Dichloromethylphenylsilane
Dichlorvos

Dicrotophos-

Diepoxybutane

Diethyi chlorophosphate
Diethyl-p-phenylenediamine
Diethylcarbamazine citrate
Digitoxin

Diglycidyl ether

Digoxin

Dimefox

Dimethoate

Dimethyl phosphorochloridothioate
Dimethy] phthalate

Dimethy] sulfate

Dimethyl sulfide
Dimethyl-p-phenylenediamine
Dimethyldichlorosilane
Dimethylhydrazine
Dimetilan

Dinitrocresoi

Dinoseb

Dinoterb

Dioctyl phthalate

Dioxathion

Dioxolane

Diphacinone
Diphosphoramide, octamethy]-
Disulfoton

Dithiazanine iodide
Dithiobiuret

EPN

Emetine, dihydrochloride
Endosulfan

Endothion

Endrin

Ergocalciferol

Ergotamine tartrate
Ethanesulfonyl chloride, 2-chloro-
Ethanol, 1,2-dichloro-, acetate
Ethion

Ethoprophos

Ethy! thiocyanate
Ethylbis(2-chloroethyl)amine
Ethylene fluorohydrin
Ethylenediamine
Ethyleneimine

Ethylmercuric phosphate
Fenamiphos

Fenitrothion

Fensulfothion

Fluenetil

Fluorine

Fluoroacetamide
Fluoroacetic acid

18

00149-74-6
00062-73-7
00141-66-2
01464-53-5
00814-49-3
00093-05-0
01642-54-2
00071-63-6
02238-07-5
20830-75-5
00115-26-4
00060-51-5
02524-03-0
00131-11-3
00077-78-1
00075-18-3
00099-98-9
00075-78-5
00057-14-7
00644-64-4
00534-52-1
00088-85-7
01420-07-1
00117-84-0
00078-34-2
00646-06-0
00082-66-6
00152-16-9
00298-04-4
00514-73-8
00541-53-7
02104-64-5
00316-42-7
00115-29-7
02778-04-3
00072-20-8
00050-14-6
00379-79-3
01622-32-8
10140-87-1
00563-12-2
13194-48-4
00542-90-5
00538-07-8
00371-62-0
00107-15-3
00151-56-4

00122-14-5
00115-90-2
04301-50-2
07782-41-4
00640-19-7
00144-49-0

Fluoroacety! chloride
Fluorouracil

Fonofos

Formaldehyde cyanohydrin
Formetanate

Formothion

Formparanate

Fosthietan

Fuberidazole

Furan

Gallium trichloride
Hexachlorocyclopentadiene
Hexachloronaphthalene
Hexamethylenediamine, N,N’-dibutyl-
Hydrazine

Hydrocyanic acid
Hydrogen fluoride
Hydrogen selenide
Indomethacin

Iridium tetrachloride

Iron, pentacarbony}-
Isobenzan

Tsobutyronitrile

Tsocyanic acid, 3,4-dichlorophenyl ester

Isodrin

Isofluorphate
Isophorone diisocyanate
Isopropyl chloroformate
Isopropyl formate

Isopropylmethylpyrazolyl dimethylcarbamate

Lactonitriie
Leptophos
Lewisite
Lindane
Lithium hydride
Malononitrile
Manganese, tricarbonyl
methylcyclopentadieny)
Mechlorethamine
Mephosfolan
Mercuric acetate
Mercuric chloride
Mercuric oxide
Mesitylene
Methacrolein diacetate
Methacrylic anhydride
Methacrylonitrile
Methacryloy! chloride
Methacryloyloxyethyl isocyanate
Methamidophos
Methanesulfonyl fluoride
Methidathion
Methiocarb
Methomyl
Methoxyethylmercuric acetate

00359-06-8
00051-21-8
00944-22-9
00107-16-4
23422-53-9
02540-82-1
17702-57-7
21548-32-3
03878-19-1
00110-00-9
13450-90-3
00077-47-4
01335-87-1
04835-11-4
00302-01-2
00074-90-8
07664-39-3
07783-07-5
00053-86-1
10025-97-5
13463-40-6
00297-78-9
00078-82-0
00102-36-3
00465-73-6
00055-91-4
04098-71-9
00108-23-6
00625-55-8
00119-38-0
00078-97-7
21609-90-5
00541-25-3
00058-89-9
07580-67-8
00109-77-3

12108-13-3
00051-75-2
00950-10-7
01600-27-7
07487-94-7
21908-53-2
00108-67-8
10476-95-6
00760-93-0
00126-98-7
00920-46-7
30674-80-7
10265-92-6
00558-25-8
60950-37-8
02032-65-7
16752-77-5
00151-38-2


on

~

©

. Are

. Have responsibilities and procedures been

established for those who are assigned Tescue or
ting dui
to take physical examinations which demonetrate
their fit ess s to perform: such duties? If so, how

Are

search and

rescue procedt es? Are they familiar with the

location of utility disconnects and all evacuation
8? Ar y PPI

and trained in first aid/emergency ‘medical

treatment? Are they provided with

©: A

personnel provided with a properly equipped

vehicle(s) to reduce response time?

. Are documents readily available for reference in

an emergency? Are decision logic (decision-

making) charts (or other documents) formulated
making) charts (0! jccuments) formulated

for planning and executing the following
activities:

* Selection of protective clothing?

© Emergency shutdown of equipment?
* Evacuation of the plant?

© Evacuation of the surrounding populace?

How did management arrive at these decisions?

. Have definite volumes of air contaminants been
whe

5

. Are

Are
. Are hospitals, physi

Have dispersion models been calculated to assist
in planning of evacuation? If not, how does
management deai with a hazard that is spreading
into new areas of the plant and the community?

. Are employees or recovery personnel trained and

are procedures in place for monitoring the site
and adjacent areas to identify levels of
col heir

: P
quantities and placed in useable locations; e.g.,

fone power one pula for emergency
light
light td

for supplying water to fight fires: PPE, safety
showers connected to alarms, etc.?

© Is emergency equipment checked, tested, and
calibrated, periodically for operational

teadiness?

© Are personnel trained and experienced in its

© Is emergency equipment of appropriate type
for any emergency which may occur?

. Are local emergency response personnel brought

into the site periodically for familiarization?

© Are potential probiem areas and processes
pointed out and discussed?

* Are locations where personnel normally work
pointed out?

systems developed and in place? Are they
vulnerable to power failure or other disruption?
Do ambient plant noise levels interfere with voice
communication?

in an emergency compatible. with site equipment?

. Is there a written spill control plan, e.g.,

containment, neutralization, disposal, appropriate
PPE, etc.?

. Are incompatibilities of released material

anticipated?

. Are normally innocuous materials likely to
become hazardous due to an emergency?
h

certain materials when heated release hazardous
levels of toxic substances not existing during
normal conditions, etc.

hospitals, physici

medical/paramedical staff provided with:

© Lists of hazardous chemicals and Material
Safety Data Sheets?


U.S. Department of Labor

Occupational Safety and Health Administration

Regional Offices

Region |
(CT*, MA, ME, NH, RI, VT*)
16-18 North Street

1 Dock Square Building

4" Floor

Boston, MA 02109
Telephone: (617) 223-6710

Region Ii

(NY, NY* Puerto Rico*, Virgin
Isalnds*)

1 Astor Plaza, Room 3445
1515 Brodway

New Yrok, NY 10036
Telephone: (212) 944-3432

Region Ili

(DC, DE, MD*, PA, VA*, WV)
Gateway Building, Suite 2100
3535 Market Street
Philadelphia, PA 19104
Telephone: (215) 596-1201

Region IV
(AL, FL, GA, KY*, MS, NC*, SC*
TN*)

1375 Peachtree Street, N.E.
Suite 587

Atlanta, GA 30367

Telephone: (404) 347-3573

Region V

(IL, IN*, MI*, MN*, OH, WI)
230 South Dearborn Street
Chicago, il 60604
Telephone: (312) 353-2220

Region VI
(AR, LA, NM*, OK, TX)
525 Griffin Square Building, Room 602
Dallas, TX 75202

Telephone: (214) 767-4731

Region VII
(iA*, KS, MO, NE)

911 Walnut Street, Room 406
Kansas City, MO 64106

Telephone: (816) 374-5861

Region Vill

(CO, MT, ND, SD, UT*, WY*)
Federal Building, Room 1554

1961 Stout Street

Denver, CO 80294

Telephone: (303) 844-3061

Region IX
(American Samoa, AZ*, CA*, Guam,

Hi*, NV* Pacific Trust Territories)
P.O. Box 36017
450 Golden Gate Avenue

San Francisco, CA 94102
Telephone: (415) 556-7260

Region X
{AK*, ID, OR*, WA*)
Federal Office Building
Room 6003
909 First Avenue
Seattle, WA 98174
Telephone: (206) 442-5930

*These States and territories operate their own OSHA-approved job safety and health programs
(except Connecticut and New York whose plans cover public employees only).


Disaster Prevention

There are three tasks to perform before any
meaningful analysis of an emergency response system
can begin. The first task is to identify the key
pr Ti of the produc pi 3S and
to understand how operational processes are kept
within safe bounds under normal conditions.
Conceptually, it is the normal process instrumentation

and contro! measures that provide the first and
and contro! measures that provide the first and

greatest degree of protection to plant employees and
to the public, The four areas listed below identify
some major subsystems or components which are
commonly found in chemical plants. Each has a
bearing on the safety of operations under normal and
emergency conditions.

1. A management subsystem which includes man-
agement personnel, process specifications, plant

n

defines roles, “for both normal and emergency
operations, and provides appropriate training.
This may also include labor/management safety

3. A physical subsystem which may include
transportation systems for materials, ventilation
sy’
systems, refrigeration systems, storage areas,
communications systems, and other process-

related equipi

4. An emergency services subsystem including in-
plant and community components.

A second task is to understand how critical failure
points are identified, and what controls are used to
ensure safe operations. This involves assessing the

of the components and, particularly.
of the components and, particularly,

identifying which safety features in the system should
be backed up with alternative instrumentation,
procedures, or equipment designed to ensure that
process variables are kept within safe limits.

The third task i is to identify the emergency response
sy
Conceptually, it is a latent system that is active only
when preventive measures have failed and an incident
has occurred. This system is the most difficult to

evaluate because:

1. It is not observable except in emergencies.

2. The emergency response system also may involve
resources and subsystems that lie wholly or
Partially outside of the physical or ‘Managerial

local frefehters may supplement i in-plant fire ,
brigades; local hospitals may provide care to
injured workers in addition to in-plant first aid;
with traffic control,
evacuating of ‘workers and ¢ community, and
expediting communications and the flow of

ue equipment.

3. Finally, there is the question of defining the point
at which the emergency system ‘‘shuts down’?

and normal operations begin after an emergency.

Plant Management

All the plann:

2 and preparation of safe plant
All the plann

¢ planning and preparation of safe plant
operation is meaningless, unless it can be

implemented. In the event of a problem, there is no
time for committee or front office decisions. Correct

decisions have to be made at the lowest organizational

level possible, and those decisions have to be
communicated to other affected Personnel This

ended to establish whether t
have been considered in the program.

1. Who is in charge? What are the lines of authority
under normal operating conditions? In transition
Ss, like during startup and

procedures? In emergencies?

2. Can information be transmitted quickly and easily

from:

worker?

ker to

orker to supervisor

supervisor to

pa
| |

oe nn

=

—
—
|



Methyl 2-chloroacrylate
Methyl! chloroformate
Methyl disulfide
Methyl isocyanate
Methyl isothiocyanate
Methyl mercaptan
Methyl phenkapton
Methyl phosphonic dichloride
Methy] thiocyanate
Methyl vinyl ketone
Methylhydrazine
Methylmercuric dicyanamide
Methyltrichlorosilane
Metolcarb

Mevinphos
Mexacarbate
Mitomycin C
Monocrotophos
Muscimol

Mustard gas

Nickel

Nickel carbonyl
Nicotine

Nicotine sulfate

Nitric acid

Nitric oxide
Nitrocyclohexane
Nitrogen dioxide
Nitrosodimethylamine
Norbormide
Organorhodium complex
Orotic acid

Osmium tetroxide
Ouabain

Oxamy!

Oxetane, 3,3-bis(chloromethyl)
Oxydisulfoton

Ozone

Paraquat

Paraquat methosulfate
Parathion
Parathion-methyl

Paris green
Pentaborane
Pentachloroethane
Pentachlorophenol
Pentadecylamine
Peracetic acid
Perchloromethylmercaptan
Phenarsazine oxide
Phenol

Phenol, 2,2’-thiobis(4-chloro-6-methy]-

Phenol, 2,2'-thiobus[4,6-dichioro-

00080-63-7
00079-22-1
00624-92-0
00624-83-9
00556-61-6
00074-93-1
03735-23-7
00676-97-1
00556-64-9
00078-94-4
00060-34-4
00502-39-6
00075-79-6
01129-41-5
07786-34-7
00315-18-4
00050-07-7
06923-22-4
02763-96-4
00505-60-2
07440-02-2
13463-39-3
00054-11-5
00065-30-5
07697-37-2
10102-43-9
01122-60-7
10102-44-0
00062-75-9
00991-42-4
PMN-82-147
00065-86-1
20816-12-0
00630-60-4
23135-22-0
00078-71-7
02497-07-6
10028-15-6
01910-42-5
02074-50-2
00056-38-2
00298-00-0
12002-03-8
19624-22-7
00076-01-7
00087-86-5
02570-26-5
00079-21-0
00594-42-3
00058-36-6
00108-95-2
04418-66-0
00097-18-7

Phenol, 3-(1-methylethyl)-, methylcarbamate 00064-00-6

Phenyl dichloroarsine

00696-28-6

Phenylhydrazine hydrochloride

Phenylmercury acetate

Phenylsilatrane

Phenylthiourea

Phorate

Phosacetim

Phosfolan

Phosmet

Phosphamidon

Phosphine

Phosphonothioic acid, methyl-,
0-(4-nitrophenyl...

Phosphonothioic acid, methyl-, O-ethy! O-[4-..
Phosphonothioic acid, methy!-,S-[2-[bis...

Phosphoric acid, dimethyl
4-(methylthio)phenyl...
Phosphorous trichloride
Phosphorus

Phosphorus oxychloride
Phosphorus pentachloride
Phosphorus pentoxide
Phylloquinone
Physostigmine
Physostigmine, salicylate (1:1)
Picrotoxin

Piperidine

Piprotal

Pirimifos-ethyl

Platinous chloride

Platinum tetrachloride
Potassium arsenite
Potassium cyanide
Potassium silver cyanide
Promecarb

Propargyl bromide
Propiolactone, .beta.-
Propionitrile

Propionitrile, 3-chloro-
Propy! chloroformate
Propylene glycol, allyl ether
Propyleneimine

Prothoate

Pseudocumene

Pyrene

Pyridine, 2-methy]-5-vinyl-
Pyridine, 4-amino-

Pyridine, 4-nitro-, 1-oxide
Pyriminil

Rhodium trichloride
Salcomine

Sarin

Selenium oxychloride
Selenous acid
Semicarbazide hydrochloride

Silane, (4-aminobuty])diethoxymethy]-

00059-88-1
00062-38-4
02097-19-0
00103-85-5
00298-02-2
04104-14-7
00947-02-4
00732-11-6
13171-21-6
07803-51-2

02665-30-7
-02703-13-1
50782-69-9

03254-63-5
07719-12-2
07723-14-0
10025-87-3
10026-13-8
01314-56-3
00084-80-0
00057-47-6
00057-64-7
00124-87-8
00110-89-4
05281-13-0
23505-41-1
10025-65-7
13454-96-1
10124-50-2
00151-50-8
00506-61-6
02631-37-0
00106-96-7
00057-57-8
00107-12-0
00542-76-7
00109-61-5
01331-17-5
00075-55-8
02275-18-5
00095-63-6
00129-00-0
00140-76-1
00504-24-5
01124-33-0
53558-25-1
10049-07-7
14167-18-1
00107-44-8
07791-23-3
07783-00-8
00563-41-7
03037-72-7

19


Related Publications

BLS Publication 412-3 - What Every Employer Needs to Know About OSHA Recordkeeping
OSHA 3084 - Chemical Hazard Communication

OSHA 3047 - Comsultation Services for the Employer

OSHA 3088 - How to Prepare for Workplace Emergencies

OSHA 3077 - Personal Protective Equipment

OSHA 3079 - Respiratory Profection

Hazard Communication Regional Coordinators

Region HCS Coordinator Telephone
Boston Joseph Normand 617-223-6710
New York Cathic Mannion 212-944-3432
Philadelphia James Johnston 215-596-1201
Atlanta Charles Anderson 404-347-3573
Chicago Kenneth Yotz 312-353-2220
Dallas Dean McDaniel 214-767-4731
Kansas City Mary Marphy 816-374-5861
Denver John Healy 303-837-3061
San Francisco Dean Ikeda 414-556-0585

Seattle Carl Halgren 206-442-5930


. 4-Fluoro-2-hydroxybutyric acid, amides
. Hydrogen fluoride

. Hydroxyacetonitrile (Glycolonitrile)

. 1,2,3,7,8,9-Hexachlorodibenzo-p-dioxin
 Isodrin

Hexamethylphosphoramide

. Juglone (5-Hydroxynaphtalene-1 ,4-dione)
. Warfarin

. 4,4'-Methylenebis (2-chloroaniline)
. Ethion

. Aldicarb

. Nickel tetracarbonyl!

- Isobenzan

. Pentaborane

. 1-Propen-2-chloro-1 ,3-diol-diacetate
. Propyleneimine

. Oxygen difluoride

|. Sulphur dichloride

. Selenium hexafluoride

Hydrogen selenide

. TEPP
. Sulfotep
. Dimefox

1-Tri(cyclohexyl)stannyl-1H-1,2,4-triazole

. Triethylenemelamine

. Cobalt (powders, compounds)

. Nickel (powders, compounds)

. Anabasine

. Tellurium hexafluoride

. Trichloromethanesulpheny] chloride

. 1,2-Dibromoethane (Ethylene dibromide)
. Flammable substances as defined in

Annex IV (c)(i)

. Flammable substances as defined in

Annex IV (c)(ii)

. Diazodinitrophenol

. Diethylene glyco! dinitrate

. Dinitrophenol, salts

|. 1-Guanyl-4-nitrosaminoguany]-1-tetrazene
. Bis (2,4,6-trinitrophenyl)amine

. Hydrazine nitrate

. Nitroglycerine

. Pentaerythritol tetranitrate

. Cyclotrimethylene trinitramine

. Trinitroaniline

. 2,4,6-Trinitroanisole

. Trinitrobenzene

. Trinitrobenzoic acid

. Chlorotrinitrobenzene

. N-Methyl-N,2,4,6-N-tetranitroaniline

. 2,4,6-Trinitrophenol (Picric acid)

. Trinitrocresol

. 2,4,6-Trinitrophenetole

. 2,4,6-Trinitroresorcinol (Styphnic acid)

145,

147.
148.
149.
150.

151.

152.
153.
154.
155.

156.

157.

158.

159.

160.
161.

162.

163.

165.

166.
167.
168.

169.

170
17h,
172,
173.
174,
175.
176.
177,

178.

2,4,6-Trinitrotoluene

. Ammonium nitrate?

Cellulose nitrate (containing > 12.6% nitrogen)
Suiphur dioxide

Hydrogen chloride (liquified gas)

Flammable substances as defined in

Annex IV (c)(iii)

Sodium chlorate 1

tert-Butyi peroxyacetate (concentration > 70%)
tert-Buty! peroxyisobutyrate (concentration =80%)
tert-Butyl peroxymaleate (concentration > 80%)
tert-Butyl peroxy isopropyl carbonate
(concentration=80%)

Dibenzyl peroxydicarbonate (concentration>90%)
2,2-Bis (tert-butylperoxy) butane

(concentration> 70%)

1,1-Bis (tert-butylperoxy) cyclohexane.
(concentration> 80%)

Di-sec-butyl peroxydicarbonate

(concentration =80%)

2,2-Dihydroperoxypropane (concentration > 30%)
Di-n-propyl peroxydicarbonate

(concentration =80%)
3,3,6,6,9,9-Hexamethyl-1,2,4,5-
tetroxacyclononane(concentration > 75%)

Methy! ethyl ketone peroxide

(concentration 60%)

. Methyl isobutyl ketone peroxide

(concentration> 60%)

Peracetic acid (concentration 2 60%)

Lead azide

Lead 2,4-6-trinitroresorcinoxide (Lead styphnate)
Mercury fulminate
Cyclotetramethylenetetranitramine

2,2',4,4' ,6,6’-Hexanitrostilbene
1,3,5-Triamino-2,4,6-Trinitrobenzene

Ethylene glycol dinitrate

Ethyl nitrate

Sodium picramate

Barium azide

Di-isobutyry! peroxide (concentration > 50%)
Diethyl peroxydicarbonate (concentration > 30%)
tert-Butyl peroxypivalate (concentration > 77%)

1 Where this substance is in a state which gives
it properties capable of creating a major-accident
hazard.


7. Are piping, valves, and fittings designed
according to the recognized standards for the
working pressures, temperatures, structural
stresses, and chemical conditions to which they
may be subjected? Is non-destructive testing
conducted routinely to ensure that minimum wall
thicknesses are maintained?

8. Is piping well-supported and protected against
physical damage?

9. Are pipe lines for reactive chemicals pitched to
drain, with drain valves at low points?

10. Are main shutoff valves which can affect the
safety of the system conspicuously labeled?

11. Do shutoff valves indicate their ‘‘open’’ or
“‘shut’’ position?

12. Where improper operations or leaking of valves
can lead to hazardous situation, are interlocked
valves or double valves and vents used to
minimize hazard?

Protective Systems (not quality control)

1, Heating or cooling systems may be for product
control or for safety control. Cooling may be
necessary to prevent a runaway reaction in
reaction vessels. Reactive chemicals also may be
cooled in storage to provide more time to
respond to an initiated reaction.

What protective devices are there for the
heating or cooling systems? temperature

alarms? backup systems or redundancies?
procedural controls?

Are heat transfer materials for heating or
cooling incompatible with reactive materials?

Is refrigeration automatically actuated in
emergencies?

Are manual valves located in safe areas?

Are intermittent power failures considered and
backup provisions implemented?

2. Are there explosion suppression systems? How
are they tested and maintained?

3. Are systems inerted to exclude contaminants
which may be catalysts or reactive materials?
Examples include:

* Passivating vessels and piping or components
(before system startup).

© Providing an inert gas atmosphere such as a
nitrogen blanket on flammable materials.

© Submerging reactive materials (such as sodium
in kerosene).

Direct Fired Systems
Do furnaces and heaters have:

1. Adequate draft?

2. Positive fuel ignition?

3. Combustion safeguards?

4. Fuel controls?

5. Water or liquid level indicators?

6. Pressure relief devices?

7. High temperature alarms?

8. Emergency shutoff facilities?

9. Backflow protection?

Electrical Equipment

All wiring and electrical equipment in chemical plants
must be installed in accordance with the National
Electrical Code. Equipment used must be approved
where applicable.

1. Proper installation and maintenance is essential.

2. Adequate clearance or insulation shouid be
provided between conduits and hot surfaces to
prevent damage to the wiring insulation.

3. Equipment must be properly grounded and/or
bonded in hazardous areas to minimize static
electricity, both within and outside of equipment.
Are other appropriate steps taken to prevent
buildup of a static charge?

4. Equipment should be shielded from lightning by
protective ground wires, rods, or masts.


Materials Compatibility

At least two factors shouid be considered in materiais
selection: First, will the material(s) contaminate or
cause a reaction in the chemicals to be handled or
processed? Second, will the chemicals to be processed

processes, there are preferred materials; preferences
sometimes are economic, and sometimes they are
based on chemical reactivity or compatibility. The

ere is to identify readily 2
ere is to identify readily a

that might be used but that are incompatible with the
chemicals involved. (For example, copper tubing
should not be used with acetylene because it catalyzes
a reaction in the acetylene.) These questions are

pertinent to chemicals in all categories (i.e.,

health,

flammability, reactivity). Among questions to be

asked are:

1.

Are any metals incompatible with the chemicals
so that they should not be used for process

, OF storage syst

. Are any sealing materials for use in packing

(e.g., pumps) or gaskets (e.g., flanges)
incompatible with the chemicals so they should
not be used in process equipment, piping, or
storage systems?

. If incompatible materials are identified, what

procedures does the company have to ensure that
only acceptable materials are used in new or

ed equipment? Besides purchase order
ed equipment? Besides purchase order
specifications, is there also inspection by plant
personnel to ensure the specifications were
foliowed?

Contamination Control

Potentially reactive chemicals may have their

reactions catalyzed by cot

enter systems whenever seals are opened. Examples
include water or rust which may easily enter a system

durin: fi
during transfer froi

during hookup or disconnect, or during pressurizing
or venting of tanks.

1.

If such potential catalysts are identified, how are
they excluded from the system? Examples
include:

If vessels are pressurized by inert gases, are

there filters in the gas lines to remove solid
particles?

If vacuum relief or pressure relief valves are
on the vessels, how are they protected so no
potentially hazardous contaminant can enter
through them when open?

2. When systems are opened for maintenance
purposes, what precautions are taken to prevent

contamination? What is done to safeguard the
system while it is open? What precautions are
taken to ensure that replacement parts are free of
contaminants and/or incompatible materials?
When connections are made and broken (e.g.
during transfer from rail
measures are taken to ensure contaminants do not
enter the system?

Physical Facilities

Much plant equipment could be considered ancillary
to the production processes. Examples of systems that
may need to be present, properly inspected, and
functional are:

1. Emergency eye wash or shower.

3. Portable firefighting equipment, if employees or
a fire brigade are to use portabie firefighting
equipment.

Questions to be asked about these systems include:
How ofien are ihey iesied? What capac
have? Is the capacity sufficient for the anticipat
emergency?



3. How is information exchange accomplished
during transition periods (starting and stopping
work)?

4. Is operator jargon commonly and completely
understood by those affected by the jargon?
Examples: MIC—methyl isocyanate, Black
Betsy—boiler, Monitor—stationary firefighting
nozzles.

5. Are signals clear? Are audibie signais
distinguishable and understood?

6. How has management complied with
requirements of the OSHA Hazard
Communication Standard (29 CFR 1910.1200)?
Are monitoring records, training records, and
material safety data sheets available?

7. Standard operating procedures should be
examined and discussed. The process of updating
these procedures—inciuding modifications,
communication, and training—should be
understood.

8. Does a written emergency plan exist? It should
be discussed with management. It should be
understood which contingencies are included in
the plan, why they are included, and why
management considers them to be adequate for
the process, site, and situation.

The Personnel Subsystem

1. What are the job classifications of employees
who work at the site? Are all job titles present
on all work shifts? Are there potentially crucial
omissions?

2. Are employees aware of their roles during
emergencies? Are all critical tasks represented on
all shifts?

3. Who is responsible for training employees? How
often is training provided covering standard
operating procedures? Emergency procedures?
How is effectiveness of training evaluated by
management?

The Physical Subsystem.

It is obviously important to see the physical plant and
to relate information contained in operating
procedures, emergency plans, and ‘‘blueprints’’ with
actual structures, materials, and processes. In
inspecting the physical plant, the underlying question
is ‘‘What keeps this operation—or this phase of the
operation—within safe limits, including mechanical
and electronic systems, human intervention, and
routine maintenance activity?’’ Particular attention
should be given to:

Plant Layout

Plant layout has some specific safety aspects.
Examples include:

1, Separation and isolation

© Chemicals which may react with one another
are to be physically separated, e.g., oxidizers
are to be stored in areas remote from fuel
storage.

Areas of potential explosions (e.g., storage of
explosives, reaction vessels) are to be isolated
so if there is an explosion, the damage and
risk to employees is minimized.

2. Drainage

© Where hazardous liquids may leak or spill
from piping or vessels, what provisions are
made to prevent their spread to areas where
employees may be exposed to the hazard?
Examples of possible methods include diking
and grading.

© Has the company made any provisions to
control unexpected hazardous vapor or gas
releases within the drain lines?

3. Housekeeping
© Are work areas well maintained?
4. Enclosed spaces

© Some processes which are safe in open air may
become hazardous if enclosed. If areas of
potential or frequent leaks or spills are
enclosed to prevent environmental
contamination or the spread of the chemical,
are there adequate precautions to protect
employees? Examples include ventilating the
room and treating the exhaust; automatically
sampling the air in the room or vault; having
employees sample before entering the room.


APPENDIX Il

Acutely Toxic Chemicals

The Environmental Protection Agency published this
comprehensive list of acutely toxic chemicals in
November, 1985 to help identify hazardous chemicals
in use in the United States. This alphabetical list
contains the chemical name as well as the Chemical

Abstract Service (CAS) number.

Common Name

Acetone cyanohydrin
Acetone thiosemicarbazide
Acrolein

Acrylyl chloride
Aldicarb

Aldrin

Allyl alcohol

Allylamine

Aluminum phosphide
Aminopterin

Amiton

Amiton oxalate
Ammonium chloroplatinate
Amphetamine

Aniline, 2,4,6-trimethyl-
Antimony pentafluoride
Antimycin A

Antu

Arsenic pentoxide
Arsenous oxide
Arsenous trichloride
Arsine

Azinphos-ethyl
Azinphos-methy!
Bacitracin

Benzal chloride

Benzenamine, 3-(trifluoromethyl)-
Benzene, 1-(chloromethyl)-4-nitro-

Benzenearsonic acid

Benzenesulfony! chloride

Benzotrichloride

Benzyl chloride

Benzyl cyanide

Bicyclo[2.2. 1 Jheptane-2-
carbonitrile, 5-chloro...

Bis(chloromethy]) ketone

Bitoscanate

Boron trichloride

Boron trifluoride

Boron trifluoride compound
with methyl ether (1:1)

Bromadiolone

CAS Number

00075-86-5
01752-30-3
00107-02-8
00814-68-6
001 16-06-3
00309-00-2
00107-18-6
00107-11-9
20859-73-8
00054-62-6
00078-53-5
03734-97-2
16919-58-7
00300-62-9
00088-05-1
07783-70-2
01397-94-0
00086-88-4
01303-28-2
01327-53-3
07784-34-1
07784-42-1
02642-71-9
00086-50-0
01405-87-4
00098-87-3
00098- 16-8
00100-14-1
00098-05-5
00098-09-9
00098-07-7
00100-44-7
00140-29-4

15271-41-7
00534-07-6
04044-65-9
10294-34-5
07637-07-2

00353-42-4
28772-56-7

Butadiene

Buty! isovalerate
Butyl vinyl ether
C.I. basic green 1
Cadmium oxide
Cadmium stearate
Calcium arsenate
Camphechlor
Cantharidin
Carbachol chloride

Carbamic acid, methyl-, o-[[(2,4-dimethyl...

Carbofuran
Carbophenothion

Carvone

Chlordane

Chlorfenvinfos

Chlorine

Chlormephos
Chlormequat chloride
Chloroacetaldehyde
Chloroacetic acid
Chloroethanol
Chloroethy] chloroformate
Chloromethy] ether
Chloromethy] methyl! ether
Chlorophacinone
Chloroxuron
Chlorthiophos

Chromic chloride

Cobalt

Cobalt carbonyl

Cobalt, [[2,2°-[1,2-ethanediylbis

(nitrilomethy...
Colchicine
Coumafuryl
Coumaphos
Coumatetralyl
Cresylic acid
Crimidine
Crotonaldehyde
Crotonaldehyde
Cyanogen bromide
Cyanogen iodide
Cyanophos
Cyanuric fluoride
Cycloheximide
Cyclopentane
Decaborane(14)
Demeton
Demeton-S-methyl
Dialifos
Diborane
Dibuty! phthalate

Dichlorobenzalkonium chloride

Dichloroethy] ether

00106-99-0
00109-19-3
00111-34-2
00633-03-4
01306-19-0
02223-93-0
07778-44-1
08001-35-2
00056-25-7
00051-83-2
26419-73-8
01563-66-2
00786-19-6
02244-16-8
00057-74-9
00470-90-6
07782-50-5
24934-91-6
00999-81-5
00107-20-0
00079-11-8
00107-07-3
00627-11-2
00542-88-1
00107-30-2
03691-35-8
01982-47-4
21923-23-9
10025-73-7
07440-48-4
10210-68-1

62207-76-5
00064-86-8
00117-52-2
00056-72-4
05836-29-3
00095-48-7
00535-89-7
00123-73-9
04170-30-3
00506-68-3
00506-78-5
02636-26-2
00675-14-9
00066-81-9
00287-92-3
17702-41-9
08065-48-3
00919-86-8
10311-84-9
19287-45-7
00084-74-2
08023-53-8
00111-44-4

17


Instrumentation

Suitable controls and instruments should be provided
for both normal conditions of operation and for
emergencies. Instrumentation includes sensors,
indicators, recorders, and transmitters for
measurements such as temperature, pressure, flow,
liquid level, and analysis.

Many self-acting control devices, such as pressure
regulators, normally fail in the open position, which
may be the unsafe position. In such cases, emergency
backup controls should be provided. In the case of
pressure regulators, this includes pressure relieving
devices down-stream and automatic shutoff valves
interlocked with excess pressure switches.

1. Do instruments and controls consider failure in
their design?

© Examples: Control valves should be arranged
so that, on loss of instrument air or actuating
power, they will go into the safe position.
‘Where loss of instrument air or power could
lead to an unsafe condition, emergency air or
power supplies should be provided.

2. Are instruments made of material capable of
withstanding the corrosive or erosive conditions
to which they are subjected?

3. Do instrument sensors measure the true status of
the system they are designed to protect or
control?

* Examples: In a large reactor, many
thermocouples may be needed since the
temperature may not be uniform throughout. In
sensing liquid flow through a pipe, a flow
switch in the pipe is more reliable than
monitoring power supply to a pump.

4. Are grouped instrument leads and control
locations protected against exposure to explosion,
fire, or toxic chemicals where they are critically
needed to shut down the process safely? In
addition to normal controls, are accessible
emergency controls provided by which pumps or
automatic valves controlling the flow of
flammable liquids could be operated in event of
fire?

5. Are all indicating dials, indicating lights,
recorders, alarms, and switches which affect
Process safety conspicuously labeled as to their
function and meaning?

6. Are instruments constructed and installed so that
they can be easily inspected and maintained?

7. Are separate safety control and interlock systems
relied upon rather than relying on the production
process control system for safety supervision of
the process?

8. Are instruments in hazardous areas (as defined in
National Electrical Code) intrinsically safe or
enclosed so that they will not act as ignition
sources?

9. Are critical measurements recorded (as is
preferable) rather than merely indicated by lights
or dials so that rate of change in processes will
be more readily evident, and greater management
supervision can be maintained over operator
practices?

10. Do important control valves have steel bodies
and are they yoked to withstand fire exposure,
impact, and vibration?

11. How often is routine maintenance or replacement
performed on key instruments?

Piping Systems

Piping and instrument diagrams are used to follow the
formulation or reaction process and also to check
safety devices and system protections. Questions that
may be asked include:

1. Do reaction vessels, storage tanks, or pressure
vessels have safety relief devices to prevent
over-pressurization?

2. Are there shutoff valves that can render safety
relief devices ineffective? If so, what additional
precautions are taken?

3. Where do materials vent when released through
the safety relief devices?

4. If there is a loss of electrical or pneumatic
power, do controls fai] in a mode that is safe?

5. Will instrumentation detect leaks and spills?
(E.g., when material is being pumped from one
vessel to another, is there any check to assure
that as the level falls in one vessel, it rises in the
other?)

6. Are temperature or liquid level controls or
alarms provided?


U.S. Department of Labor
Occupationai Safety and Health Administration
1986

OSHA 3091



Response to Emergencies

Assessing the adequacy of a written emergency plan
is an art, not a science. It involves judgment as to the
reasonableness of the assumptions underlying the plan
(e.g., what is a reasonable worst-case estimate?) as
well as the adequacy of countermeasures designed to
protect life and to limit environmental and property
damage.

A few general principles may be useful in approach-

o this task:
g this task:

1. Are the priorities of the pian clearly stated as
to—safety of plant personnel and the public?
control of hazard? minimizing damage to
property?

2. Does the plan deal with reasonable accident
scenarios (minor incident to ‘‘worst case’’)?

3. Is the plan practical?

4. Is the plan simple?

we

. Is the plan easy to understand?

6. Will it deal with any type of emergency? For
example, are contingencies included for: fire and
explosion? release of highly toxic materials? large
chemical spills? acts of nature? power failure?
sabotage including bomb threats, etc.?

~

eo

. Is the plan updated periodically, e.g., annually or
whenever processes, materials, procedures, or
key personnel change?

9. Are there emergency drills or simulations
involving all members of the response team
including public agencies?

where improvement is needed?

* How are the results of the drill evaluations
communicated to the employees?

Are drills conducted for all shifts?

10

10.

. Has plant m

Are safety responsibilities a ‘‘critical element’’ in
supervisors’ performance standards? For
example, how is safety performance considered
relative to production demands an
into performance appraisals?

Has plant manage:

management worked with community
leaders to develop an appropriate public response

plan?

gency

plan, questions concerning control and coordination
include:

1.

Will one person be designated to coordinate all
efforts? Is there always an individual onsite who
has been trained and has the ability to take the
initial actions necessary to minimize the
emergency?

. Has there been prior consideration/coordination

of all pote:

es such

of all pote ‘esponse groups or ag

that there will not be loss of contro) due to over-
or underresponse?

. Does the safety committee have oversight relative

to the plan? Are employee representatives an
integral part of the committee? Are members
involved in plant audits? How do they receive
feedback on action taken relative to their
recommendations?


The design and construction of pressure vessels and
storage tanks 1 must be i in accordance with accepted

I. Pressure vessels must be designed and
constructed in accordance with applicable codes,
standards, state and local laws, and regulations.

© Vessels should be equipped with overpressure
protection as required. Vents should be
arranged to discharge to a point where ignition
of escaping vapors or liquids will not seriously
expose personnel, the equipment, or structures.
Relief devices should be kept free of corr

or fouling and should be operable at all times.

Often an inert atmosphere is mai ina
vessel or tank to keep the atmosphere out of
the flammable range. The consequences of
contamination or failure to use an inert gas
should be analyzed and equ

should be analyzed and equi
procedures should be devised to cover the
situation.

Unprotected sight glasses should be avoided in
Process equipment wherever possible.

. Storage tanks should be designed based on the

quantity, temperature, pressure, reactivity, and
corrosiveness of the material stored. The design
shouid include overpressure equipment and vents
and should consider the interrelationship of each
part of the overall system, e.g., the effect of a
gasket which blows out at 25 psi at one point in
the system when the relief valves are set at 60
psi.

Nv

Pumps and Compressors

Pumps and compressors are the workhorses of
chemical plants for moving every type of liquid and
gas.

1. Failure of moving parts or packing glands can
cause escape of flammable or toxic liquids or
gases. Remotely controlled switches and shutoff
valves are needed to control the flow of fuel in
an emergency.

Nv

Eq

ent used for transfer

nable vapors

or gases should be installed to minimize vibration
and thus to avoid loosening of fittings and joints.



Inspection and Maintenance

All equipment must be shut down sometime, no

matter

infrequently. When safety systems are

nfrequently. When safety systems are
shut down, what backup systems or procedures are
available to provide replacement protection (e.g., stop
process until safety systems are available again)? If
shutoff valves can isolate safety relief valves, what
measures ensure that the system is protected from
over- pressurization (e.g., person stationed to monitor
pressure)? What system is in place to ensure that
maintenance of critical safety features are corrected
immediately? What ensures that less critical features
are corrected within a reasonable period?

Pressure vessels also need periodic inspection and
testing because of normal wear and potential
corrosion either at weids or in the base material. The
combination of pressure and volume determine the
hazard: high volume, low pressure systems can have
the same potential energy for release as low volume,
high pressure systems.

When potentially corrosive chemicals are used (e.g.,
acids, caustics), or the plant atmosphere is corrosive

fe. ear the ocean, or

near the ocean, or from che:

ical releases

within the plant), what measures are taken to ensure
system integrity? Examples include periodic pressure
testing, x-ray, etc.

General Containment and Controls

During normal operations it is difficult if not
impossible to keep a material completely in a closed
system. Vacuum must be relieved when a liquid level
drops, and pressure must be Telieved when the tank is
nd Is

the questions to be asked focus on minimizing such
necessary releases and rendering the released
chemicals harmless before discharge to the
atmosphere. Examples of questions to be pursued
include:

1. Where do emergency relief vents discharge? Are
they piped to scrubbers, neutralizers,
incinerators, precipitators, etc. to remove
hazardous materials?

2. What precautions are taken to minimize spills
when connections are broken? Is the line purged
prior to the disconnect? Are purge gases treated?
Are quick disconnects used? Do employees wear
personal protective equipment (PPE) when
disconnecting? Is there a dike or some method to
collect and contain small spills or releases? Is the
area ventilated and is ventilated air treated?

Material Handling

As long as chemicals are maintained in a closed
system, they are safe and harmless. Che
Processes using hazardous chemicals should ‘be
designed to maintain that closed system. After design
and maintenance, the only potential probiems are:
introduction of raw materials into the closed system
and the removal of products (either the desired
product for shipment or waste) from the closed

systems. This section deals with those hazards.

1. How are raw materials received and shipped?

2. Are aterials transfers accomplished
2. Are raw materials transfers accomplished in a

closed system?

© Who performs transfer (company or shipper)?

Is the system pressurized or blanketed?

Do critical systems have connections that are
not interchangeable? Examples: potable water
with process water? water and reactive
chemicals? incompatible reactive chemicals?

3. How are unwanted products disposed of:

© Flare towers?

© Scrubbers?

Ditches: properly lined? Where do they drain?

© Tertiary treatment?

Are provisions made or considered to preclude
incompatible chemical mixing in waste
drainage?



Sodium anthraquinone-1-sulfonate
Sodium arsenate

Sodium arsenite

Sodium azide (Na(N3))
Sodium cacodylate
Sodium cyanide (Na(CN))
Sodium fluoroacetate
Sodium pentachlorophenate
Sodium selenate

Sodium selenite

Sodium tellurite
Strychnine

Strychnine, sulfate
Sulfotep

Sulfoxide, 3-chloropropyl octyl
Sulfur tetrafluoride

Sulfur trioxide

Sulfuric acid

TEPP

Tabun

Tellurium

Tellurium hexafluoride
Terbufos

Tetraethyllead
Tetraethyltin
Tetranitromethane

Thallic oxide

Thallous carbonate
Thallous chloride
Thallous malonate
Thallous sulfate

Thallous sulfate
Thiocarbazide

Thiocyanic acid, (2-benzothiazolylthio)

methyl...
Thiofanox
Thiometon
Thionazin
Thiopheno}
Thiosemicarbazide
Thiourea, (2-chlorophenyl)-
Thiourea, (2-methylphenyl)-
Titanium tetrachloride
Toluene 2,4-diisocyanate
Toluene 2,6-diisocyanate
Triamiphos
Triazofos
Trichloro(chloromethy!)silane
Trichloro(dichlorophenyl)silane
Trichloroacety! chloride
Trichloroethylsilane
Trichloronate
Trichlorophenylsilane
Trichlorphon
Triethoxysilane

20

00128-56-3
0763i-89-2
07784-46-5
26628-22-8
00124-65-2
00143-33-9
00062-74-8
00131-52-2
13410-01-0
10102-18-8
10102-20-2
00057-24-9
00060-41-3
03689-24-5
03569-57-1
07783-60-0
07446-11-9
07664-93-9
00107-49-3
00077-81-6
13494-80-9
07783-80-4
13071-79-9
00078-00-2
00597-64-8
00509-14-8
01314-32-5
06533-73-9
07791-12-0
02757-18-8
07446-18-6
10031-59-1
02231-57-4

21564-17-0
39196-18-4
00640-15-3
00297-97-2
00108-98-5
00079-19-6
05344-82-1
00614-78-8
07550-45-0
00584-84-9
00091-08-7
01031-47-6
24017-47-8
01558-25-4
27137-85-5
00076-02-8
00115-21-9
00327-98-0
00098- 13-5
00052-68-6
00998-30-1

Trimethylchlorosilane 00075-77-4
Trimethylolpropane phosphite 00824-11-3
Trimethyltin chloride 01066-45-1
Triphenyltin chloride 00639-58-7
Tris(2-chloroethyl)amine 00555-77-1
Valinomycin 02001-95-8
Vanadium pentoxide 01314-62-1
Vinyinorbornene 03048-64-4
Warfarin 0008 1-81-2
Warfarin sodium 00129-06-6
Xylylene dichloride 28347-13-9
Zinc phosphide 01314-84-7
Zinc, dichloro[4 ,4-dimethyl-5-

([[(methylamino)... 58270-08-9
Trans-1,4-Dichlorobutene 00110-57-6

2U.S. G.P.0, 1987- 181-519+64210


introduction

More than two thousand deaths from a methyl
isocyanate chemical leak in Bhopal, India, drew world
attention to the serious hazards in the chemical
industry. Following that tragedy, the Occupational
Safety and Health Administration (OSHA) developed
guidelines to aid employers in reducing the number of
potential hazards in chemical industries.

This publication is designed to encourage chemical
industry employers to review and strengthen overall
safety precautions to guard against chemical disasters.
It contains guidelines used by OSHA compliance
officers to evaluate employer safety programs,
particularly in the areas of disaster prevention and
emergency response. It also includes two lists of
acutely toxic chemicals whose presence in the
workplace should signal the need for safety and health
measures to protect workers.

The guidelines are aimed at the conditions and
processes found in the “chemical industry,” including
(but not limited to) firms in SICs 28 and 29.'
However, they are written to be used in a wide
spectrum of workplaces which produce industrial and
consumer chemical products.

OSHA also publishes a manual called “How to Prepare
for Workplace Emergencies” which can help any type
of business in developing an emergency plan. A free
copy may be obtained from any OSHA area office.

'Svandard Industrial Classification Manual, 972 Edition. Office of
Management and Budget, Statistical Policy Division, Government Printing
Office, Washington. (Pages 111-128.)

2


* Acute symptoms?

© Delayed symptoms?

© Bioassay tests?

* Special treatment required?

20. Have local health care professionals been
involved in the development or review of the

plan?

21. Is public information planned and is one person
designated as spokesperson to avoid speculation
and panic? coordinated with other responding
groups?

investigation responsibilities and procedures
developed? What is the policy on investigating
injury versus non-injury accidents? Are reports
required? Are causal analyses performed?

23. Has any consideration been given to potential
sewer contamination during an
emergency/disaster, ¢.g., introduction of
flammable/explosive or toxic materials into the
system?

Recordkeeping Requirements

The Secretary of Labor has said that “the comerstone
of any successful, effective safety and health program
is accurate and complete recordkeeping.” Because of
its importance, OSHA places special importance on
recordkeeping.

Employers of 11 or more employees must maintain
records of occupational injuries, illnesses, and deaths
as they occur. The purposes of keeping such records
are to inform employees of the effectiveness of their
employer's safety and health program, to permit the
Bureau of Labor Statistics (BLS) to complete survey
material, and to help define hazardous industries.

In addition, while the following items are not required
for all OSHA standards. they should be recorded to
accurately monitor and assess occupational hazards.

of measurement. operation involving exposure.
sampling and analytical methods used and evidence
of their accuracy: number. duration. and results of
samples taken: type of respiratory protective devices
worn: and name, social security number. and the
results of all employee exposure measurements. This
record should be kept for 30 years.

Employee physical/medical examinations, including
the name and social security number of the

employee: physicia
employee; physiciat

employee medical complaints related to exposure to
toxic substances: and information provided to the
examining physician. These records should be
maintained for the duration of empioyment plus 30
yes

Employee Training. These records should be kept
for one year beyond the last date of employment by
that employee

All records should be made available. upon request. to
the OSHA Assistant Secretary. the Director of
NIOSH, affected employees. former employees, and
designated representatives.

Training

An adequate emergency plan will address a training

& questions apply:

ors and employees

review and development in their areal

2. Have employees and front line supervisors been
trained in the recognition of early warning signs
(e.g., unusual odors or sounds, signs and
symptoms of exposure, unusual vessel!
temperature or pressure readings, leaks,
vibration, etc.)?

3. Is safety and emergency plan training provided to
all new employees and all other employees who

assume a new job? How often is eme!

response training repeated?

ency

4. Are front line supervisors involved in training
employees? To what extent?

5. Is there a method to evaluate training?

6. Are contractors who come on site required to
hazards and

precautions?

13


APPENDIX |

Toxic Chemicals

The following list was developed as part of an
international effort to identify chemical hazards.
OSHA adopted the list as published in 1985 by the

International Labor Organization as an aid in ranking

hazards for inspection targeting purposes.

i. 4-Aminodiphenyi

2. Benzidine

3. Benzidine salts

4. Dimethylnitrosamine

5. 2-Naphthylamine

6. Beryllium (powders, compounds)

7. Bis(chloromethyl)ether

8. 1,3-Propanesultone

9. 2,3,7,8-Tetrachlorodibenzo-p-dioxin (TCDD)

10. Arsenic pentoxide, Arsenic (V) acid and salts

11. Arsenic trioxide, Arsenious (III) acid and salts

12. Arsenic hydride (Arsine)

13. Dimethylcarbamoyl chloride

14. 4-(Chloroformyl) morpholine

15. Carbonyl chloride (Phosgene)

i6. Chiorine

17. Hydrogen sulphide

18. Acrylonitrile

19. Hydrogen cyanide

20. Carbon disulphide

21. Bromine

22. Ammonia

23. Acetylene (Ethyne)

24. Hydrogen

25. Ethylene oxide

26. Propyiene oxide

27, 2-Cyanopropan-2-o1 (Acetone cyanohydrin)

28. 2-Propenal (Acrolein)

29. 2-Propen-!-ol (Allyl alcohol)

30. Allylamine

31. Antimony hydride (Stibine)

32. Ethyleneimine

33. Formaldehyde (concentration=90%)

34. Hydrogen phosphide (Phosphine)

35. Bromomethane (Methyl bromide)

36. Methyl isocyanate

37. Nitrogen oxides

38. Sodium selenite

39. Bis(2-chloroethyl) sulphide

40. Phosacetim.

41. Tetraethyl lead

42. Tetramethyl lead

43. Promurit (1-(3,4-Dichlorophenyl)
-3-triazenethio-carboxamide)

. Chlorfenvinphos

. Crimidine

. Chloromethy! methyl ether

. Dimethyl phosphoramidocyanidic acid
. Carbophenothion

. Dialifos

. Cyanthoate

. Amiton

. Oxydisulfoton

. 0O-Diethy] S-ethylsulphinylmethy!

phosphorothioate

. OO-Diethy! S-ethylsulphonylmethyl

phosphorothioate

. Disulfoton

. Demeton

. Phorate

. OO-Diethy! S-ethylthiomethy! phosphorothioate
. OO-Diethy! S-isopropylthiomethyl

phosphorodithioate

. Pyrazoxon

. Pensulfothion

. Paraoxon (Diethyl 4-nitrophenyl phosphate)
. Parathion

. Azifiphos-ethy!

. OO-Diethy] S-propylthiomethyl

phosphorodithioate

. Thionazin

. Carbofuran

. Phosphamidon

. Tirpate (2,4-Dimethyl-1 ,3-dithiolane-

2-carboxaldehydeO- methylcarbamoyloxime
Mevinphos
Parathion-methyl

. Azinphos-methy!

. Cycloheximide

. Diphacinone

. Tetramethylenedisulphotetramine
. EPN

. 4-Fluorobutyric acid

. 4-Fluorobutyric
. 4-Fluorobutyric aci
. 4-Fluorobutyric acid, amides

. 4-Fluorocrotonic acid

. 4-Fluorocrotonic acid, salts

. 4-Fluorocrotonic acid, esters

. 4-Fluorocrotonic acid, amides

. Fluoroacetic acid

. Fluoroacetic acid, salts

. Fluoroacetic acid, esters

. Fluoroacetic acid, amides

. Fluenetil

. 4-Fluoro-2-hydroxybutyric acid

. 4-Fluoro-2-hydroxybutyric acid, salts
. 4-Fluoro-2-hydroxybutyric acid, esters

salts
, esters

15


Material contained in this publication is
in the public domain and may be
reproduced, fully or partially, without
permission of the Federal Government.
Source credit is requested but not
required. Permission is required only
to reproduce any copyrighted material
contained herein.


Safety & Health Guide
for the
Chemical Industry

U.S. Department of Labor
William E. Brock, Secretary

Occupational Safety and Health Administration
John A. Pendergrass, Assistant Secretary
1986

OSHA 3091


a

~

2

. Has the plan been distributed to:

© All key personnel up and down the company
chain of command including employee
representatives and the switchboard operator?

Police officials?

.

Fire officials and paramedics?

Local government?

Hospitals and physicians?
© Mutual aid industries?

® Utility companies?

. When changes are made in the emergency plan,

have provisions been established to communicate
those changes to individuals with a need to
know?

. What mechanisms exist to aliow the reporting of

nsafe acts or

hazard areas?

nauthorized employees in high

Will a coniroi cenier be established in a safe
location? Alternatively, are process control

centers already established in safe locations, with

appropriate architecture and support systems?

. Are procedures in place for notifying transient

personnel ‘on the site, such as delivery and
shipping services, of an emergency through the

sections)?”

. Are emergency rosters and call out plans

developed?

. Are emergency service listings and phone

numbers developed and distributed? Does the

switchboard operator have a copy? Do all phones

have a brief listing of immediately needed
emergency numbers posted on them?

. Are organizational charts developed and

distributed for day-to-day operators and
emergency operator:

. Are lists of raw materials, intermediates,

products, and their locations within the plant
provided with the plan?

* Are the associated hazardous chemicais listed
e with the O: H:

Communication Standard?

© Are flammable, reactive, physical, radioactive,

and other hazards liste:

© Are appropriate disposal methods listed?

. Are current maps. flow charts, diagrams, and

biueprints part of the pian? overail site map?
ining city and/or state maps inclu

topography? —_

. Will additional security be needed and planned

for?

Will strict accountability of personnel entering
and leaving the area be maintained?

Will only authorized personnel be granted
entry?

Will traffic control be a problem?

.

Are certain areas of the site more vulnerable to
sabotage?

vacations, holidays, a and 2nd and 3rd
shift situations considered?

. Have procedures been established for employees

who remain on site to Perform critical operations
4



Evacuation

It is essential that an effective plan for evacuation of
an area during an emergency situation be included in
the overall written emergency plan. Questions
concerning this aspect of the plan include:

1. Are decision logic charts available such that
supervisors on each shift could make an informed
decision to evacuate the site?

2. Are decision logic charts available such that the
supervisors on each shift could provide local
authorities the information necessary to decide
when to evacuate the surrounding population?

3. Has cooperation of the local weather bureau been
coordinated to predict temperature, winds,
inversion levels, and other meteorologic
conditions that could affect gas or vapor
concentrations?

4. Are formulas or dispersion models provided for
calculating concentrations of air contaminants
down wind?

5. Have evacuation routes inside and outside the
plant been planned and coordinated with local
authorities?

* Have employees and the local populace been
informed of the routes to be used?

¢ Are primary and alternate evacuation routes
clearly indicated in the plan?

6. Are detection and alarm systems provided, e.g.,
for fire or toxic release?
© Are there any periodic checks to ensure that
detection and alarm systems are maintained in
operable conditions?
© Do alarm systems meet the requirements, as
appropriate, of 29 CFR 1910.165?
7. Are evacuation instructions and signals for

evacuation clear and understood by employees
and by the surrounding populace?

8. Have provisions been made for the evacuation of
handicapped persons?

9. Have ‘‘safe distances’’ been considered when
regrouping areas were designated?

10. Have evacuation wardens been designated?

11. Are supervisors on each shift capable of
executing the entire plan on their own?

14

12. Are employees instructed to proceed to
Tegrouping points located cross wind from the
contaminant’s source and at a ‘‘safe distance’’
from the danger zone? Are the regrouping points
well known by employees? Have restrictive
topographical conditions been considered?

© Is there a wind sock or wind vane on the site
to determine wind direction?

Is a complete copy of the emergency plan
located in a safe place?

© Are adequate supplies and equipment located at
these points?

© Are key personnel designated to make
accountability checks at the regrouping points
and to report the medical conditions of those
present and the names of those missing?

Are adequate communication systems available
at these points?

Reentry and Cleanup

When evaluating plans for reentry and cleanup of an
area which has been evacuated due to an emergency
situation, the following questions should be
considered:

1. Will safe levels for reentry be determined
through environmental sampling by competent
persons?

2. Are chemical residues likely to present a hazard?

3. Could the disaster have created unstable
chemicals?

4. Are ‘‘booby traps”’ likely to be present from the
incident?

© Hangup?
© Unstable structures?

© Developed pressure in pipes, vessels,
containers, and pumps?

5. Are employees qualified to do cleanup tasks?
‘Will greater hazards likely result from attempting
to maintain their employment rather than with
contract companies who are experienced in the
fequired tasks?

6. How is equipment decontaminated?

7. Is critical safety equipment on hand prior to
Startup operations?