkofthe
contractor, andotherpersonswith appropriateknowledgeandexperienceto thoroughlyinvestigate
and analyzetheincident.
(d) Areportshallbepreparedattheconclusionoftheinvestigationwhichincludesataminimum:
(1) Dateofincident;
(2) Dateinvestigationbegan;
(3) Adescriptionoftheincident;
(4) Thefactors thatcontributedto theincident; and,
(5) Anyrecommendationsresultingfrom theinvestigation.
(e) Theowneroroperatorshallestablishasystemtopromptlyaddress andresolvetheincidentreport
findings andrecommendations. Resolutionsandcorrectiveactionsshallbedocumented.
(f) Thereportshallbereviewedwithall affectedpersonnelwhosejobtasksarerelevantto theincident
findings includingcontractemployeeswhereapplicable.
(g) Incidentinvestigationreportsshallberetainedfor five years.
Sec. 68.83 Employeeparticipation.
(a) Theowneroroperatorshall developawrittenplanofactionregardingthe implementationofthe
employeeparticipationrequiredbythissection.
(b) Theowneroroperatorshallconsultwithemployeesandtheirrepresentativeson theconductand
developmentofprocess hazardsanalyses andon thedevelopmentoftheotherelementsofprocess
safetymanagementin this rule.
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(c) Theowneroroperatorshallprovidetoemployeesandtheirrepresentativesaccess to processhazard
analysesandto all otherinformationrequiredto bedevelopedunderthisrule.
Sec. 68.85 Hotwork permit.
(a) Theowneroroperatorshallissueahotwork permitforhotworkoperationsconductedonorneara
coveredprocess.
(b) Thepermitshalldocumentthatthefire preventionandprotectionrequirementsin 29CFR 1910.252(a)
havebeenimplementedpriorto beginningthehotworkoperations; itshallindicatethedate(s)
authorizedforhotwork; andidentifytheobjectonwhichhotwork is to be performed. Thepermit
shallbekeptonfile untilcompletionofthe hotworkoperations.
Sec. 68.87 Contractors.
(a) Application.Thissectionappliestocontractorsperformingmaintenanceorrepair, turnaround, major
renovation,orspecialtyworkonoradjacentto acoveredprocess. Itdoes notapplytocontractors
providingincidentalserviceswhichdonotinfluenceprocess safety, suchasjanitorial work, food and
drinkservices,laundry,deliveryorothersupplyservices.
(b) Owneroroperatorresponsibilities.
(1) Theowneroroperator,whenselectingacontractor,shallobtainandevaluateinformation
regardingthecontractowneroroperator'ssafetyperformanceand programs.
(2) Theowneroroperatorshallinformcontractowneroroperatoroftheknownpotentialfire,
explosion,ortoxicreleasehazardsrelated to thecontractor'sworkandtheprocess.
(3) Theowneroroperatorshallexplainto thecontractowneroroperatortheapplicableprovisionsof
subpartEofthis part.
(4) Theowneroroperatorshalldevelopandimplementsafeworkpracticesconsistentwith Sec.
68.69(d), to controltheentrance,presence,andexitofthecontractowneroroperatorand
contractemployeesin coveredprocessareas.
(5) Theowneroroperatorshallperiodicallyevaluatetheperformanceofthecontractowneror
operatorinfulfilling theirobligationsas specifiedin paragraph(c) ofthis section.
(c) Contractowneroroperatorresponsibilities.
(1) Thecontractowneroroperatorshallassurethateachcontractemployeeis trainedin the work
practices necessaryto safelyperformhis/herjob.
(2) Thecontractowneroroperatorshall assurethateachcontractemployeeisinstructedin the
known potentialfire, explosion, ortoxicreleasehazards relatedto his/herjobandtheprocess,
andtheapplicableprovisionsoftheemergencyactionplan.
(3) Thecontractowneroroperatorshall documentthateachcontractemployeehasreceivedand
understoodthetrainingrequiredbythis section. Thecontractowneroroperatorshallpreparea
record whichcontainstheidentityofthe contractemployee,thedateoftraining,andthe means
usedto verifythattheemployeeunderstood the training.
(4) Thecontractowneroroperatorshall assure thateachcontractemployeefollows thesafetyrules
ofthestationarysourceincludingthesafeworkpracticesrequiredbySec. 68.69(d).
(5) Thecontractowneroroperatorshalladvisetheowneroroperatorofanyuniquehazards
presentedbythecontractowneroroperator'swork, orofanyhazardsfoundbythecontract
owneroroperator'swork.
SubpartE- EmergencyResponse
Page 72 of132
Amanda Stephens
August 15,2011
Source: 61 FR31725,June20, 1996,unless otherwisenoted.
(a) Exceptas providedinparagraph(b) ofthis section, the owneroroperatorofastationarysourcewith
Program2and Program 3processesshallcomplywith therequirementsofSec. 68.95.
(b) Theowneroroperatorofstationarysourcewhoseemployees will notrespond to accidentalreleases
ofregulatedsubstancesneednotcomplywithSec. 68.95ofthispartprovided that theymeetthe
following:
(1) Forstationarysources withanyregulatedtoxicsubstanceheld in aprocessabovethethreshold
quantity, the stationarysourceis includedin thecommunityemergencyresponseplandeveloped
under42U.S.C. 11003;
(2) Forstationarysourceswithonlyregulatedflammable substancesheld in aprocessabovethe
thresholdquantity, theowneroroperatorhascoordinatedresponseactions with thelocalfire
department; and
(3) Appropriatemechanismsareinplaceto notifyemergencyresponders when thereis aneed for a
response.
Sec. 68.95 Emergencyresponseprogram.
(a) Theowneroroperatorshalldevelopand implementan emergencyresponseprogramfor thepurpose
ofprotectingpublichealthand theenvironment. Suchprogramshallincludethefollowingelen1ents:
(1) Anemergencyresponseplan, whichshallbemaintainedat the stationarysourceandcontainat
leastthefollowing elements:
(i) Proceduresfor informingthepublic and localemergencyresponseagenciesabout
accidental releases;
(ii) Documentationofproperfirst-aid andemergencymedicaltreatmentnecessaryto treat
accidental humanexposures;and
(iii)Proceduresand measuresforemergencyresponseafteran accidental releaseofaregulated
substance;
(2) Proceduresfortheuseofemergencyresponseequipmentand for itsinspection, testing, and
maintenance;
(3) Trainingforall employeesin relevantprocedures; and
(4) Procedures toreview and update, as appropriate, theemergencyresponseplanto reflectchanges
at thestationarysourceandensurethatemployeesare informedofchanges.
(b) Awrittenplanthatcomplieswith otherFederalcontingencyplan regulationsorisconsistentwiththe
approachin the NationalResponseTeam'sIntegratedContingencyPlan Guidance("OnePlan")and
that, amongothermatters, includesthe elementsprovidedin paragraph(a) ofthis section,shall
satisfythe requirementsofthis sectioniftheowneroroperatoralsocomplieswithparagraph(c) of
this section.
(c) Theemergencyresponseplandevelopedunderparagraph(a)(1)ofthis sectionshallbecoordinated
withthecommunityemergencyresponseplandevelopedunder42U.S.C. 11003. Upon requestofthe
localemergencyplanningcommitteeoremergencyresponseofficials,theowneroroperatorshall
promptlyprovideto thelocalemergencyresponseofficialsinforn1ationnecessaryfor developingand
implementingthecommunityemergencyresponseplan.
Page 73 of 132
August 15, 2011
Amanda Stephens
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SubpartF - RegulatedSubstancesfor AccidentalReleasePrevention
Sec. 68.100 Purpose.
Source: 59 FR4493,Jan. 31, 1994,unlessotherwisenoted.
Redesignatedat61 FR31717,June20, 1996.
Thissubpartdesignates substancestobelistedundersection 112(r)(3),(4), and(5) oftheCleanAirAct,
as amended,identifiestheirthresholdquantities,andestablishestherequiren1entsfor
petitioningto addordeletesubstancesfromthelist.
Sec. 68.115 Thresholddetermination.
(a) Athresholdquantityofaregulated substancelistedin Sec. 68.130is presentatastationarysourceif
thetotalquantityofthe regulatedsubstancecontainedinaprocessexceedsthethreshold.
(b) Forthepurposesofdeterminingwhethermorethan athresholdquantityofaregulatedsubstanceis
presentat thestationarysource,the followingexemptionsapply:
(1) Concentrationsofaregulatedtoxic substanceinamixture. Ifaregulatedsubstanceispresentin a
mixtureandtheconcentrationofthe substanceis belowonepercentbyweightofthemixture,
theamountofthesubstancein themixtureneed notbeconsideredwhendeterminingwhether
morethan athresholdquantityis presentatthe stationarysource. Exceptforoleum,toluene2,4-
diisocyanate, toluene2,6-diisocyanate,andtoluenediisocyanate (unspecifiedisomer),ifthe
concentrationoftheregulatedsubstancein themixtureisonepercentorgreaterbyweight,but
theowneroroperatorcan demonstratethatthepartialpressureoftheregulatedsubstancein the
mixture(solution) underhandlingorstorageconditionsin anyportionoftheprocessis lessthan
10millimetersofmercury (mmHg), the amountofthesubstancein themixturein thatportion
oftheprocessneednotbeconsideredwhendeterminingwhethermorethan athresholdquantity
is presentat thestationarysource. Theowneroroperatorshalldocumentthis partial pressure
measurementorestimate.
(2) Concentrationsofaregulatedflammablesubstancein amixture.
(i) General provision. Ifaregulatedsubstanceis presentin amixtureandtheconcentrationof
thesubstanceis belowonepercentbyweightofthemixture, the mixtureneednotbe
consideredwhendeterminingwhethermorethan athresholdquantityofthe regulated
substanceis presentatthestationarysource. Exceptas providedin paragraph(b)(2) (ii) and
(iii) ofthis section,iftheconcentrationofthesubstanceisonepercentorgreaterbyweight
ofthemixture, then, forpurposesofdeterminingwhetherathresholdquantityis presentat
thestationarysource,theentireweightofthe mixtureshallbetreatedas theregulated
substanceunless theowneroroperatorcan demonstratethatthemixtureitselfdoes nothave
aNationalFireProtectionAssociationflammabilityhazardratingof4. Thedemonstration
shall bein accordancewiththedefinitionofflammabilityhazardrating4in theNFPA704,
StandardSystemfor theIdentificationoftheHazardsofMaterialsforEmergency
Response,NationalFireProtectionAssociation, Quincy,MA, 1996. Availablefromthe
NationalFireProtection Association, 1BatterymarchPark,Quincy,MA02269-9101. This
incorporationbyreferencewas approvedbytheDirectoroftheFederalRegisterin
accordancewith5U.S.C. 552(a)and 1CFRpart51. Copiesmaybeinspectedatthe
EnvironmentalProtectionAgencyAirDocket(6102), Attn: DocketNo. A-96-08,
WatersideMall,401 M. St. SW.,WashingtonDC; oratthe OfficeofFederal Registerat
Page 74of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
800NorthCapitolSt.,NW,Suite700,Washington,DC. Boilingpointandflash pointshall
bedefined anddeterminedin accordance withNFPA30,FlammableandCombustible
LiquidsCode,NationalFireProtectionAssociation,Quincy,MA, 1996. Availablefrom the
NationalFireProtectionAssociation, 1BatterymarchPark, Quincy,MA02269-9101.This
incorporationbyreferencewas approvedbytheDirectoroftheFederalRegisterin
accordancewith5U.S.C. 552(a)and 1CFRpart51. Copiesmaybeinspectedat the
EnvironmentalProtectionAgencyAirDocket(6102),Attn: DocketNo. A-96-08,
WatersideMall,401 M. St. SW.,WashingtonDC;orat theOfficeofFederalRegisterat
800NorthCapitolSt.,NW., Suite700,Washington,DC. Theowneroroperatorshall
documenttheNationalFireProtectionAssociationflammabilityhazardrating.
(ii) Gasoline. Regulated substancesin gasoline,whenindistributionorrelatedstoragefor use
as fuel for internalcombustionengines,neednotbeconsideredwhendeternliningwhether
morethan athresholdquantityis presentat astationarysource.
(iii) Naturallyoccurringhydrocarbonmixtures. Priortoentryintoanaturalgas processingplant
orapetroleumrefiningprocessunit, regulatedsubstancesin naturallyoccurring
hydrocarbonmixtures neednotbeconsideredwhendeterminingwhethermorethan a
thresholdquantityis presentat astationarysource. Naturallyoccurringhydrocarbon
nlixturesincludeanycombinationofthefollowing: condensate,crudeoil, field gas,and
producedwater,eachas defined in Sec. 68.3 ofthis part.
(3) Articles. Regulatedsubstancescontainedin articles neednotbeconsideredwhendetermining
whethermorethanathresholdquantityis presentat thestationarysource.
(4) Uses. Regulatedsubstances,whenin usefor thefollowing purposes,neednotbeincludedin
determiningwhethermorethan athresholdquantityis presentat thestationarysource:
(i) Useas astructuralcomponentofthe stationarysource;
(ii) Useofproductsforroutinejanitorialmaintenance;
(iii) Usebyemployeesoffoods, drugs,cosmetics,orotherpersonalitemscontainingthe
regulatedsubstance; and
(iv) Useofregulatedsubstancespresentin processwaterornon-contactcoolingwateras drawn
from theenvironmentormunicipal sources,oruseofregulated substancespresentin air
usedeitheras compressedairoras partofcombustion.
(5) Activitiesinlaboratories.If aregulatedsubstanceis manufactured,processed, orusedin a
laboratoryat astationarysourceunderthesupervisionofatechnicallyqualifiedindividual as
definedinSec. 720.3(ee)ofthischapter,thequantityofthe substanceneednotbeconsideredin
determiningwhetherathresholdquantityispresent. Thisexemptiondoes not applyto:
(i) Specialtychemicalproduction;
(ii) Manufacture,processing,oruseofsubstancesinpilotplantscaleoperations; and
(iii) Activitiesconductedoutsidethelaboratory.
Sec. 68.120 Petition process.
(a) Anypersonmaypetitionthe Administratortomodify,byadditionordeletion, thelistofregulated
substancesidentifiedin Sec. 68.130. Basedon theinformationpresentedbythepetitioner, the
Administratormaygrantordenyapetition. .
(b) Asubstancemaybe addedto thelistif, in the caseofan accidentalrelease,itisknown to causeor
maybereasonablyanticipated to causedeath, injury,orserious adverseeffectsto humanhealthor
theenvironment.
Page 75 of 132
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ISPCalvertCity
(c) Asubstancemaybedeletedfrom thelistifadequatedataonthe healthandenvironmentaleffectsof
thesubstanceare availableto determinethatthesubstance, in thecaseofan accidentalrelease, is not
knowntocauseand maynotbereasonablyanticipatedtocausedeath,injury, orserious adverse
effectsto humanhealthortheenvironment.
(d) Nosubstanceforwhichanationalprimaryanlbientairqualitystandardhas beenestablishedshallbe
added to thelist. NosubstanceregulatedundertitleVIoftheClean AirAct, as amended, shallbe
added to thelist.
(e) Theburdenofproofis on thepetitionertodemonstratethatthecriteriafor additionand deletionare
nlet. Apetitionwillbedeniedifthisdemonstrationis notmade.
(f) TheAdministratorwillnotacceptadditionalpetitionsonthesanlesubstancefollowingpublicationof
afinal noticeofthedecisionto grantordenyapetition,unlessnewdatabecomesavailablethatcould
significantlyaffectthebasisfor thedecision.
(g) Petitionsto modifythelistofregulatedsubstancesmustcontainthefollowing:
(1) Nameand addressofthepetitionerandabriefdescriptionoftheorganization(s) thatthe
petitionerrepresents, ifapplicable;
(2) Name, address,and telephonenumberofacontactpersonforthe petition;
(3) Commonchemicalname(s),conlmonsynonym(s),ChemicalAbstractsServicenumber, and
chemicalformulaandstructure;
(4) Actionrequested (addordeleteasubstance);
(5) Rationalesupportingthepetitioner'sposition; thatis, howthe substancemeetsthecriteriafor
additionanddeletion. A shortsummaryofthe rationalemustbesubmittedalongwithamore
detailed narrative; and
(6) Supportingdata; thatis, thepetitionmustincludesufficientinformationto scientificallysupport
the requesttomodifythelist. Suchinformationshallinclude:
(i) Alistofall supportdocuments;
(ii) Documentationofliteraturesearchesconducted,including, butnotlimitedto, identification
ofthedatabase(s) searched, thesearchstrategy,datescovered, and printed results;
(iii)Effectsdata(animal, human,andenvironmentaltestdata) indicatingthepotentialfor death,
injury, orseriousadversehumanandenvironmentalimpactsfrom acuteexposurefollowing
an accidentalrelease; printedcopiesofthedatasources, in English, shouldbeprovided; and
(iv) Exposuredataorpreviousaccidenthistorydata,indicatingthepotentialforserious adverse
humanhealthorenvironmentaleffectsfroman accidental release. Thesedatamayinclude,
butarenotlimitedto, physicalandchemicalpropertiesofthesubstance,suchas vapor
pressure; modelingresults, includingdataand assumptionsused andmodeldocumentation;
andhistoricalaccidentdata,citingdatasources.
(h) Within 18 monthsofreceiptofapetition,theAdministratorshallpublishin theFederalRegistera
noticeeitherdenying thepetitionorgrantingthepetitionandproposingalisting.
Sec. 68.125 Exemptions.
Agriculturalnutrients. Anlmoniausedas an agricultural nutrient, when heldbyfarmers, is exemptfrom
all provisionsofthis part.
Sec. 68.126 Exclusion.
FlammableSubstances Used as FuelorHeldfor Saleas Fuel at Retail Facilities. Aflammable substance
listedinTables3and4 ofSec. 68.130is neverthelessexcludedfrom all provisionsof
Page 76 of 132
Amanda Stephens
August 15, 2011
ISPCalvertCity
thispartwhen thesubstanceis usedas afuel orheldfor saleas afuel ataretail facility.
Sec. 68.130 Listofsubstances.
(a) Regulatedtoxicand flammablesubstancesundersection 112(r)oftheCleanAirActarethe
substanceslistedinTables 1, 2, 3, and4. Thresholdquantitiesfor listedtoxic and flammable
substancesarespecifiedinthetables.
(b) Thebasisforplacingtoxic andflammablesubstanceson thelistofregulatedsubstancesare
explainedinthenotesto thelist.
Table 1 to Sec. 68.130 - List of Regulated Toxic
Substances and Threshold Quantities for Accidental Release Prevention
[Alphabetical Order - 77 Substances]
Threshold
Chemical name CAS No. quantity Basis for
(lbs) listing
Acrolein [2-Propenal] .......... 107-02-8 5,000 b
Acrylonitrile [2- 107-13-1 20,000 b
Propenenitrile] .
Acrylyl chloride [2-Propenoyl 814-68-6 5,000 b
chloride] .
Allyl alcohol [2-Propen-l-ol] .. 107-18-61 15,000 b
Allylamine [2-Propen-l-amine] .. 107-11-9 10,000 b
Ammonia (anhydrous) ............ 7664-41-7 10,000 a, b
Ammonia (conc 20% or greater) .. 7664-41-7 20,000 a, b
Arsenous trichloride........... 7784-34-1 15,000 b
Arsine......................... 7784-42-1 1,000 b
Boron trichloride [Borane, 10294-34-5 5,000 b
trichloro-] .
Boron trifluoride [Borane, 7637-07-2 5,000 b
trifluoro-].
Boron trifluoride compound with 353-42-4 15,000 b
methyl ether (1:1) [Boron,
trifluoro [oxybis [metane]]-,
T-4- .
Bromine........................ 7726-95-6 10,000 a, b
Carbon disulfide............... 75-15-0 20,000 b
Chlorine....................... 7782-50-5 2,500 a, b
Chlorine dioxide [Chlorine 10049-04-4 1,000 c
oxide (Cl02)].
Chloroform [Methane, trichloro- 67-66-3 20,000 b
] .
Chloromethyl ether [Methane, 542-88-1 1,000 b
oxybis[chloro-] .
Chloromethyl methyl ether 107-30-2 5,000 b
[Methane, chloromethoxy-].
Crotonaldehyde [2-Butenal] ..... 4170-30-3 20,000 b
Crotonaldehyde, (E) - [2- 123-73-9 20,000 b
Butenal, (E) -] .
Cyanogen chloride.............. 506-77-4 10,000 c
Cyclohexylamine 108-91-8 15,000 b
[Cyclohexanamine] .
Diborane....................... 19287-45-7 2,500 b
Dimethyldichlorosilane [Silane, 75-78-5 5,000 b
Page77of132
Amanda Stephens
August 15, 2011
dichlorodimethyl-] .
l,l-Dimethylhydrazine
[Hydrazine, l,l-dimethyl-].
Epichlorohydrin [Oxirane,
(chloromethyl)-] .
Ethylenediamine [1,2-
Ethanediamine] .
Ethyleneimine [Aziridine] ......
Ethylene oxide [Oxirane] .......
Fluorine.......................
Formaldehyde (solution) ........
Furan..........................
Hydrazine......................
Hydrochloric acid (conc 37% or
greater) .
Hydrocyanic acid...............
Hydrogen chloride (anhydrous)
[Hydrochloric acid] .
Hydrogen fluoride/Hydrofluoric
acid (conc 50% or greater)
[Hydrofluoric acid] .
Hydrogen selenide..............
Hydrogen sulfide...............
Iron, pentacarbonyl- [Iron
carbonyl (Fe(CO) 5), (TB-5-11)-
] .
Isobutyronitrile
[Propanenitrile, 2-methyl-].
Isopropyl chloroformate
[Carbonochloridic acid, 1-
methyl ethyl ester] .
Methacrylonitrile [2-
Propenenitrile, 2-methyl-].
Methyl chloride [Methane,
chloro-] .
Methyl chloroformate
[Carbonochloridic acid,
methylester] .
Methyl hydrazine [Hydrazine,
methyl-] .
Methyl isocyanate [Methane,
isocyanato-] .
Methyl mercaptan [Methanethiol]
Methyl thiocyanate [Thiocyanic
acid, methyl ester] .
Methyltrichlorosilane [Silane,
trichloromethyl-] .
Nickel carbonyl................
Nitric acid (conc 80% or
greater) .
Nitric oxide [Nitrogen oxide
(NO)] .
Oleum (Fuming Sulfuric acid)
[Sulfuric acid, mixture with
sulfur trioxide] \1\.
Peracetic acid [Ethaneperoxoic
acid] .
Perchloromethylmercaptan
57-14-7
106-89-8
107-15-3
151-56-4
75-21-8
7782-41-4
50-00-0
110-00-9
302-01-2
7647-01-0
74-90-8
7647-01-0
7664-39-3
7783-07-5
7783-06-4
13463-40-6
78-82-0
108-23-6
126-98-7
74-87-3
79-22-1
60-34-4
624-83-9
74-93-1
556-64-9
75-79-6
13463-39-3
7697-37-2
10102-43-9
8014-95-7
79-21-0
594-42-3
Page 78 of 132
15,000
20,000
20,000
10,000
10,000
1,000
15,000
5,000
15,000
15,000
2,500
5,000
1,000
500
10,000
2,500
20,000
15,000
10,000
10,000
5,000
15,000
10,000
10,000
20,000
5,000
1,000
15,000
10,000
10,000
10,000
10,000
b
b
b
b
a, b
b
b
b
b
d
a, b
a
a, b
b
a, b
b
b
b
b
a
b
b
a, b
b
b
b
b
b
b
e
b
b
Amanda Stephens
August 15, 2011
[Methanesulfenyl chloride,
trichloro-].
Phosgene [Carbonic dichloride] . 75-44-5 500 a, b
Phosphine...................... 7803-51-2 5,000 b
Phosphorus oxychloride 10025-87-3 5,000 b
[Phosphoryl chloride] .
Phosphorus trichloride 7719-12-2 15,000 b
[Phosphorous trichloride].
Piperidine..................... 110-89-4 15,000 b
Propionitrile [Propanenitrile] 107-12-0 10,000 b
Propyl chloroformate 109-61-5 15,000 b
propylester] .
Propyleneimine [Aziridine, 2- 75-55-8 10,000 b
methyl-] .
Propylene oxide [Oxirane, 75-56-9 10,000 b
methyl-] .
Sulfur dioxide (anhydrous) 7446-09-5 5{000 a{ b
Sulfur tetrafluoride [Sulfur 7783-60-0 2,500 b
fluoride (SF4), (T-4) -].
Sulfur trioxide.......... ...... 7446-11-9 10,000 a, b
Tetramethyllead [Plumbane, 75-74-1 10,000 b
tetramethyl-] .
Tetranitromethane [Methane, 509-14-8 10,000 b
tetrani tro-] .
Titanium tetrachloride 7550-45-0 2,500 b
[Titanium chloride (TiC14) (T-
4) -] .
Toluene 2,4-diisocyanate 584-84-9 10,000 a
[Benzene, 2,4-diisocyanato-1-
methyl-] \1\.
Toluene 2,6-diisocyanate 91-08-7 10{000 a
[Benzene, l,3-diisocyanato-2-
methyl-] \1\.
Toluene diisocyanate 26471-62-5 10,000 a
(unspecified isomer) [Benzene,
l,3-diisocyanatomethyl-] \1\.
Trimethylchlorosilane [Silane, 75-77-4 10{000 b
chlorotrimethyl-] .
Vinyl acetate monomer [Acetic 108-05-4 15,000 b
acid ethenyl ester] .
\1\ The mixture exemption in Sec. 68.115(b) (1) does not apply to the substance.
Note: Basis for Listing:
a Mandated for listing by Congress.
b On EHS list, vapor pressure 10 mmHg or greater.
c Toxic gas.
d Toxicity of hydrogen chloride, potential to release hydrogen chloride,
and history of accidents.
e Toxicity of sulfur trioxide and sulfuric acid, potential to release
sulfur trioxide, and history of accidents.
Table 2 to Sec. 68.130 - List of Regulated Toxic
Substances and Threshold Quantities for Accidental Release Prevention
[CAS Number Order - 77 Substances]
Threshold
Page 79 of 132
August 15, 2011
CAS No.
50-00-0................
57-14-7................
60-34-4................
67-66-3................
74-87-3................
74-90-8................
74-93-1................
75-15-0................
75-21-8................
75-44-5................
75-55-8................
75-56-9................
75-74-1................
75-77-4................
75-78-5................
75-79-6................
78-82-0................
79-21-0................
79-22-1................
91-08-7................
106-89-8...............
107-02-8.. . . . . . . . . . . . ..
107-11-9............."
Chemical name
Formaldehyde
(solution) .
l,l-Dimethylhydrazine
[Hydrazine, 1,1-
dimethyl-] .
Methyl hydrazine
[Hydrazine, methyl-]
Chloroform [Methane,
trichloro-].
Methyl chloride
[Methane, chloro-].
Hydrocyanic acid......
Methyl mercaptan
[Methanethiol] .
Carbon disulfide......
Ethylene oxide
[Oxirane] .
Phosgene [Carbonic
dichloride] .
Propyleneimine
[Aziridine, 2-methyl-
] .
Propylene oxide
[Oxirane, methyl-].
Tetramethyllead
[Plumbane,
tetramethyl-] .
Trimethylchlorosilane
[Silane,
chlorotrimethyl-] .
Dimethyldichlorosilane
[Silane,
dichlorodimethyl-] .
Methyltrichlorosilane
[Silane,
trichloromethyl- J .
Isobutyronitrile
[Propanenitrile, 2-
methyl-] .
Peracetic acid
[Ethaneperoxoic acid] .
[Carbonochloridic
acid, methylester].
Toluene 2,6-
diisocyanate
[Benzene, 1,3-
diisocyanato-2-methyl-
J\l\.
Epichlorohydrin
[Oxirane,
(chloromethyl)-J.
Acrolein [2-PropenalJ.
Allylamine [2-Propen-1-
amine] .
Page 80 of 132
quantity
(lbs)
15,000
15,000
15,000
20,000
10,000
2,500
10,000
20,000
10,000
500
10,000
10,000
10,000
10,000
5,000
5,000
20,000
10,000
5,000
10,000
20,000
5,000
10,000
Amanda Stephens
ISP Calvert City
Basis for
listing
b
b
b
b
a
a, b
b
b
a, b
a, b
b
b
b
b
b
b
b
b
b
a
b
b
b
August 15, 2011
107-12-0. . . . . . . . . . . . . .. Propionitrile 10,000
[Propanenitrile] .
107 -13 -1. . . . . . . . . . . . . . . Acrylonitrile [2- 20,000
Propenenitrile] .
107-15-3 ............... Ethylenediamine [1,2- 20,000
Ethanediamine] .
107-18-6 .............. , Allyl alcohol [2- 15,000
Propen-1-ol] .
107-30-2............... Chloromethyl methyl 5,000
ether [Methane,
chloromethoxy-] .
108-05-4 ............... Vinyl acetate monomer 15,000
[Acetic acid ethenyl
ester] .
108-23-6. . . . . . . . . . . . . .. Isopropyl 15,000
chloroformate
[Carbonochloridic
acid, l-methylethyl
ester] .
108-91-8............... Cyclohexylamine 15,000
[Cyclohexanamine] .
109-61-5............... Propyl chloroformate 15,000
[Carbonochloridic
acid, propylester].
110- 00- 9. . . . . . . . . . . . . .. Furan ................ . 5,000
110-89-4............... Piperidine ........... . 15,000
123-73-9 ............... Crotonaldehyde, (E)- 20,000
[2-Butenal, (E)-].
126-98-7 ............... Methacrylonitrile [2- 10,000
Propenenitrile, 2-
methyl-] .
151-56-4............... Ethyleneimine 10,000
[Aziridine] .
302-01-2............... Hydrazine ............ . 15,000
353-42-4............... Boron trifluoride 15,000
compound with methyl
ether (1:1) [Boron,
trifluoro[oxybis[meth
ane]]-, T-4-.
506-77-4............ . .. Cyanogen chloride ..... 10,000
509-14-8............... Tetranitromethane 10,000
[Methane, tetranitro-
] .
542-88-1............... Chloromethyl ether 1,000
[Methane,
oxybis[chloro-] .
556-64-9.......... . .... Methyl thiocyanate 20,000
[Thiocyanic acid,
methyl ester] .
584-84-9............... Toluene 2,4- 10,000
diisocyanate
[Benzene, 2,4-
diisocyanato-1-methyl-
]\1\.
594-42-3............... Perchloromethylmercapt 10,000
an [Methanesulfenyl
chloride, trichloro-].
624-83-9............... Methyl isocyanate 10,000
Page 81 of 132
Amanda Stephens
ISP Calvert City
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
b
c
b
b
b
a
b
a, b
August 15, 2011
814-68-6...............
4170-30-3..............
7446-09-5..............
7446-11-9..............
7550-45-0..............
7637-07-2..............
7647-01-0..............
7647-01-0..............
7664-39-3..............
7664-41-7..............
7664-41-7..............
7697-37-2..............
7719-12-2..............
7726-95-6..............
7782-41-4..............
7782-50-5..............
7783-06-4..............
7783-07-5..............
7783-60-0..............
7784-34-1..............
7784-42-1..............
7803-51-2..............
8014-95-7..............
10025-87-3.............
10049-04-4.............
10102-43-9.............
10294-34-5.............
13463-39-3.............
13463-40-6.............
[Methane, isocyanato-
] .
Acrylyl chloride [2-
Propenoyl chloride] .
Crotonaldehyde [2-
Butenal] .
Sulfur dioxide
(anhydrous) .
Sulfur trioxide.......
Titanium tetrachloride
[Titanium chloride
(TiC14) (T-4)-] .
Boron trifluoride
[Borane, trifluoro-].
Hydrochloric acid
(conc 37% or greater) .
Hydrogen chloride
(anhydrous)
Hydrogen fluoride/
Hydrofluoric acid
(conc 50% or greater)
Ammonia (anhydrous) ...
Ammonia (conc 20% or
greater) .
Nitric acid (conc 80%
or greater) .
Phosphorus trichloride
[Phosphorous
trichloride] .
Bromine...............
Fluorine..............
Chlorine..............
Hydrogen sulfide......
Hydrogen selenide.....
Sulfur tetrafluoride
[Sulfur fluoride
(SF4), (T-4) -] .
Arsenous trichloride..
Arsine................
Phosphine.............
Oleum (Fuming Sulfuric
acid) [Sulfuric acid,
mixture with sulfur
trioxide]\1\.
Phosphorus oxychloride
Chlorine dioxide
[Chlorine oxide
(CI02)] .
Nitric oxide [Nitrogen
oxide (NO)].
Boron trichloride
[Borane, trichloro-].
Nickel carbonyl.......
Iron, pentacarbonyl-
[Iron carbonyl
Page 82 of 132
5,000
20,000
5,000
10,000
2,500
5,000
15,000
5,000
1,000
10,000
20,000
15,000
15,000
10,000
1,000
2,500
10,000
500
2,500
15,000
1,000
5,000
10,000
5,000
1,000
10,000
5,000
1,000
2,500
Amanda Stephens
ISP Calvert City
b
b
a, b
a, b
b
b
d
a
a, b
a, b
a, b
b
b
a, b
b
a, b
a, b
b
b
b
b
b
e
b
c
b
b
b
b
Amanda Stephens
August 15, 2011
(Fe(CO) 5), (TB-5-11)-
] .
19287-45-7.. . . . . . . . . . .. Diborane.............. 2,500 b
26471-62-5............. Toluene diisocyanate 10,000 a
(unspecified isomer)
[Benzene, 1,3-
diisocyanatomethyl-
1]\1\.
\1\ The mixture exemption in Sec. 68.115(b) (1) does not apply to the substance.
b On EHS list, vapor pressure 10 mmHg or greater.
c Toxic gas.
d Toxicity of hydrogen chloride, potential to release hydrogen chloride,
and history of accidents.
e Toxicity of sulfur trioxide and sulfuric acid, potential to release
sulfur trioxide, and history of accidents.
Table 3 to Sec. 68.130 - List of Regulated
Flammable Substances \1\ and Threshold Quantities for Accidental Release
Prevention
[Alphabetical Order - 63 Substances]
Threshold
Chemical name CAS No. quantity Basis for
(lbs) listing
Acetaldehyde................... 75-07-0 10,000 g
Acetylene [Ethyne] ............. 74-86-2 10,000 f
Bromotrifluorethylene [Ethene, 598-73-2 10,000 f
bromotrifluoro-] .
1,3-Butadiene.................. 106-99-0 10,000 f
[[Page 183]]
Butane......................... 106-97-8 10,000 f
1-Butene......... .............. 106-98-9 10,000 f
2-Butene....................... 107-01-7 10,000 f
Butene......................... 25167-67-3 10,000 f
2-Butene-cis................... 590-18-1 10,000 f
2-Butene-trans [2-Butene, (E)]. 624-64-6 10,000 f
Carbon oxysulfide [Carbon oxide 463-58-1 10,000 f
sulfide (COS)].
Chlorine monoxide [Chlorine 7791-21-1 10,000 f
oxide] .
2-Chloropropylene [l-Propene, 2- 557-98-2 10,000 g
chloro-] .
1-Chloropropylene [l-Propene, 1- 590-21-6 10,000 g
chloro-] .
Cyanogen [Ethanedinitrile]..... 460-19-5 10,000 f
Cyclopropane................... 75-19-4 10,000 f
Dichlorosilane [Silane, 4109-96-0 10,000 f
dichloro-] .
Difluoroethane [Ethane, 1,1- 75-37-6 10,000 f
difluoro-] .
Page 83 of 132
Amanda Stephens
August 15, 2011
Dimethylamine [Methanamine, N- 124-40-3 10,000 f
methyl-] .
2,2-Dimethylpropane [Propane, 463-82-1 10,000 f
2,2-dimethyl-] .
Ethane ........................ . 74-84-0 10,000 f
Ethyl acetylene [l-Butyne] .... . 107-00-6 10,000 f
Ethylamine [Ethanamine] ....... . 75-04-7 10,000 f
Ethyl chloride [Ethane, chloro- 75-00-3 10,000 f
] .
Ethylene [Ethene] ............. . 74-85-1 10,000 f
Ethyl ether [Ethane, 1,1' 60-29-7 10,000 9
-oxybis-] .
Ethyl mercaptan [Ethanethiol] .. 75-08-1 10,000 9
Ethyl nitrite [Nitrous acid, 109-95-5 10,000 f
ethyl ester] .
Hydrogen ...................... . 1333-74-0 10,000 f
Isobutane [Propane, 2-methyl] .. 75-28-5 10,000 f
Isopentane [Butane, 2-methyl-]. 78-78-4 10,000 9
Isoprene [1,3-Butadinene, 2- 78-79-5 10,000 9
methyl-] .
Isopropylamine [2-Propanamine]. 75-31-0 10,000 9
Isopropyl chloride [Propane, 2- 75-29-6 10,000 9
chloro-] .
Methane ....................... . 74-82-8 10,000 f
Methylamine [Methanamine] ..... . 74-89-5 10,000 f
3-Methyl-1-butene ............. . 563-45-1 10,000 f
2-Methyl-1-butene ............. . 563-46-2 10,000 9
Methyl ether [Methane, oxybis-] 115-10-6 10,000 f
Methyl formate [Formic acid, 107-31-3 10,000 9
methyl ester] .
2-Methylpropene [l-Propene, 2- 115-11-7 10,000 f
methyl-] .
1,3-Pentadinene ............... . 504-60-9 10,000 f
Pentane ....................... . 109-66-0 10,000 9
1- Pentene ..................... . 109-67-1 10,000 9
2 - Pentene, (E) - ............... . 646-04-8 10,000 9
2-Pentene, (Z) - ............... . 627-20-3 10,000 9
Propadiene [1,2-Propadiene] ... . 463-49-0 10,000 f
Propane ....................... . 74-98-6 10,000 f
Propy1ene [ 1 - Propene] ......... . 115-07-1 10,000 f
Propyne [l-Propyne] ........... . 74-99-7 10,000 f
Silane ........................ . 7803-62-5 10,000 f
Tetrafluoroethylene [Ethene, 116-14-3 10,000 f
tetrafluoro-] .
Tetramethylsilane [Silane, 75-76-3 10,000 9
tetramethyl-] .
Trichlorosilane [Silane, 10025-78-2 10,000 9
trichloro-] .
Trifluorochloroethylene 79-38-9 10,000 f
[Ethene, chlorotrifluoro-].
Trimethylamine [Methanamine, 75-50-3 10,000 f
N,N-dimethyl-] .
Vinyl acetylene [1-Buten-3-yne] 689-97-4 10,000 f
Vinyl chloride [Ethene, chloro- 75-01-4 10,000 a, f
] .
Vinyl ethyl ether [Ethene, 109-92-2 10,000 9
ethoxy-] .
Vinyl fluoride [Ethene, fluoro- 75-02-5 10,000 f
Page 84 of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
] .
Vinylidene chloride [Ethene, 75-35-4 10,000 g
1,1-dichloro-].
Vinylidene fluoride [Ethene, 75-38-7 10,000 f
1,1-difluoro-].
Vinyl methyl ether [Ethene, 107-25-5 10,000 f
methoxy-] .
\1\ A flammable substance when used as a fuel or held for sale as a fuel
at a retail facility is excluded from all provisions of this part (see
Sec. 68.126).
f Flammable gas.
9 Volatile flammable liquid.
Table 4 to Sec. 68.130 - List of Regulated Flammable Substances \1\ and Threshold
Quantities for Accidental Release Prevention
[CAS Number Order - 63 Substances]
Threshold
CAS No. Chemical name CAS No.
quantity Basis for listing
(lbs)
60-29-7........................ Ethyl ether [Ethane, 60-29-7
10,000 g
1,1[prime]-oxybis-] .
74-82-8.. . . . . . . . . . . . . . . . . . . . . .. Methane....................... 74-82-8
10,000 f
74-84-0.. . . . . . . . . . . . . . . . . . . . . .. Ethane........................ 74-84-0
10,000 f
74-85-1. . . . . . . . . . . . . . . . . . . . . . .. Ethylene [Ethene] ............. 74-85-1
10,000 f
74-86-2. . . . . . . . . . . . . . . . . . . . . . .. Acetylene [Ethyne] ............ 74-86-2
10,000 f
74- 89- 5. . . . . . . . . . . . . . . . . . . . . . .. Methylamine [Methanamine] ..... 74-89-5
10,000 f
74- 98- 6. . . . . . . . . . . . . . . . . . . . . . .. Propane....................... 74-98-6
10,000 f
74- 99-7. . . . . . . . . . . . . . . . . . . . . . .. Propyne [1- Propyne] ........... 74-99-7
10,000 f
75-00-3.. . . . . . . . . . . . . . . . . . . . . .. Ethyl chloride [Ethane, chloro- 75-00-3
10,000 f
] .
75-01-4........................ Vinyl chloride [Ethene, chloro- 75-01-4
10,000 a, f
] .
75-02-5............... ......... Vinyl fluoride [Ethene, fluoro- 75-02-5
10,000 f
] .
75-04-7.. . . . . . . . . . . . . . . . . . . . . .. Ethylamine [Ethanamine] ....... 75-04-7
10,000 f
Page 85 of 132
August 15, 2011
75-07-0.......................,
10,000 9
75-08-1........................
10,000 9
75-19-4.. . . . . . . . . . . . . . . . . . . . . ..
10,000 f
75-28-5........................
10,000 f
75-29-6........................
10,000 9
75-31-0........................
10,000 9
75-35-4........................
10,000 9
75-37-6........................
10,000 f
75-38-7........................
10,000 f
75-50-3........................
10,000 f
75-76-3........................
10,000 9
78-78-4........................
10,000 9
78-79-5........................
10,000 9
79-38-9........................
10,000 f
106-97-8.......................
10,000 f
106-98-9.......................
10,000 f
196-99-0.......................
10,000 f
107-00-6.......................
10,000 f
107-01-7.......................
10,000 f
107-25-5.......................
10,000 f
107-31-3.......................
10,000 9
109-66-0.......................
10,000 9
109-67-1.. . . . . . . . . . . . . . . . . . . . ..
10,000 9
109-92-2.......................
10,000 9
Acetaldehyde..................
Ethyl mercaptan [Ethanethiol].
Cyclopropane..................
Isobutane [Propane, 2-methyl].
Isopropyl chloride [Propane, 2-
chloro-] .
Isopropylamine [2-Propanamine]
Vinylidene chloride [Ethene,
I,1-dichloro-].
Difluoroethane [Ethane, 1,1-
di fl uoro-] .
Vinylidene fluoride [Ethene,
I,1-difluoro-].
Trimethylamine [Methanamine,
N, N-dimethyl-].
Tetramethylsilane [Silane,
tetramethyl-] .
Isopentane [Butane, 2-methyl-]
Isoprene [l,3,-Butadiene, 2-
methyl-] .
Trifluorochloroethylene
[Ethene, chlorotrifluoro-].
Butane........................
I-Butene......................
1,3-Butadiene.................
Ethyl acetylene [l-Butyne] ....
2-Butene......................
Vinyl methyl ether [Ethene,
methoxy-] .
Methyl formate [Formic acid,
methyl ester].
Pentane.......................
1-Pentene.....................
Vinyl ethyl ether [Ethene,
Page 86 of 132
Amanda Stephens
ISP Calvert City
75-07-0
75-08-1
75-19-4
75-28-5
75-29-6
75-31-0
75-35-4
75-37-6
75-38-7
75-50-3
75-76-3
78-78-4
78-79-5
79-38-9
106-97-8
106-98-9
106-99-0
107-00-6
107-01-7
107-25-5
107-31-3
109-66-0
109-67-1
109-92-2
August 15, 2011
109-95-5.......................
10,000 f
115-07-1.... ...................
10,000 f
115-10-6.......................
10,000 f
115-11-7.................. .....
10,000 f
116-14-3.......................
10,000 f
124-40-3.......................
10,000 f
460-19-5.......................
10,000 f
463-49-0.......................
10,000 f
463-58-1.......................
10,000 f
463-82-1.......................
10,000 f
504-60-9.......................
10,000 f
557-98-2.................... ...
10,000 9
563-45-1.......................
10,000 f
563-46-2.......................
10,000 9
590-18-1.. . . . . . . . . . . . . . . . . . . . ..
10,000 f
590-21-6.......................
10,000 9
598-73-2...... .................
10,000 f
624-64-6.......................
10,000 f
627-20-3............ ...........
10,000 9
646-04-8.......................
10,000 9
689-97-4.......................
10,000 f
1333-74-0......................
10,000 f
4109-96-0......................
10,000 f
ethoxy-] .
Ethyl nitrite [Nitrous acid,
ethyl ester].
Propylene [l-Propene] .........
Methyl ether [Methane, oxybis-
] .
2-Methylpropene [l-Propene, 2-
methyl-] .
Tetrafluoroethylene [Ethene,
tetrafluoro-].
Dimethylamine [Methanamine, N-
methyl-] .
Cyanogen [Ethanedinitrile]....
Propadiene [1,2-Propadiene] ...
Carbon oxysulfide [Carbon
oxide sulfide (COS)].
2,2-Dimethylpropane [Propane,
2,2-dimethyl-] .
1,3-Pentadiene...... ..........
2-Chloropropylene [l-Propene,
2- chloro-] .
3-Methyl-1-butene.............
2-Methyl-1-butene......... ....
2-Butene-cis.......... ........
1-Chloropropylene [l-Propene,
1-chloro-] .
Bromotrifluorethylene [Ethene,
bromotrifluoro-] .
2-Butene-trans [2-Butene, (E)]
2-Pentene, (Z) - ...............
2- Pentene, (E) - ....... ........
Vinyl acetylene [1-Buten-3-
yne] .
Hydrogen......................
Dichlorosilane [Silane,
Page 87 of 132
Amanda Stephens
ISP Calvert City
109-95-5
115-07-1
115-10-6
115-11-7
116-14-3
124-40-3
460-19-5
463-49-0
463-58-1
463-82-1
504-60-9
557-98-2
563-45-1
563-46-2
590-18-1
590-21-6
598-73-2
624-64-6
627-20-3
646-04-8
689-97-4
1333-74-0
4109-96-0
Amanda Stephens
August 15, 2011
ISP Calvert City
dichloro-] .
7791-21-1...................... Chlorine monoxide [Chlorine 7791-21-1
10,000 f
oxide] .
7803- 62- 5. . . . . . . . . . . . . . . . . . . . .. Si1ane........................ 7803-62-5
10,000 f
10025-78-2..................... Trichlorosilane 10025-78-2
10,000 g
[Silane,trichloro-].
25167-67-3. . . . . . . . . . . . . . . . . . . .. Butene........................ 25167-67-3
10,000 f
\1\ A flammable substance when used as a fuel or held for sale as a fuel at a retail
facility is excluded from
all provisions of this part (see Sec. 68.126).
f Flammable gas.
g Volatile flammable liquid.
SubpartG- RiskManagementPlan
Sec. 68.150 Submission.
Source: 61 FR31726,June20, 1996,unless otherwisenoted.
(a) Theowneroroperatorshall submitasingleRMPthatincludes the informationrequiredbySec.Sec.
68.155 through68.185forall coveredprocesses. TheRMPshall besubmittedinamethodand
formatto acentralpointas specifiedbyEPApriorto June21, 1999.
(b) Theowneroroperatorshall submitthefirstRMPno laterthanthelatestofthefollowingdates:
(1) June21, 9 9 9 ~
(2) Threeyears afterthe dateonwhicharegulatedsubstanceis firstlistedunderSec. 68.130;or
(3) Thedateonwhicharegulatedsubstanceis firstpresentaboveathresholdquantityin aprocess.
(c) SubsequentsubmissionsofRMPs shallbein accordancewithSec. 68.190.
(d) NotwithstandingtheprovisionsofSec.Sec. 68.155 to 68.190,the RMPshallexcludeclassified
information.Subjectto appropriateproceduresto protectsuchinformationfrompublic
disclosure,classifieddataorinformationexcludedfrom theRMPmaybemadeavailablein a
classifiedannex to the RMPforreviewbyFederalandstaterepresentatives who havereceived
the appropriatesecurity clearances.
(e) Proceduresforassertingthatinformationsubmittedinthe RMPis entitledto protectionas
confidentialbusinessinformationare setforth inSec.Sec. 68.151 and 68.152.
Sec. 68.151 Assertionofclaimsofconfidentialbusinessinfornlation.
(a) Exceptas providedinparagraph(b) ofthis section, an owneroroperatorofastationarysource
requiredtoreportorotherwiseprovideinformationunderthispartmaymakeaclaimofconfidential
business information for any such informationthatmeetsthe criteriasetforth in 40CFR 2.301.
(b) Notwithstandingtheprovisionsof40CFRpart2, an owneroroperatorofastationarysourcesubject
to this partmaynotclaimas confidentialbusinessinformationthefollowinginformation:
Page 88 of 132
Amanda Stephens
August 15, 2011
(1) RegistrationdatarequiredbySec. 68.160(b)(l)through (b)(6) and (b)(8), (b)(10) through(b)(13)
andNAICS codeand Programlevel oftheprocesssetforth in Sec. 68.160(b)(7);
(2) Offsiteconsequenceanalysis datarequiredbySec. 68.165(b)(4),(b)(9), (b)(10), (b)(11), and
(b)(12).
(3) AccidenthistorydatarequiredbySec. 68.168;
(4) PreventionprogramdatarequiredbySec. 68.170(b),(d), (e)(1), (f)through(k);
(5) PreventionprogramdatarequiredbySec. 68.175(b), (d), (e)(1), (f)through(p); and
(6)EmergencyresponseprogramdatarequiredbySec. 68.180.
(c) Notwithstandingtheproceduresspecifiedin 40CFRpart2, an owneroroperatorassertingaclaimof
CBIwithrespectto inforn1ationcontainedinitsRMP,shallsubmittoEPAatthetimeitsubmitsthe
RMPthe following:
(l)Theinformationclaimedconfidential,providedin aformat to bespecifiedbyEPA;
(2) Asanitized(redacted)copyoftheRMP, withthenotation"CBI"substitutedfortheinformation
claimedconfidential,exceptthatagenericcategoryorclassnameshallbesubstitutedfor any
chemicalnameoridentityclaimedconfidentialand
(3) Thedocumentordocumentssubstantiatingeachclaimofconfidentialbusinessinformation, as
describedinSec. 68.152.
Sec. 68.152 Substantiatingclaimsofconfidentialbusinessinformation.
(a) An owneroroperatorclaimingthatinformationisconfidentialbusinessinformationmust
substantiatethatclaimbyprovidingdocumentationthatdemonstratesthattheclaimmeets the
substantivecriteriasetforthin 40CFR2.30l.
(b) Informationthatissubmittedas partofthesubstantiationmaybeclaimedconfidentialbymarkingit
as confidentialbusinessinformation. Informationnotso markedwill betreatedas publicandmaybe
disclosed withoutnoticetothe submitter. Ifinformationthatissubmittedas partofthe substantiation
isclain1ed confidential, theowneroroperatormustprovideasanitizedand unsanitized versionofthe
substantiation.
(c) Theowner,operator,orseniorofficialwithmanagementresponsibilityofthe stationarysourceshall
signacertificationthatthesignerhaspersonallyexaminedtheinformationsubmittedand thatbased
on inquiryofthepersonswhocompiledthe information,theinformationis true, accurate, and
complete,and thatthoseportionsofthesubstantiationclaimedas confidentialbusinessinformation
would, ifdisclosed, reveal trade secretsorotherconfidentialbusinessinformation.
Sec.68.155 Executivesummary.
Theowneroroperatorshallprovidein theRMPan executivesummarythatincludesabriefdescriptionof
thefollowingelements:
(a) Theaccidental releasepreventionandemergencyresponsepoliciesatthe stationarysource;
(b) Thestationarysourceand regulatedsubstanceshandled;
(c) Theworst-casereleasescenario(s) and thealternativerelease scenario(s),includingadministrative
controlsandmitigation measuresto limitthedistancesforeachreportedscenario;
(d) Thegeneral accidentalreleasepreventionprogramandchemical-specificpreventionsteps;
(e) Thefive-yearaccidenthistory;
(f) Theemergencyresponseprogram; and
(g) Plannedchangesto improvesafety.
Page 89 of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
Sec. 68.160 Registration.
(a) Theowneroroperatorshallcompleteasingleregistrationformandincludeitin the RMP.Thefornl
shallcoverall regulatedsubstanceshandledin coveredprocesses.
(b) Theregistration shall includethefollowing data:
(1) Stationarysourcename, street,city,county,state,zipcode,latitudeandlongitude,methodfor
obtaininglatitudeandlongitude, anddescription oflocationthatlatitudeandlongitude
represent;
(2)ThestationarysourceDunand Bradstreetnumber;
(3)NameandDunandBradstreetnumberofthecorporateparentcompany;
(4) Thename, telephonenumber, andmailingaddressoftheowneroroperator;
(5) ThenameandtitleofthepersonorpositionwithoverallresponsibilityforRMPelementsand
implementation;
(6) Thename,title, telephonenumber, and 24-hourtelephonenumberoftheemergencycontact;
(7) Foreachcoveredprocess,thenan1e andCAS numberofeachregulatedsubstanceheldabovethe
thresholdquantityin theprocess,themaximumquantityofeachregulatedsubstanceormixture
in theprocess(inpounds)to two significantdigits, thefive- orsix-digitNArCScodethatmost
closelycorrespondstotheprocess, andtheProgramleveloftheprocess;
(8)ThestationarysourceEPAidentifier;
(9) Thenunlberoffull-timeemployeesatthestationarysource;
(10)Whetherthe stationarysourceis subjectto 29CFR 1910.119;
(11) Whetherthestationarysourceis subjectto 40CFRpart355;
(12) If the stationarysourcehas aCAATitleVoperatingpermit, thepermitnumber; and
(13) ThedateofthelastsafetyinspectionofthestationarysourcebyaFederal,state,orlocal
governmentagencyandtheidentityoftheinspectingentity.
(14) SourceorParentCompanyE-MailAddress (Optional);
(15) SourceHomepageaddress (Optional)
(16)Phonenumberat the sourcefor publicinquiries(Optional);
(17) LocalEmergencyPlanningCommittee(Optional);
(18) OSHAVoluntaryProtectionProgramstatus(Optional);
Sec. 68.165 Offsiteconsequenceanalysis.
(a) Theowneroroperatorshallsubmitin theRMPinformation:
(1) Oneworst-casereleasescenariofor eachProgram 1process; and
(2) ForProgram2and 3processes, oneworst-casereleasescenarioto representall regulatedtoxic
substancesheld abovethe thresholdquantityandoneworst-caserelease scenarioto representall
regulatedflammablesubstancesheld abovethe thresholdquantity. If additional worst-case
scenariosfor toxicsorflammables arerequiredbySec. 68.25(a)(2)(iii),the owneroroperator
shall submitthe sameinformationon theadditional scenario(s). Theowneroroperatorof
Program2and3processesshall alsosubmitinformationononealternativereleasescenariofor
eachregulatedtoxic substanceheld abovethe thresholdquantityandonealternativerelease
scenarioto representall regulatedflammable substancesheldabovethe thresholdquantity.
(b) Theowneroroperatorshall submitthe following data:
(1) Chemicalname;
(2) Percentageweightofthechemicalin aliquidmixture(toxics only);
(3) Physical state(toxicsonly);
(4)Basisofresults(givemodelnameifused);
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(5) Scenario(explosion,fire, toxic gas release,orliquidspiII andevaporation);
(6) Quantityreleasedinpounds;
(7) Releaserate;
(8)Releaseduration;
(9)Windspeed and atmosphericstabilityclass(toxicsonly);
(10)Topography(toxicsonly);
(11) Distanceto endpoint;
(12) Publicandenvironmentalreceptors withinthedistance;
(13)Passivemitigationconsidered; and
(14)Activemitigationconsidered(alternativereleasesonly);
Sec. 68.168 Five-yearaccidenthistory.
Theowneroroperatorshallsubmitin theRMPthe informationprovidedin Sec. 68.42(b)oneach
accidentcoveredbySec. 68.42(a).
Sec. 68.170 Preventionprogram/Program2.
(a) ForeachProgram2 process,theowneroroperatorshall providein theRMPtheinformation
indicatedin paragraphs(b) through (k) ofthis section. Ifthesameinformationapplies to morethan
onecoveredprocess,theowneroroperatormayprovidetheinformationonlyonce,butshall indicate
to whichprocessestheinformationapplies.
(b) Thefive- orsix-digitNAICS codethatmostcloselycorrespondsto theprocess.
(c) Thename(s) ofthechemical(s)covered.
(d) Thedateofthemostrecentrevieworrevision ofthe safetyinformationand alistofFederalorstate
regulationsorindustry-specificdesigncodesand standards used to demonstratecompliancewiththe
safetyinformationrequirement.
(e) Thedateofcompletionofthe mostrecenthazardrevieworupdate.
(1) Theexpecteddateofcompletionofanychangesresultingfrom the hazardreview;
(2) Majorhazardsidentified;
(3) Process controls in use;
(4)Mitigationsystemsin use;
(5)Monitoringanddetection systemsin use; and
(6) Changessincethelasthazardreview.
(f) Thedateofthemostrecentrevieworrevision ofoperatingprocedures.
(g) Thedateofthenlostrecentrevieworrevision oftrainingprograms;
(1)Thetypeoftrainingprovided- classroom,classroompluson thejob,on thejob;and
(2) Thetypeofcompetencytestingused.
(h) Thedateofthemostrecentreview orrevisionofmaintenanceproceduresand thedateofthe most
recentequipmentinspectionortestand theequipmentinspectedortested.
(i) Thedateofthemostrecentcomplianceauditand theexpecteddateofcompletionofanychanges
resultingfrolll thecomplianceaudit.
(j)Thedate ofthemostrecentincidentinvestigationand theexpecteddate ofcompletionofany
changesresultingfromtheinvestigation.
(k)Thedateofthe mostrecentchangethattriggered arevieworrevisionofsafetyinformation,the
hazardreview, operatingormaintenance procedures,ortraining.
Sec. 68.175 Preventionprogram/Program3.
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(a) ForeachProgram3process, theowneroroperatorshallprovidetheinformationindicatedin
paragraphs(b) through(p) ofthis section.Ifthesameinformationapplies to morethanonecovered
process, the owneroroperatormayprovidetheinformationonlyonce,butshallindicateto which
processestheinformationapplies.
(b) Thefive- orsix-digitNAICScodethatmostcloselycorrespondsto theprocess.
(c) Thename(s)ofthe substance(s)covered.
(d) Thedateon whichthe safetyinformationwaslastreviewedorrevised.
(e) Thedateofcompletionofthe mostrecentPHAorupdate andthe techniqueused.
(1) Theexpecteddateofcompletionofanychangesresultingfrom thePHA;
(2) Majorhazardsidentified;
(3) Processcontrolsin use;
(4) Mitigationsystemsin use;
(5) Monitoringanddetectionsystemsinuse; and
(6) ChangessincethelastPHA.
([) Thedateofthe mostrecentreview orrevisionofoperatingprocedures.
(g) Thedateofthe mostrecentreview orrevisionoftrainingprograms;
(1) Thetypeoftrainingprovided- classroom,classroomplusonthejob,onthejob;and
(2) Thetypeofcompetencytestingused.
(h) Thedateofthemostrecentrevieworrevisionofmaintenanceproceduresand the dateofthemost
recentequipmentinspectionortestand theequipmentinspectedortested.
(i) Thedateofthe mostrecentchangethattriggeredmanagementofchangeproceduresandthe dateof
the mostrecentrevieworrevisionofmanagementofchangeprocedures.
U) Thedateofthe mostrecentpre-startupreview.
(k) Thedateofthe mostrecentcomplianceauditand theexpecteddate ofcompletionofanychanges
resultingfromthecomplianceaudit;
(I) Thedate ofthemostrecentincidentinvestigationandthe expecteddateofcompletionofanychanges
resultingfronl theinvestigation;
(m) Thedateofthe mostrecentrevieworrevision ofemployeeparticipationplans;
(n) Thedateofthe mostrecentreview orrevisionofhot workpermitprocedures;
(0) Thedateofthe mostrecentreview orrevision ofcontractorsafetyprocedures; and
(p) Thedateofthe mostrecentevaluationofcontractorsafetyperformance.
Sec. 68.180 Emergencyresponseprogram.
(a) TheowneroroperatorshallprovideintheRMPthefollowinginformation:
(1) Doyou haveawrittenemergencyresponseplan?
(2) Doestheplanincludespecific actions tobetakeninresponse toan accidental releasesofa
regulatedsubstance?
(3) Does theplanincludeproceduresforinformingthepublic andlocalagencies responsiblefor
respondingto accidental releases?
(4) Doestheplanincludeinformationonemergencyhealthcare?
(5) Thedateofthe mostrecentrevieworupdateoftheemergencyresponseplan;
(6) Thedateofthe mostrecentemergencyresponsetrainingforemployees.
(b) Theowneroroperatorshallprovidethe nameandtelephone numberofthe localagencywithwhich
emergencyresponseactivitiesand theemergencyresponseplanis coordinated.
(c) TheowneroroperatorshalllistotherFederalorstateemergencyplanrequirements to whichthe
stationarysourceis subject.
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Sec. 68.185 Certification.
(a) ForProgram 1processes,theowneroroperatorshallsubmitin theRMPthecertificationstatement
providedinSec. 68.12(b)(4).
(b) Forallothercoveredprocesses,theowneroroperatorshall submitin theRMPasinglecertification
that, to thebestofthe signer'sknowledge,information,and beliefformed afterreasonableinquiry,
the informationsubmittedis true, accurate, and complete.
Sec. 68.190 Updates.
(a) TheowneroroperatorshallreviewandupdatetheRMPas specifiedin paragraph(b) ofthis section
andsubmititinamethodandformatto acentralpointspecifiedbyEPApriorto June21, 1999.
(b) Theowneroroperatorofastationarysourceshallreviseand updatetheRMPsubmittedunderSec.
68.150asfollows:
(l)Withinfive yearsofits initial submissionormostrecentupdaterequiredbyparagraphs(b)(2)
through(b)(7)ofthis section, whicheveris later.
(2) Nolaterthan threeyears afteranewlyregulatedsubstanceis firstlistedbyEPA;
(3) Nolaterthan thedateon whichanewregulatedsubstanceis firstpresentin an alreadycovered
processaboveathresholdquantity;
(4) Nolaterthanthedate on whicharegulatedsubstanceis first presentaboveathresholdquantityin
anew process;
(5) Withinsix monthsofachangethatrequiresarevisedPHAorhazardreview;
(6) Withinsixmonthsofachangethatrequires arevisedoffsiteconsequenceanalysisas providedin
Sec. 68.36; and
(7) Withinsixmonthsofachangethatalters the Programlevel thatappliedto anycoveredprocess.
(c) If astationarysourceis no longersubjectto thispart, the owneroroperatorshall submitarevised
registrationto EPAwithin six monthsindicatingthatthe stationarysourceis nolongercovered.
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Regulationsand Requirements ISPCalvertCity
SubpartH- OtherRequirements
Sec. 68.200 Recordkeeping.
Theowneroroperatorshallmaintainrecordssupportingtheimplementationofthis partforfive years
unlessotherwiseprovidedin subpartD ofthispart.
Sec. 68.210 Availabilityofinformationto thepublic.
(a) TheRMPrequiredundersubpartGofthis partshall beavailableto thepublicunder42U.S.C.
7414(c).
(b) Thedisclosureofclassifiedinforn1ationbytheDepartmentofDefenseorotherFederalagenciesor
contractorsofsuchagenciesshallbecontrolledbyapplicablelaws, regulations,orexecutiveorders
concerningthe releaseofclassifiedinformation.
Sec. 68.215 Permitcontentand airpermittingauthorityordesignatedagencyrequirements.
(a) Theserequiren1ents applyto anystationarysourcesubjectto this part68 and parts70or71 ofthis
chapter. The40CFRpart70orpart71 permitfor the stationarysourceshallcontain:
(1) A statementlistingthis partas an applicable
(2) Conditionsthatrequirethesourceowneroroperatortosubmit:
(i) Acomplianceschedulefor meetingtherequirementsofthispartbythe dateprovidedin
Sec. 68.10(a)oc
(ii) As partofthecompliancecertificationsubmittedunder40CFR70.6(c)(5), acertification
statementthatthe sourceis in compliancewithallrequirementsofthis part,includingthe
registrationandsubmissionofthe RMP.
(b) Theowneroroperatorshall submitanyadditional relevantinformationrequestedbythe air
permittingauthorityordesignatedagency.
(c) For40CFRpart70orpart71 permitsissuedpriorto thedeadlineforregisteringandsubmittingthe
RMPand whichdonotcontainpermitconditionsdescribedin paragraph(a)ofthis section,the
owneroroperatororairpermittingauthorityshallinitiatepermitrevisionorreopeningaccordingto
theproceduresof40CFR70.7or71.7 toincorporatethe termsandconditionsconsistentwith
paragraph(a) ofthis section.
(d) Thestatemaydelegatethe authorityto implementandenforcethe requirementsofparagraph(e) of
this section toastateorlocalagencyoragencies otherthan theairpermittingauthority. An up-to-
datecopyofanydelegationinstrumentshallbemaintainedbythe airpermittingauthority.Thestate
mayenterawritten agreementwiththe AdministratorunderwhichEPAwillimplementandenforce
the requirements ofparagraph(e)ofthis section.
(e) Theairpermittingauthorityorthe agencydesignatedbydelegationoragreementunderparagraphCd)
ofthis sectionshall,ata minimum:
(1) Verifythatthe sourceowneroroperatorhasregisteredandsubmittedan RMPorarevisedplan
whenrequiredbythis
(2) Verifythatthe sourceowneroroperatorhas submittedasourcecertificationorin its absence
has submittedacompliancescheduleconsistentwithparagraph(a)(2)ofthis
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(3) Forsomeorall ofthesourcessubjectto this section,useoneormoremechanismssuchas, but
notlimitedto, acon1pletenesscheck,sourceaudits,recordreviews,orfacilityinspectionsto
ensurethatpermittedsources areincompliancewiththerequirementsofthis part; and
(4) Initiateenforcementactionbasedon paragraphs(e)(1) and(e)(2) ofthis sectionas appropriate.
Sec. 68.220 Audits.
(a) In additiontoinspectionsforthepurposeofregulatorydevelopmentandenforcementofthe Act, the
implementingagencyshallperiodicallyauditRMPssubmittedundersubpartG ofthis partto review
the adequacyofsuchRMPsand requirerevisionsofRMPswhen necessarytoensurecompliance
withsubpartGofthis part.
(b) Theimplementingagencyshall selectstationarysourcesforauditsbasedon anyofthefollowing
criteria:
(1) Accidenthistoryofthe stationarysource;
(2) Accidenthistoryofotherstationarysourcesin the sameindustry;
(3) Quantityofregulatedsubstancespresentat thestationarysource;
(4) Locationofthestationarysourceandits proximityto thepublicandenvironmentalreceptors;
(5) Thepresenceofspecificregulatedsubstances;
(6) Thehazardsidentifiedinthe RMP;and
(7) Aplanprovidingfor neutral,randomoversight.
(c) Exemptionfrom audits. A stationarysourcewithaStarorMeritrankingunderOSHA'svoluntary
protectionprogramsha11 beexemptfromauditsunderparagraph(b)(2)and(b)(7) ofthis section.
(d) Theimplementingagencyshallhaveaccess to thestationarysource, supportingdocumentation, and
any areawherean accidental releasecouldoccur.
(e) Basedon the audit, theimplementingagencymayissuetheowneroroperatorofastationarysourcea
written preliminarydeterminationofnecessaryrevisions tothestationarysource'sRMPtoensure
thattheRMPmeets thecriteriaofsubpartG ofthispart. Thepreliminarydeterminationshallinclude
an explanationfor thebasisfor therevisions,reflectingindustrystandardsandguidelines(such as
AIChE/CCPS guidelines and ASMEand APIstandards)to theextentthatsuchstandardsand
guidelinesare applicable, andshall includeatimetablefor theirimplementation.
(f) Writtenresponseto apreliminarydetermination.
(1) Theowneroroperatorshall respondinwritingto apreliminarydeterminationmadein
accordancewithparagraph(e) ofthis section.Theresponseshall statetheowneroroperatorwill
implementtherevisionscontainedinthepreliminarydeterminationinaccordancewiththe
tin1etable includedinthepreliminarydeterminationorshallstatethattheowneroroperator
rejects therevisions in wholeorin part. Foreachrejectedrevision,theowneroroperatorshall
explainthebasis forrejectingsuchrevision. Suchexplanationmayincludesubstituterevisions.
(2) Thewrittenresponseunderparagraph(f)(1)ofthis sectionshallbereceivedbythe
implementingagencywithin90days oftheissueofthepreliminarydeterminationorashorter
periodoftimeas the implementingagencyspecifiesin thepreliminarydeterminationas
necessaryto protectpublichealth andtheenvironment. Priorto the writtenresponsebeingdue
andupon written requestfrom theowneroroperator,theimplementingagencymayprovidein
writingadditional timefor the responsetobereceived.
(g) Afterprovidingthe owneroroperatoran opportunityto respondunderparagraph(f)ofthis section,
theimplementingagencymayissuetheowneroroperatorawrittenfinal determinationofnecessary
revisions to thestationarysource'sRMP. Thefinal determinationmayadoptormodifytherevisions
containedin the preliminarydeterminationunderparagraph(e) ofthis sectionormayadoptor
modifythesubstituterevisions providedin theresponseunderparagraph(f)ofthis section. Afinal
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determinationthatadopts arevisionrejectedbytheowneroroperatorshallincludean explanation
ofthebasisfor therevision. Afinal determinationthatfails to adoptasubstituterevisionprovided
underparagraph(f)ofthis sectionshallincludean explanationofthebasisforfindingsuch
substituterevisionunreasonable.
(h) Thirtydays aftercompletionoftheactionsdetailedintheimplementationschedulesetinthefinal
determinationunderparagraph(g) ofthis section,theowneroroperatorshallbein violationof
subpartG ofthispartand this sectionunlesstheowneroroperatorrevisestheRMPpreparedunder
subpartG ofthispartas requiredbythefinal determination,andsubmitstherevisedRMPas
requiredunderSec. 68.150.
(i) Thepublicshall haveaccessto thepreliminarydeterminations,responses, and final determinations
underthis sectionin amannerconsistentwithSec. 68.210.
U) Nothingin this sectionshallpreclude, limit, orinterferein anywaywiththeauthorityofEPAorthe
statetoexerciseitsenforcement,investigatory, andinformationgatheringauthoritiesconcerningthis
partunderthe Act.
Appendix A to Part 68 - Table of Toxic Endpoints
[As defined in Sec. 68.22 of this part]
Toxic
CAS No. Chemical name endpoint (mg/
L)
107-02-8................" Acrolein [2-Propenal] ......... 0.0011
107-13-1.. . . . . . . . . . . . . . . .. Acrylonitrile [2- 0.076
Propenenitrile] .
814-68-6.................. Acrylyl chloride [2-Propenoyl 0.00090
chloride] .
107-18-6.. . . . . . . . . . . . . . . .. Allyl alcohol [2-Propen-1-ol]. 0.036
107-11-9.................. Allylamine [2-Propen-1-amine]. 0.0032
7664-41-7................. Ammonia (anhydrous) ........... 0.14
7664-41-7................. Ammonia (conc 20% or greater). 0.14
7784-34-1................. Arsenous trichloride.......... 0.010
7784-42-1................. Arsine........................ 0.0019
10294-34-5................ Boron trichloride [Borane, 0.010
trichloro-] .
7637-07-2................. Boron trifluoride [Borane, 0.028
trifluoro-] .
353-42-4.................. Boron trifluoride compound 0.023
with methyl ether (1:1)
[Boron,
trifluoro[oxybis[methane]]-,
T-4.
7726-95-6. . . . . . . . . . . . . . . .. Bromine....................... 0.0065
75-15-0................... Carbon disulfide.............. 0.16
7782-50-5................. Chlorine...................... 0.0087
10049-04-4................ Chlorine dioxide [Chlorine 0.0028
oxide (CI02)].
67-66-3................... Chloroform [Methane, trichloro- 0.49
] .
542-88-1.......... ........ Chloromethyl ether [Methane, 0.00025
oxybis[chloro-] .
107-30-2.................. Chloromethyl methyl ether 0.0018
[Methane, chloromethoxy-].
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4170-30-3.................
123-73-9..................
506-77-4..................
108-91-8..................
19287-45-7................
75-78-5...................
57-14-7...................
106-89-8..................
107-15-3..................
151-56-4..................
75-21-8...................
7782-41-4.................
50-00-0...................
110-00-9..................
302-01-2..................
7647-01-0.................
74-90-8...................
7647-01-0.................
7664-39-3.................
7783-07-5.................
7783-06-4.................
13463-40-6................
78-82-0...................
108-23-6..................
126-98-7..................
74-87-3...................
79-22-1...................
60-34-4...................
624-83-9..................
74-93-1...................
556-64-9..................
75-79-6...................
13463-39-3................
7697-37-2.................
Crotonaldehyde [2-Butenal] ....
Crotonaldehyde, (E) -, [2-
Butenal, (E) -] .
Cyanogen chloride.............
Cyclohexylamine
[Cyclohexanamine] .
Diborane......................
Dimethyldichlorosilane
[Silane, dichlorodimethyl-].
1,1-Dimethylhydrazine
[Hydrazine, 1,1-dimethyl-].
Epichlorohydrin [Oxirane,
(chloromethyl)-] .
Ethylenediamine [1,2-
Ethanediamine] .
Ethyleneimine [Aziridine] .....
Ethylene oxide [Oxirane] ......
Fluorine......................
Formaldehyde (solution) .......
Furan.........................
Hydrazine.....................
Hydrochloric acid (conc 37% or
greater) .
Hydrocyanic acid..............
Hydrogen chloride (anhydrous)
Hydrogen fluoride/Hydrofluoric
acid (conc 50% or greater)
Hydrogen selenide.............
Hydrogen sulfide..............
Iron, pentacarbonyl- [Iron
carbonyl (Fe(CO) 5), (TB- 5-11)-
] .
Isobutyronitrile
[Propanenitrile, 2-methyl-]
Isopropyl chloroformate
[Carbonochloride acid, 1-
methyl ethyl ester] .
Methacrylonitrile [2-
Propenenitrile, 2-methyl-].
Methyl chloride [Methane,
chloro-] .
methylester] .
Methyl hydrazine [Hydrazine,
methyl-] .
Methyl isocyanate [Methane,
isocyanato-] .
Methyl mercaptan
[Methanethiol] .
Methyl thiocyanate [Thiocyanic
acid, methyl ester] .
Methyltrichlorosilane [Silane,
trichloromethyl-] .
Nickel carbonyl...............
Nitric acid (conc 80% or
0.029
0.029
0.030
0.16
0.0011
0.026
0.012
0.076
0.49
0.018
0.090
0.0039
0.012
0.0012
0.011
0.030
0.011
0.030
0.016
0.00066
0.042
0.00044
0.14
0.10
0.0027
0.82
0.0019
0.0094
0.0012
0.049
0.085
0.018
0.00067
0.026
Page 97 of 132
August 15, 2011
greater) .
10102-43-9 ................ Nitric oxide [Nitrogen oxide
(NO)] .
8014-95-7 ................ . Oleum (Fuming Sulfuric acid)
[Sulfuric acid, mixture with
sulfur trioxide] .
79-21-0 .................. . Peracetic acid [Ethaneperoxoic
acid] .
594-42-3 ................. . Perchloromethylmercaptan
[Methanesulfenyl chloride,
trichloro-] .
75-44-5 .................. . Phosgene [Carbonic dichloride]
7803-51-2 ................ . Phosphine .................... .
10025-87-3 ............... . Phosphorus oxychloride
7719-12-2 ................ . Phosphorus trichloride
[Phosphorous trichloride] .
110-89-4 ................. . piperidine ................... .
107-12-0 ................. . Propionitrile [Propanenitrile]
109-61-5 ................. . Propyl chloroformate
propylester] .
75-55-8 .................. . Propyleneimine [Aziridine, 2-
methyl-] .
75-56-9 .................. . Propylene oxide [Oxirane,
methyl-] .
7446-09-5 ................ . Sulfur dioxide (anhydrous)
7783-60-0 ................ . Sulfur tetrafluoride [Sulfur
fluoride (SF4), (T-4) -] .
7446-11-9 ................ . Sulfur trioxide .............. .
75-74-1 .................. . Tetramethyllead [Plumbane,
tetramethyl-] .
509-14-8 ................. . Tetranitromethane [Methane,
tetranitro-] .
7750-45-0................. Titanium tetrachloride
[Ti tanium chloride (TiC14) (T-
4) -] .
584-84-9.................. Toluene 2,4-diisocyanate
methyl-] .
91-08-7 ................... Toluene 2,6-diisocyanate
methyl-] .
26471-62-5................ Toluene diisocyanate
(unspecified isomer)
[Benzene, 1,3-
diisocyanatomethyl-]
75-77-4................... Trimethylchlorosilane [Silane,
chlorotrimethyl-] .
108-05-4 .............. . ... Vinyl acetate monomer [Acetic
acid ethenyl ester] .
Amanda Stephens
ISP Calvert City
0.031
0.010
o . 0045
0.0076
0.00081
0.0035
0.0030
0.028
0.022
0.0037
0.010
0.12
0.59
0.0078
0.0092
0.010
0.0040
0.0040
0.020
0.0070
0.0070
0.0070
0.050
0.26
[61 FR 31729, June 20, 1996, as amended at 62 FR 45132, Aug. 25, 1997]
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APPENDIX3
EXCERPTFROM ASME BOILER AND PRESSURE VESSELCODE, SECTION VIII
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DJ . _ I
. E \ 1
E [ ., .
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'.; ,(" T Ill: ' 111 - nH"
L ,- J
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11([
pi c . od
7i
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.. III ~ I I ! l
tJG. J
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APPENDIX 4
EXCERPTS FROM API 510, PRESSURE VESSEL INSPECTION CODE
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eTION = WNERJUSEH ORGANtZATIOIN
1I1I 11:).,1:10r
'" .4
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API 51
5.8-4 Hydrostatic Pres-sur.
5.8,4.1 rti \ ' 1 " ' d tn s.
5.8.5 ,Pn&um8tic Pressure Tests
5.8.6 Te'St Ten perature and Brittl e Fracture Considerabon$
5.8. T Tesfng AJternativ'C's
n' l . t li:r a major repai r alt 'r-
nIy l.ti r;: r the !.:n In,.;Cr JTlI d have
. a.r
' d fr
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APPENDIX 5
EXCERPT FROM NATIONAL BOARD INSPECTION CODE
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------------------------- ...
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l It
06
u
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APPENDIX 6
EXCERPT FROM ASME 831.1, POWER PIPING
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ChapterV
Exa1mi'nat.iron.ande.sting
])6 . TlOIN NO EXAM. ATi0N
,) 6.1
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APPENDIX7
EXCERPTFROM ASME BOILER AND PRESSURE VESSELCODE, SECTION I
(Referredto by ASME B31.1)
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APPENDIX 8
EXCERPT FROM ASME 831.3, PROCESS PIPING
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Regulationsand Requirements ISPCalvertCity
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APPENDIX 9
EXCERPT FROM API 570, PIPING INSPECTION CODE
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n ' : ~ l l ~ l O n m n il;
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. 1
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August 15, 2011
APPENDIX 10
EXCERPTS FROM API 653, TANK INSPECTION, REPAIR, ALTERATION, &RECONSTRUCTION
Page 119 of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
Se
1 1 General'
7,
t
7. . Roof, son
7.
is
Page 120 of 132
Amanda Stephens
August 15, 2011
Page 121 of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
-2
the a
8
p rrn th
I Je
e
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k) t,
I)
13.2 Recordkeep ng
13. I I bu n mited 0 In nt 9 .
G I,.
Page 122 of 132
AmandaStephens
August 15,2011
APPENDIX 11
EXCERPTFROM API 620, DESIGN &CONSTRUCTION OF LARGE, WELDED, LOW-PRESSURE
STORAGETANKS
Page 123of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
I
7.2 ners
(uJ r1y ""n,-' "' .-. ......
7.3
1.5
If ,
Page 124 of 132
Amanda Stephens
August 15, 2011
ISPCalvertCity
APPENDIX 12
EXCERPTFROM API RP 578, MATERIALVERIFICATION PROGRAM FOR NEWAND EXISTING
ALLOY PIPING SYSTEMS
Page 125of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
o r t in . pe J repuir.
ry a un I nn f
31
Il!Jen r I
Page 126 of 132
Amanda Stephens
August 15, 2011
ISPCalvertCity
m MI
Page 127of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
4,.3.4 nt Pnorit izatio
ttl al to 2 n m ),
eJ OM t S In d Cl r igh
Page 128 of 132
Amanda Stephens
August 15, 2011
ISP Calvert City
APPENDIX 13
EXCERPT FROM API RP 574, INSPECTION PRACTICES FOR PIPING SYSTEM COMPONENTS
Page 129 of 132
Amanda Stephens
August 15, 2011
ISP CalvertCity
10."11. 2
9-
c old
S 0
Page 130of132
Amanda Stephens
August 15, 2011
ISP Calvert City
APPENDIX 14
EXCERPT FROM API RP 577, WELDING INSPECTION AND METALLURGY
Page 131 of 132
Amanda Stephens
August 15, 2011
"
Page 132 of 132

Material Control/Quality Assurance Requirements For Chemical Plants and Refineries

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