## APP E N D I XA: 40 CFR P A RT 6 81 

### TITLE 40 - PROTECTION OF ENVI RONMENT

CHAPTER I - ENVI RONMENTAL PROTECTI ON AGENCY (CONTINU ED)

PART 68 - CHEMICAL A CCIDENT PREVENTI ON PROVISI ONS Subpart A - General

Sec. 68.1 Scope. 68.2 Stay ed provis ions. 68.3 Def initions. 68 .1 0 A pp li ca bi li ty. 68.12 General re quireme nts. 68.15 Man ageme nt. Subpart B - Hazard Assessment

68.20 App licability 68.22 Off site cons equenc e analy sis para meters. 68.25 Worst-case r elease scenar io analy sis. 68.28 Alte rnative releas e scena rio anal ysi s. 68.30 Defining offsite impacts - population. 68.33 Def ining of fsite impa cts - environment. 68.36 Review and update. 68.39 Documentation. 68 .4 2 F iv e- yea r a cc id en t h is to ry. Subpart C - Program 2 Prevention Program

68.48 Safety information. 68.50 Hazard review. 68.52 Ope rating procedu res. 68.54 Train ing. 68.56 Maintenance. 68.58 Compl iance a udits. 68.60 Incident investigation. Subpart D - Program 3 Prevention Program

68.65 Process safety information. 68.67 Proc ess hazar d analy sis. 68.69 Ope rating procedu res. 68.71 Train ing. 68 .7 3 M ec ha ni ca l i nt eg ri ty.

### 68.75 Management of chang e. 68.77 Pre-startup review. 68.79 Compl iance a udits. 68.81 Incident investigation. 68.83 Employee par ticipation. 68.85 Hot work perm it. 68.87 Contr actors. Subpart E - Emerg ency Response

68 .9 0 A pp li ca bi li ty. 68.95 Eme rgenc y r esponse p rogra m. Subpart F - Regulated Substances for Acc idental Release Prevention

68.100 Purpose. 68.115 Threshold determination. 68.120 Pet ition proc ess. 68.125 Exem ptions. 68.126 Exclusion. 68.130 List of subst ances. Subpart G - Risk Management Plan

68.150 Submission. 68.151 Assertion of claims of confidential business information. 68.152 Substantiating claims of confidential business information. 68 .1 55 Ex ec ut iv e s um ma ry. 68.160 Registration. 68.165 Of fsite con sequenc e analy sis. 68 .1 68 Fi ve -ye ar ac ci de nt hi st or y. 68.170 Prevention program/Program 2. 68.175 Prevention program/Program 3. 68.180 Eme rgenc y r esponse p rogra m. 68.185 Certification. 68.190 Up dates. Subpart H - Other R equirem ents
68.20 0 Reco rdkeep ing. 68.210 Availability of information to the public. 68.215 Per mit conten t and air permittin g autho rity or desig nated ag ency require ments. 68.220 Au dits. Appendix A t o Part 68 -Table of Toxic Endpo ints

### Authority: 42 U.S.C. 7412(r), 7601(a)( 1), 7661-7661f. Source: 59 FR 4493, Jan. 31, 1994, unless otherwise noted. Subpart A - General § 68.1 Scope. This part sets forth the list of regulated substances and thre sholds, the petition process for adding or deleting substances to the list of regulated substanc es, the requirements for owners or operato rs of stat ionary sources concer ning the prevent ion of ac cidenta l releas es, and th e State accide ntal rele ase pre vention pr ograms approve d under se ction 112( r). The l ist of subst ances, threshol d quantitie s, and ac cident pr evention regula tions promu lgated under thi s part do n ot limit in any way the general duty provisions under section 112(r)(1). § 68.3 Def initions. For the p urposes o f this par t: Accidental release means an unanticipa ted emission of a regulated substance or other extremely hazardous substance into the a mbient air from a stationary source. Act means the Clean Air Act as amended (42 U.S.C. 7401 et seq.) A dministrative controls mean wri tten proc edural m echanis ms used fo r hazard control. Ad mi ni st ra to r m ea ns th e a dm in is tr at or of th e U .S . E nv ir on me nt al Pr ot ec ti on Ag en cy. AIChE/CCPS means the American I nstitute of Chemical Engineers/Center for Chemical Pr oc es s S af et y. API means the American Petr oleum Institute. Article means a m anufac tured ite m, as def ined unde r 29 CFR 19 10.1200( b), that is formed to a specif ic shape or desig n during manufacture, tha t has end u se funct ions depe ndent in whole or in part up on the sha pe or des ign duri ng end u se, and th at does no t releas e or othe rwise result in exposure to a regulated substance under norma l conditions of processing and use. ASME mean s the Amer ican Soci ety of Mecha nical Eng ineers. CAS means the Chemical Abstracts Service. Catastrophic release means a major uncontrolled e mission, fire, or explosion, involving
one or mor e regu lated sub stances that pre sents immin ent and su bstantial endang erment to public health a nd the env ironment. Classified information means ``classified infor mation'' as defined in the Classified Information Procedures A ct, 18 U.S.C. App. 3, section 1(a) as ``a ny information or mater ial that has been determined by the United States Government pursuant to an executive order, statute, or regulat ion, to req uire p rotect ion aga inst unaut horiz ed dis closu re for r eason s of na tion al secu rity.'' Condensa te means hyd rocarb on liquid se parate d from na tural g as that c ondense s due to chang es in tempe rature , pressur e, or both , and remains liquid at standa rd condit ions. Covered process means a process that has a regulated substance present in more tha n a threshold quantity as deter mined under § 68.115. Crude oil means any na turally occur ring, unrefined petroleum liquid. Designated agency means the state, local, or Federal ag ency de signated by the state under

### the provisions of § 68.215(d). DOT means the United States Department of Transportation. Environmental receptor means natural are as such as national or state parks, forests, or monuments; officially desig nated wildlife sanctuaries, preserves, re fuges, or areas; and Fe deral wilderness areas, that could be exposed at any time to toxic concentrations, radiant heat, or overpressure greate r than or equal to the endpoints provided in § 68.22(a) , as a result of a n accide ntal rele ase and t hat can b e identif ied on loc al U. S. Ge ologica l Survey maps. Field gas means gas extracte d from a production well before the ga s enters a natural gas process ing plan t. Hot work m eans wor k involving electri c or ga s welding , cutting , brazing , or simila r flame or spark -produc ing ope rations. Implementing ag ency mea ns the state or local agency that obtains delegation for an accidental release prevention prog ram under subpart E, 40 CFR part 63. The implementing agency may, but is not required to, be the sta te or local air permitting agenc y. I f no state or local agency is granted delegation, EPA will be the implementing a gency for that state. Injur y me ans any effec t on a huma n that re sults eithe r from dir ect exposu re to toxic concentrations; radiant heat; or overpressure s from accidental releases or from the dir ect consequences of a vapor cloud explosion (such as fly ing glass, debris, and other projectiles) f rom an accidental release and that re quires medical treatment or hospitalization. Major change means introduction of a new process, process equipment, or regula ted substance, an alteration of process chemistry that results in any chang e to safe operating limits, or other alteration that introduces a new hazard. Mechanical integrity means the process of ensuring that proce ss equipment is fabricated from the p roper ma terials o f constr uction an d is prope rly installed , maintained, and r eplace d to prevent failure s and acc idental r elease s. Medical treatment means treatment, other than first aid, administere d by a phy sician or registered professional personnel unde r standing orders from a phy sician. Mitigation or mitigation system mea ns specific activities, technologies, or equipment desig ned o r dep loy ed to capt ure o r con trol s ubsta nces upon l oss of cont ainme nt to m inimi ze exposure of the public or the environment. Passive mitigation means equipment, devices, or technologies that function without human, mechanical, or other e nergy input. Active mitigation means eq uipment, d evices, or techn ologies that nee d human, me chanica l, or othe r energ y in put to function. NAI CS means North Amer ican I ndustry Classific ation Sy stem. NFPA means the National Fire Protection Association. Natural gas processing plant ( gas plant) means any processing site engag ed in the extractio n of natur al gas l iquids fro m field g as, fra ctionation of mixed na tural g as liquids t o natural gas products, or both, classified as North Ame rican Industrial Classification Sy stem (NAICS) code 211112 (pre viously Standard I ndustrial Classification (SIC) code 1321). Offsite means areas bey ond the property bounda ry of the stationar y source, a nd areas within the property boundar y to which the public has routine a nd unrestricted access during or outside bu siness hou rs. 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.

### Petroleu m refinin g proc ess unit me ans a pro cess unit used in an establish ment prima rily engag ed in petr oleum re fining a s define d in NAI CS code 324 11 for pe troleum r efining (former ly SIC code 2911) and used for the following: Producing transportation fuels (such as g asoline, diesel fuels, and jet fuels), heating fuels (suc h as kerosene, fuel gas distillate, and fuel oils), or lubrica nts; Separ ating pe troleum; o r Separa ting, cr acking , react ing, or r eforming intermed iate petroleum streams. Examples of such units include, but are not limited to, petroleum based solvent un its, alky lation unit s, catal ytic hyd rotrea ting, ca taly tic hy droref ining, c ataly tic hydrocrac king, catal ytic refor ming, catal ytic crack ing, cr ude di stil lati on, l ube oi l proc essin g, hydrogen p roduc tion , iso meriz ation , pol ymerizat ion, therm al pro cesses , and b lendi ng, sweeten ing, and treatin g proc esses. Pe troleum r efining process units inclu de sulfur plants. Population means the public. Process means any activity involving a re gulated substance including any use, storage, manufacturing, handling , or on-si te moveme nt of such substanc es, or co mbination o f these activities. For the purposes of this definition, any group of vessels that are interconnec ted, or separate vessels that are located such tha t a regulated substance could be involved in a potential release, shall be considered a sing le process. Produced water means wate r extracted from the earth from an oil or natural gas produc tion well, or that is separated from oil or natural gas af ter extraction. Public means any person except employees or c ontractors at the stationary source. Public re ceptor m eans off site resi dences, institution s (e.g. , schools, hospitals) , industria l,
commerc ial, and o ffice b uildings , parks, or recr eationa l areas inhabite d or occu pied by the public at any time without restriction by the stationary sourc e where members of the public could be exposed to toxic concentrations, radiant heat, or overpressure, as a r esult of an accidental release. Regula ted substa nce is an y su bstance listed pur suant to se ction 112( r)(3) o f the Clea n Air Act as amended, in § 68.130. Replace ment in kind means a r eplace ment that s atisfies the desig n specif ications. Retail fa cility means a s tationar y so urce at which mor e than one -half of the incom e is obtained from direct sales to end users or at which more tha n one-half of the fuel sold, by volume, is sold throu gh a cy linder e xchange progra m. RMP means th e risk man ageme nt plan re quired un der subpa rt G of thi s part. Stationary source me ans any buildings, struc tures, equipment, installations, or substance emitting stationary a ctivities which belong to the same industrial group, which are located on one or more contiguous properties, which are unde r the control of the same person (or persons under common control), and from which an accidental re lease may oc cur. The term stationary source does not apply to transportation, including storage incident to transportation, of any regulated substance or any other extremely hazardous substanc e 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 stationar y source f or loading or unloading. Transportation includes, but is not limited to, transportation subject to oversight or regula tion under 49 CFR par ts 192, 193 , or 195, o r a state natural gas or hazardous liquid program for which the state has in eff ect a certification to DOT under 49 U.S.C. section 60105. A stationar y so urce doe s not inclu de natur ally occurr ing hy drocar bon rese rvoirs. Pr opertie s shall
no t b e c on si de re d c on ti gu ou s s ol el y be ca us e o f a ra il ro ad or pi pe li ne ri gh t- of -w ay. Thresho ld quantity means the quantity specifie d for re gulate d substanc es pursua nt to section 112(r)(5) of the Clean Air Act as ame nded, listed in § 68.130 and determined to be

### present at a stati onary source a s specif ied in § 68. 115 of this part. Typical meteor ological conditions means the temperature, wind speed, c loud cover, and atmospheric stability class, pre vailing at the site based on data gather ed at or near the site or from a local meteorological station. Vessel means any reactor, tank, drum, barrel, cy linder, vat, kettle, boiler, pipe, hose, or other container. Worst-case release means the relea se of the largest quantity of a regulated substance fr om a vessel or process line failure that results in the gr eatest distance to an endpoint defined in § 68.22(a). [59 FR 4493, Jan. 31, 1994, as amended at 61 FR 31717, June 20, 1996; 63 FR 644, Jan. 6, 1998; 64 FR 979, Jan. 6, 1999; 65 FR 13250, Mar. 13, 2000] § 6 8. 10 Ap pl ic ab il it y.

(a) An owner or operator of a stationary source that has more than a threshold quantity of a regulated substance in a proce ss, as determined under § 68.115, shall comply with the require ments of th is part no later tha n the late st of the f ollowing dates: (1) June 21, 1999; (2) Three y ears after the date on which a re gulated substance is first listed under § 68.130; or (3) The date on which a reg ulated substance is first present above a threshold quantity in a process

.

(b) Prog ram 1 elig ibility require ments. A c overed p rocess i s eligib le for Pr ogram 1 require ments as p rovided i n § 68.12( b) if it me ets all of the follow ing req uiremen ts: (1) For the five y ears prior to the submission of an RMP, the process has not had an accidental releas e of a re gulate d substanc e where exposure t o the subst ance, it s react ion produc ts, ov er pr es su re ge ne ra te d b y an ex pl os io n i nv ol vi ng th e s ub st an ce , o r r ad ia nt he at ge ne ra te d b y a fire involving the substance led to any of the following offsite: (i) Death; (ii) Injury ; or (iii) Response or restoration activities for an exposure of an environmental re ceptor; (2) The distance to a toxic or flammable endpoint for a worst-ca se release assessment conducted under Subpart B and § 68.25 is less than the distance to any public receptor, as defined in § 68.30; and

(3) Emergency response procedures have bee n coordinated between the stationary source and local eme rgenc y pl anning and resp onse org anizations

. (c) Prog ram 2 elig ibility require ments. A c overed p rocess i s subject to Progr am 2 requ irements if it does n ot meet the eligibil ity r equirem ents of e ither pa ragra ph (b) or parag raph (d) of this section.

(d) Program 3 eligibility requirements. A covered process is subject to Prog ram 3 if the process does not meet the requirements of parag raph (b) of this section, and if either of the following condition s is met: (1) The process is in NAI CS code 32211, 32411, 32511, 325181, 325188, 325192, 325199, 325211, 325311, or 32532; or

(2) The process is subject to the OSHA process safet y management standard, 29 CFR

### 1910.119. (e) I f at any time a cov ered pr ocess no l onger meets the eligibil ity c riteria of its Prog ram leve l, the owner or operator shall comply with the requirements of the new Program leve l that applies to the process and update the RMP as provided in § 68.190.

(f) The provisions of this part shall not apply to an Outer Continental Shelf (``OCS'' ) source, as defined in 40 CFR 55.2. [61 FR 31717, June 20, 1996, as amended at 63 FR 645, Jan. 6, 1998; 64 FR 979, Jan. 6, 1999] § 68.12 Ge neral r equirem ents. (a) General re quireme nts. The o wner or operato r of a sta tionary source s ubject to this part s hall submit a single RMP, as provided in Sec.§ 68.150 to 68.185. The RMP shall include a regist ration tha t reflec ts all cove red proc esses. (b) Prog ram 1 re quireme nts. I n addition to meeting the requ irements of para graph (a) of th is section, the owner or operator of a stationary source with a process eligible for Prog ram 1, as provided in § 68.10( b), shall : (1) Analyze the worst-case release scenar io for the process(es), as provided in § 68.25; document that the nearest public receptor is bey ond the distance to a toxic or flammable endpoint defined in § 68.22(a); and submit in the RMP the worst-case release sce nario as provided in § 68.165;

(2) Complete the five-y ear accident history for the process as provided in § 68.42 of this part and submit it in the RMP as provided in § 68.168;

(3) Ensure that response actions have been c oordinated with local emergency planning and response agencies; and

(4) Cert ify in the RMP the following : ``B ased on th e criter ia in 40 CF R 68.10, the distance to the spec ified endpoint for the worst-case a ccident al relea se scena rio for th e followi ng proc ess(es) is less than the distance to the nearest public receptor: [list process(es)]. Within the past five ye ars, the process (es) ha s (have) had no ac cidenta l releas e that ca used off site impacts provide d in the risk management progra m rule (40 CFR 68.10(b)(1)). No additional measures are necessary to prevent offsite impacts from accidental relea ses. In the event of fire , explosion, or a release of a regu lated sub stance f rom the pr ocess(e s), entr y within the di stance t o the spec ified endpoints may pose a da nger to public emergenc y responders. Therefore, public emerge ncy responde rs should not e nter this a rea exce pt as arr anged with the e merge ncy contact indicate d in the RMP. The undersigned certifies that, to the best of my knowledge, information, and belief, formed a fter reasonable inquiry , the information submitted is true, accurate, and complete. [Signature, title, date s igned] .''

(c) Prog ram 2 re quireme nts. I n addition to meeting the requ irements of para graph (a) of th is section, the owner or operator of a stationary source with a process subject to Program 2, as provided in § 68.10( c), shal l: (1) Develop and implement a manageme nt system as provided in § 68.15; (2) Conduct a hazard assessment as provided in Sec.§ 68.20 through 68.42; (3) Implement the Progr am 2 prevention steps provided in Sec.§ 68.48 through 68.60 or implement the Program 3 prevention steps provided in Sec.§ 68.65 through 68.87;

### (4) Dev elop and i mplement a n emerg ency response progra m as provi ded in Sec .§ 68.90 to 68.95; and

(5) Submit a s part of the RMP the d ata on pr evention progra m element s for Prog ram 2 processes as provided in § 68.170.

(d) Prog ram 3 re quireme nts. I n addition to meeting the requ irements of para graph (a) of th is section, the owner or operator of a stationary source with a process subject to Program 3, as provided in § 68.10( d) shall: (1) Develop and implement a manageme nt system as provided in § 68.15; (2) Conduct a hazard assessment as provided in Sec.§ 68.20 through 68.42; (3) Implement the preve ntion requirements of Sec.§ 68.65 through 68.87; (4) Dev elop and i mplement a n emerg ency response progra m as provi ded in Sec .§ 68.90 to 68.95 of this part; and

(5) Submit a s part of the RMP the d ata on pr evention progra m element s for Prog ram 3 processes as provided in § 68.175. [61 FR 31718, June 20, 1996] § 68.15 Ma nageme nt. (a) The owner or operator of a stationary sourc e with processes subject to Program 2 or Progra m 3 shall de velop a ma nageme nt sy stem to ove rsee the implement ation of th e risk manage ment prog ram elem ents. (b) The owner or operato r shall as sign a qu alified p erson or position tha t has the o verall responsibility for the development, implementation, and integ ration of the risk management progra m element s. (c) When responsi bility for imple menting individua l require ments of th is part is a ssigned to persons other than the person identified under parag raph (b) of this section, the names or positions of these people shall be documented and the lines of authority defined through an organ ization cha rt or simila r docume nt. [61 FR 31718, June 20, 1996] Subpart B - Hazard Assessment Source: 61 FR 31718, June 20, 1996, unless otherwise noted. § 6 8. 20 Ap pl ic ab il it y.
The owne r or oper ator of a stationar y so urce sub ject to thi s part sha ll prepa re a wor st-case release scenario analy sis as provided in § 68.25 of this part and complete the five-y ear accident history as provid ed in § 68. 42. The ow ner or op erator of a Prog ram 2 and 3 proces s must compl y with all se ctions in th is subpar t for thes e proce sses. § 68.22 Of fsite con sequenc e analy sis para meters.

### (a) Endpoints. For analy ses of offsite consequences, the following e ndpoints shall be used: (1) Toxics . The toxic e ndpoints pr ovided in a ppendix A of this part. (2) Flammables. The endpoints for flammables vary according to the scenarios studied: (i) Explosion. An over pressur e of 1 psi. (ii) Radia nt heat/exposure time . A radia nt heat of 5 kw/m 2 

### for 40 se conds. (iii) Lower flammability limit. A lower flammability limit as provided in NFPA documents or other g eneral ly r ecogn ized sourc es. (b) Wind speed/atmospheric stability class. F or the worst-case release ana lysis, the owner or operator shall use a wind speed of 1.5 meters per se cond and F atmospheric stability class. If the owner or operator can demonstrate tha t local meteorological data applicable to the stationary source show a higher minimum wind speed or less stable atmosphere at all times during the previous three years, these minimums may be use d. For analy sis of alternative scenarios, the owner or operator may use the typical meteor ological conditions for the stationary source. (c) Ambi ent tempe rature /humidity . For wor st-case releas e analy sis of a re gulate d toxic substance, the owner or operator shall use the hig hest daily maximum temperature in the previous three y ears an d avera ge humid ity f or the site , based o n temper ature/h umidity data gathered at the stationary source or at a local meteorologica l station; an owner or operator using the RMP Offsite Consequence Analy sis Guidance may use 25 o 

### C and 50 percent humidity as values f or these variabl es. For analy sis of alte rnative scenar ios, the ow ner or op erator may use typical tempera ture/humidity data ga thered at the stationary source or at a local meteorologica l station.

(d) Height of release. The worst-case release of a r egulated toxic substance shall be analy zed assuming a grou nd level ( 0 feet) releas e. For a n altern ative sc enario a naly sis of a re gulate d toxic substance, release height may be determined by the release scenario. (e) Surface roughness. The owner or operator shall use either urban or rural topography , as appropriate. Urban means that there ar e many obstacle s in the immediate area; obstacles include building s or tree s. Rural me ans ther e are no building s in the imme diate ar ea and th e terra in is generally flat and unobstructed. (f) Den se or neu trally buoy ant gas es. The o wner or operato r shall en sure tha t tables or models
us ed fo r d is pe rs io n a na lys is of re gu la te d t ox ic su bs ta nc es ap pr op ri at el y ac co un t f or ga s d en si ty. (g) Temperature of re leased substance. For worst case, liquids other than g ases liquified by refrigeration only shall be considered to be released at the hig hest daily maximum temperature, based on data for the prev ious thre e y ears ap propria te for the stationar y so urce, or at proce ss temperature, whichever is higher . For alternative scenarios, substances may be considered to be released at a process or ambient temper ature that is appropriate for the scenar io. § 68.25 Wor st-case releas e scena rio anal ysi s. (a) The owner or operato r shall an aly ze and re port in the RMP: (1) For Progra m 1 proce sses, one worst-c ase rel ease sc enario f or each Progra m 1 proce ss; (2) For Progra m 2 and 3 pr ocesses : (i) One worst-case release scenario that is estimated to create the gr eatest distance in any direction to an end point prov ided in ap pendix A of this part r esulting from an a ccident al relea se of regulated toxic substances from covered pr ocesses under worst-case conditions defined in § 68.22;

### (ii) One worst-case release sc enario that is estimated to create the gre atest distance in any direction to an endpoint defined in § 68.22(a) resulting from a n accidental release of reg ulated flammable substances from covered proce sses under worst-case conditions defined in § 68.22; and

(iii) Additional worst-case release scenar ios for a hazard class if a worst-case re lease from another covered process at the stationary source potentially a ffects public receptors different f rom those pote ntially affec ted by the worst-case r elease scenar io develo ped unde r parag raphs (a )(2)(i) or (a)(2)(ii) of this section.

(b) Determination of worst-case relea se quantity. The worst-c ase release quantity shall be the greater of the follo wing:

(1) For substances in a vessel, the gr eatest amount held in a single vessel, taking into acc ount administrative controls that limit the maximum quantity; or

(2) For substances in pipes, the grea test amount in a pipe, taking into account administrative
co nt ro ls th at li mi t t he ma xi mu m q ua nt it y.

(c) Worst-case release scena rio - toxic gases. (1) For reg ulated toxic substances that are normally ga ses at ambient temperature and handled as a g as or as a liquid under pressure, the owner or operator shall assume that the quantity in the vessel or pipe, as determined under paragraph (b) of this section, is relea sed as a gas over 10 minutes. The relea se rate shall be assumed to be the total quantity divided by 10 unless passive mitigation systems are in place. (2) For gases handled as r efrigerated liquids at ambient pressure: (i) If the relea sed substance is not contained by passive mitigation systems or if the c ontained pool would have a d epth of 1 c m or less, t he owner or opera tor shall a ssume tha t the substa nce is releas ed as a g as in 10 min utes; (ii) I f the re leased s ubstance is contained by passive m itigatio n sy stems in a p ool with a d epth greater than 1 cm, the owner or operator may assume that the quantity in the vessel or pipe , as determined under parag raph (b) of this sec tion, is spil led instan taneousl y to form a liq uid pool. The volatilization rate (release rate) shall be ca lculated at the boiling point of the substance and at the conditions specified in paragraph (d) of this section. (d) Worst-case release scenar io - toxic liquids. (1) For regulated toxic substances that are normally liquids at a mbient tem peratur e, the ow ner or op erator shall assu me that the quantity in the vesse l or pipe, as deter mined unde r parag raph (b) of this sec tion, is spil led instan taneousl y to form a liq uid pool. (i) The surface area of the pool shall be determined by assuming that the liquid spreads to 1 centimeter deep unless passive mitigation systems are in place that serve to contain the spill and limit the surface area. Where passive mitigation is in place, the surface area of the conta ined liquid shall be used to calculate the volatilization rate.

(ii) If the relea se would occur onto a surface that is not paved or smooth, the owne r or operator may take into accoun t the actu al surfa ce char acteris tics. (2) The volatilization rate shall account for the highest daily maximum temperature occurring in the past three ye ars, the temperature of the substance in the vesse l, and the concentration of the substance if the liquid spilled is a mixture or solution.

(3) The r ate of r elease to air sha ll be dete rmined fr om the vola tilization r ate of th e liquid po ol. The owne r or oper ator may use the me thodolog y in the RMP Off site Conse quence Analysis Guidance or any other publicly available techniques that account for the modeling conditions and are recognized by industry as applicable a s part of current practices. Proprietar y models that

### account for the modeling conditions may be used provided the owner or operator a llows the implementing agency access to the model and describes model feature s and differences from publicly availab le models t o local e merge ncy planner s upon req uest. (e) Worst-case release scena rio - flammable gases. The owner or operator shall assume that the quantity of the substance, a s determined under paragra ph (b) of this section and the provisions below, vaporizes resulting in a vapor cloud explosion. A y ield factor of 10 percent of the available energy released in the explosion shall be used to determine the distance to the explosion endpoint i f the mode l used is ba sed on TNT equivale nt methods

. (1) For regulated flammable substances that are normally gases at ambient temperature and handled as a gas or as a liquid under pre ssure, the owner or operator shall assume that the quantity in the ves sel or pip e, as det ermined under pa ragra ph (b) of this secti on, is rel eased a s a gas over 10 minutes. The total quantity shall be assumed to be involved in the vapor cloud explosion.

(2) For flammable gases ha ndled as refrigerated liquids at ambient pre ssure: (i) If the relea sed substance is not contained by passive mitigation systems or if the c ontained pool would have a depth of one centimeter or less, the owner or operator shall assume that the total quantity of the substance is re leased as a gas in 10 minutes, and the total quantity will be involved in the vapor cloud explosion.

(ii) I f the re leased s ubstance is contained by passive m itigatio n sy stems in a p ool with a d epth greater than 1 centimeter, the ow ner or operator may assume that the quantity in the vessel or pipe, as d etermine d under p aragr aph (b) o f this sec tion, is spil led instan taneousl y to form a liq uid pool. The volatilization rate (release rate) shall be ca lculated at the boiling point of the substance and at the condition s specif ied in par agrap h (d) of t his section. The ow ner or op erator shall assume that the quantity which be comes vapor in the first 10 minutes is involved in the vapor cloud explosion.

(f) Worst-case release scena rio - flammable liquids. The owner or operator shall assume that the quantity of the substance , as determinedunder paragr aph (b) of this section and the provisions below, vaporizesresulting in a vapor cloud explosion. A y ield factor of 10 percent of theavailable energy released in the explosion shall be used to determine thedistance to the explosion e ndpoint if the model used is ba sed on TNT equivale nt methods

. (1) For regulated flammable substances that are normally liquids at ambient temperature, the owner or operator shall assume that the entire quantity in the vessel or pipe, as determined under paragraph (b) of this section, is spilled instantaneously to form a liquid pool. For liquids at temperatures below their atmospheric boiling point, the volatilization rate shall be calc ulated at the conditions specified in paragraph (d) of this section. (2) The owner or operator shall assume that the qua ntity which becomes vapor in the first 10 minutes is involved in the vapor cloud explosion.

(g) Parameters to be applied. The ow ner or operator shall use the parameter s defined in § 68.22 to det ermin e dist ance to the en dpoi nts. The ow ner or o perato r may use t he met hodol ogy provided in the RMP Of fsite Cons equenc e Analy sis Guidan ce or an y c ommercia lly or publicly available air dispersion modeling techniques, provided the tec hniques account for the modeling conditions and are recognized by industry as applicable a s part of current practices. Proprietar y models that account for the modeling conditions may be used provided the owner or operator allows the implementing agency access to the model and describes model feature s and differe nces fr om publicly availab le models t o local e merge ncy planner s upon req uest.

### (h) Consideration of passive mitigation. Passive mitigation sy stems may be consider ed for the analy sis of wor st case p rovided t hat the mit igation sys tem is cap able of w ithstandin g the re lease event triggering the scenario and would still function as intended. (i) Factors in selecting a worst-c ase scenario. Notwithstanding the provisions of parag raph (b) of this section, the owner or operator shall select as the worst case for flammable regulate d substances or the worst case for reg ulated toxic substances, a scenario based on the following factors if such a scenario would result in a g reater distance to an endpoint defined in § 68.22(a) bey ond the sta tionary source b oundary than the s cenari o provide d under p aragr aph (b) o f this section:

(1) Smaller quantities handled at higher process tempe rature or pressure; and (2) Proximity to the boundary of the stationary sourc e. [61 FR 31718, June 20, 1996, as amended at 64 FR 28700, May 26, 1999] § 68.28 Alt ernativ e relea se scena rio anal ysi s. (a) The number of scenarios. The owne r or operator shall identify and analyze a t least one alternative release scenario f or each regulated toxic substance held in a c overed process(es) and at least one alternative release sce nario to represent all flammable substances held in cover ed process es.

(b) Scenarios to consider. (1) For ea ch scenario required under par agraph (a) of this section, the owner or operator shall select a sce nario: (i) That is more likely to occ ur than the worst-case release sc enario under § 68.25; and (ii) Tha t will rea ch an en dpoint off site, unle ss no such s cenari o exists. (2) Release scenarios considered should include, but a re not limited to, the following, where applicable:

(i) Tr ansfer hose r elease s due t o spl its o r sudd en hos e unco upli ng; (ii) Process piping releases from failure s at flanges, joints, welds, valves and valve seals, and drains or bleeds; (iii) Process vessel or pump releases due to crac ks, seal failure, or drain, bleed, or plug f ailure; (iv) Vessel overfilling and spill, or overpressurization and venting through relief valves or rupture disks; and

(v) Shippi ng cont ainer mis handling and brea kage o r punctur ing lea ding to a spill. (c) Parameters to be applied. The owner or operator shall use the appropriate para meters defined in § 68.22 to determine distance to the endpoints. The owner or oper ator may use e ither the methodology pr ovided in the RMP Offsite Consequence Analy sis Guidanceor any commercially or publicly available a ir dispersion modeling techniques, provided the techniques account for the specified modeling conditions and ar e recognized by industry as applicable a s part of current practices. Proprietar y models that account f or the modeling conditions may be used provided the owner or operator allows the implementing agency access to the model and describes model features and differe nces from publicly a vailable models to local emergency planner s upon req uest. (d) Consideration of mitigation. Active and passive mitigation sy stems may be consider ed provided they ar e capable of withstanding the event that trig gered the release a nd would still be function al.

### (e) Fa ctors in se lecting scenar ios. The o wner or operato r shall consider th e followi ng in selectin g alter native r elease scenar ios: (1) The five-y ear accident history provided in § 68.42; and (2) Failure scenarios identified under § 68.50 or § 68.67. § 68.30 Defining offsite impacts - population.

(a) The owner or operato r shall es timate in th e RMP the po pulation w ithin a cir cle with i ts center at the point of the release and a radius determined by the distance to the endpoint defined in § 68.22(a).

(b) Population to be defined. Population shall include residential population. The presence of institution s (school s, hospita ls, prison s), park s and rec reation al area s, and maj or comme rcial, office , and indu strial bui ldings sh all be not ed in the RM P. (c) Data sources acce ptable. The owner or operator may use the most recent Census data, or other updated information, to estimate the population potentially affected. (d) L evel of a ccurac y. Po pulation s hall be e stimated t o two sig nifican t digits. § 68.33 De fining o ffsite imp acts - e nvironme nt. (a) The owner or operato r shall lis t in the RMP e nvironme ntal rec eptors wi thin a cir cle with i ts center at the point of the release and a radius determined by the distance to the endpoint defined in § 68.22( a) of this part. (b) Data sources acceptable . The owner or operator may rely on information provide d on local U.S. Geological Survey maps or on any da ta source containing U.S.G.S. data to identify environm ental re ceptors

. 68.36 Review and update.

(a) The owner or operato r shall re view and update th e offsite consequence an aly ses at lea st once ev ery five y ears. (b) If chang es in processes, quantities stored or handled, or any other aspect of the stationary
so ur ce mi gh t r ea so na bl y be ex pe ct ed to in cr ea se or de cr ea se th e d is ta nc e t o t he en dp oi nt by a factor of two or more, the owner or oper ator shall complete a revised analy sis within six months of the change and submit a revised risk mana gement plan as provided in § 68.190. § 68.39 Documentation. The owner or operator shall maintain the following r ecords on the offsite consequence analy ses: (a) For worst-case sce narios, a description of the vessel or pipeline and substance sele cted as worst ca se, assum ptions and parameters use d, and the rationa le for se lection; a ssumptions shall include u se of any administr ative co ntrols an d any passive m itigatio n that wer e assume d to limit the quantity that could be re leased. Documentation shall include the anticipated effe ct of the controls and mitigation on the release quantity and rate. (b) For alternative release scenarios, a description of the scenarios identified, a ssumptions and

### parameters use d, and the rationa le for the selection of spec ific sce narios; a ssumptions shall include use of any administrative controls and any mitigation that were assumed to limit the quantity that could be rele ased. Documentation shall include the effect of the c ontrols and mitigation on the release quantity and rate. (c) Documentation of estimated quantity released, release rate, a nd duration of release. (d) Meth odology used to de termine d istance to endpoin ts. (e) Data used to estimate population and environmental rec eptors potentially aff ected. § 6 8. 42 Fi ve -ye ar ac ci de nt hi st or y.

(a) The owner or operator sha ll include in the five-ye ar accident history all accidental releases from covered processes that resulted in dea ths, injuries, or significant property damage on site, or known offsite deaths, injuries, evacuations, sheltering in place , property da mage, or environmental damage.

(b) Data required. For ea ch accidental release included, the ow ner or operator shall report the following information:

(1) Date, time, and approximate duration of the release; (2) Chemical(s) released; (3) Estima ted quant ity r elease d in pounds and, for mixtures co ntaining regula ted toxic substances, percentage c oncentration by we ight of the released reg ulated toxic substance in the liquid mixture;

(4) Five - or six-dig it NAI CS code tha t most close ly c orrespo nds to the process; (5) The type of release event and its source; (6) Weather conditions, if known; (7) On-s ite impac ts; (8) Know n offsite impacts; (9) Initiating event a nd contributing factors if known; (10) Whether offsite responders were notified if know n; and (11) Operational or process chang es that resulted from investigation of the release a nd that have been made by the time this information is submitted in accordance with §68.168. (c) L evel of a ccurac y. N umerica l estimate s may be provid ed to two si gnific ant digi ts. [61 FR 31718, June 20, 1996, as amended at 64 FR 979, Jan. 6, 1999 and 69 FR 18819, April 9, 2004] Subpart C - Program 2 Prevention Program

Source: 61 FR 31721, June 20, 1996, unless otherwise noted. § 68.48 Safety information.

(a) The owner or operato r shall co mpile and maintain t he follow ing up-t o-date s afety informat ion rela ted to the regula ted substa nces, pr ocesses , and equ ipment: (1) Material Safety Data Sheets that meet the requirements of 29 CFR 1910.1200(g ); (2) Maximum intended inventory of equipment in which the r egulated substances are stored or

### processed; (3) Safe upper an d lower te mperatu res, pre ssures, f lows, and compositions; (4) Equipment specifications; and (5) Code s and stan dards use d to desig n, build, a nd opera te the pr ocess. (b) The owner or operato r shall en sure tha t the proc ess is des igned in compliance with recog nized and g eneral ly a ccepte d good e nginee ring pr actice s. Complian ce with F ederal or state regulations that address industry -specific safe design or with industry -specific design codes and standards may be used to demonstrate compliance with this paragraph. (c) The owner or operator sha ll update the safety information if a major change occurs that makes the information inaccurate. § 68.50 Hazard review.

(a) The owner or operator sha ll conduct a review of the hazards associated with the re gulated subs tances , proc ess, a nd pro cedure s. The review shall ident ify the fo llow ing:

(1) The hazards a ssociate d with the p rocess a nd reg ulated su bstance s; (2) Opportunities for equipment malfunctions or human errors that could ca use an accidental release;

(3) The safeguards used or needed to control the hazards or prevent equipment malfunction or human error; and

(4) Any steps use d or need ed to dete ct or monit or rele ases. (b) The owner or operator may use checklists developed by persons or organizations knowledgeable about the process and e quipment as a guide to conducting the review . For processes designed to meet industry standards or Federal or state desig n rules, the hazard review shall, by inspecting a ll equipment, determine whether the process is designed, f abricated, and operate d in accordance with the a pplicabl e standa rds or ru les. (c) The owner or operato r shall do cument th e results of the re view and ensure t hat probl ems identified are resolved in a timely manner. (d) The r eview sh all be upd ated at le ast once every five y ears. Th e owner or opera tor shall a lso conduct reviews whenever a major c hange in the process occurs; all issues identified in the review shall be r esolved b efore s tartup of the chan ged pr ocess. § 68.52 Op erating procedu res. (a) The owner or operator sha ll prepare written operating proce dures that provide clear instructi ons or ste ps for sa fely conducti ng acti vities ass ociated with eac h covere d proces s consistent with the safety infor mation for that process. Operating proce dures or instructions provided by e quipment ma nufactu rers or develope d by persons or orga nizations kn owledg eable about the process and equipment may be used as a basis for a stationary source's operating procedu res. (b) Th e proce dures shall addres s the f ollo wing: (1) Initial startup; (2) Normal opera tions; (3) Temp orary operati ons; (4) Emer gency shutdown a nd opera tions;

### (5) Normal shutdown; (6) Startup following a normal or emerg ency shutdown or a major change that requires a hazar d review; (7) Consequences of deviations and steps required to cor rect or avoid deviations; and (8) Equip ment inspe ctions. (c ) T he ow ne r o r o pe ra to r s ha ll en su re th at th e o pe ra ti ng pr oc ed ur es ar e u pd at ed , i f n ec es sa ry, wheneve r a major chang e occur s and prio r to start up of the c hange d proces s. § 68.5 4 Trai ning.

(a) The owner or operator sha ll ensure that each employ ee presently operating a process, and each employee newly assigned to a covered proce ss have been trained or tested competent in the operating procedures provided in § 68.52 that per tain to their duties. For those employe es already operating a process on June 21, 1999, the owner or oper ator may ce rtify in writing that the employee ha s the required knowledge, skills, and abilities to safely carry out the duties and responsi bilities a s provide d in the ope rating procedu res. (b) Refresher training. Refre sher training shall be provided at least every three ye ars, and more often if necessary , to each employe e operating a process to ensure that the employee unde rstands and adhe res to the curren t operat ing proc edures o f the pro cess. Th e owner or opera tor, in consultation with the employees oper ating the process, shall determine the appropria te frequency of refr esher t raini ng.

(c) The owner or operator may use training conducted under Fede ral or state regulations or under industry-spec ific standards or codes or training conducted by cover ed process equipment vendors to demonstrate compliance with this section to the extent that the training meets the requirements of this section.

(d) The owner or operator shall ensure that operators are trained in any updated or new procedures prior to startup of a process af ter a major change. § 68.56 Maintenance.

(a) The owner or operator sha ll prepare and implement procedures to maintain the on-g oing mechanical integrity of the process equipment. The owner or opera tor may use proc edures or instructi ons provid ed by covere d proces s equipme nt vendor s or proc edures i n Feder al or stat e regula tions or ind ustry codes as the basis for stati onary source m aintena nce proc edures. (b) The owner or operato r shall tr ain or ca use to be t rained e ach empl oye e involve d in maintaining the on-going mechanic al integrity of the process. To ensure that the employ ee can perform the job tasks in a safe manner, eac h such employee sha ll be trained in the hazards of the process, in how to avoid or correct unsafe c onditions, and in the procedures applicable to the employ ee's jo b tasks. (c) Any maintena nce con tractor shall ens ure that each contract ma intenanc e employ ee is trained to perform the maintenance proce dures developed under parag raph (a) of this section. (d) The owner or operator shall perf orm or cause to be performed inspections and tests on process equipmen t. Ins pection a nd testing procedu res shal l follow r ecogn ized and g eneral ly accept ed good engine ering practice s. The fr equenc y of inspectio ns and tes ts of proc ess equipment shall be consistent with applicable manufacturers' recommendations, industry

### standards or codes, good engine ering practices, and prior oper ating experience. § 68.58 Comp liance a udits. (a) The owner or operator sha ll certify that they have evaluated compliance with the provisions of this subpart at least every three ye ars to verify that the procedures and practices deve loped under the rule are adequate a nd are being followed. (b) The compliance audit shall be conducted by at least one person knowledgeable in the process

.

(c) The owner or operato r shall de velop a r eport of the audit finding s. (d) The owner or operato r shall pr omptly determine and doc ument an a ppropria te respo nse to each of the findings of the compliance a udit and document that deficiencies have been cor rected. (e) The owner or operato r shall re tain the two (2) most r ecent c omplianc e audit r eports. T his requirement does not apply to any compliance audit report that is more than five y ears old. § 68.60 Incident investigation.

(a) The owner or operato r shall inv estiga te each incident which re sulted in, or could reasonably have resulted in a catastrophic release

. (b) An incident investigation shall be initiated as promptly as possible, but not later than 48 hours fol lowing th e incide nt. (c) A sum mary shall be p repare d at the c onclusion of the inv estiga tion which includes at a minimum:

(1) Date of incide nt; (2) Date investigation began; (3) A de scription of the inc ident; (4) The factors that contributed to the incident; and, (5) Any re commendations resulting from the investigation. (d) The owner or operator shall promptly address and resolve the investigation findings a nd recommendations. Resolutions and corrective actions shall be documented.

(e) The findings shall be reviewed w ith all affected personnel whose job tasks are a ffected by the findin gs. (f) I nvestig ation summa ries sha ll be reta ined for five y ears. Subpart D - Program 3 Prevention Program Source: 61 FR 31722, June 20, 1996, unless otherwise noted. § 68.65 Process safety information. (a) In acc ordance with the schedule set forth in § 68.67, the owner or ope rator shall complete a compilati on of writ ten proc ess safe ty in formatio n before conducti ng any process hazard a naly sis required by the rule. The compilation of written process safety information is to enable the owner or operator and the employ ees involved in operating the process to identify and understand the hazards posed by those proc esses involving regulated substances. This proc ess safety infor mation

### shall include information pertaining to the hazards of the reg ulated substances used or produced by the proce ss, information pertaining to the technology of the process, and information pertain ing to the equipmen t in the pro cess. (b) I nformati on perta ining to t he hazar ds of the r egulat ed substa nces in th e proce ss. This infor mati on sha ll con sist of at l east t he fol lowi ng:

(1) Toxicity information; (2) Perm issible expo sure limits ; (3) Physical data; (4) Reactivity data : (5) Corrosivity data; (6) Thermal and chemical stability data; and (7) Hazardous effects of inadvertent mixing of diffe rent materials that could foreseeably occur. Note to paragraph (b): Materia l Safety Data She ets meeti ng the r equirem ents of 29 CFR 1910.1 200(g)may be used to comply with this re quireme nt to the e xtent they contain t he infor mation re quired by this subparagraph.

(c) I nformati on perta ining to t he techn ology of the pr ocess. (1) Infor mati on con cernin g the te chnol ogy of the p rocess shall inclu de at l east t he fol lowi ng: (i) A bloc k flow dia gram or simplified process flow diag ram; (i i) Pr oc es s c he mi st ry; (i ii ) M ax im um in te nd ed in ve nt or y;

(iv) Safe upper and lower limits for such items as temperature s, pressures, flows or compositions; and,

(v) An e valuatio n of the c onseque nces of d eviation s. (2) Where the original technical information no long er exists, such information may be developed in conjunction with the process hazard analy sis in sufficient detail to support the analy sis. (d) I nformati on perta ining to t he equipm ent in the process

. (1) Information perta ining to the equipment in the process shall include: (i) Materials of construction; (ii) Piping and instrument diagrams (P&I D's); (iii) Electrical classification; (iv) Relie f sy stem desig n and des ign basi s; (v) Ventilation system desig n; (vi) Design codes and standards employ ed; (vii) Material and energy balances for processes built after June 21, 1999; and (viii) Safety sy stems (e.g. interlocks, detection or suppression sy stems). (2) The owner or operator shall document that e quipment complies with recognized and gener ally accept ed good engine ering p ractice s. (3) For existing equipment designed and constructe d in accordance with codes, standards, or practices that are no longer in g eneral use, the owner or operator shall determine and document that the equipment is designed, maintained, inspected, tested, and opera ting in a safe manner. § 68.67 Pro cess haza rd analy sis.

### (a) The owner or operator sha ll perform an initial process hazard analysis (hazard evaluation) on processes covered by this part. The process hazard analy sis shall be appropriate to the complexity of the process and shall identify , evaluate, and control the hazards involved in the process. The owner or operator shall dete rmine and document the priority order for conducting process hazard analy ses based on a rationale which includes such considera tions as extent of the process hazards, number of potentially affected employ ees, age of the process, a nd operating history of the proce ss. The process hazard analy sis shall be conducted as soon as possible, but not later than J une 21, 1999 . Process haz ards analyses comple ted to comp ly with 29 CFR 1910.119(e) are acceptable a s initial process hazards analy ses. These process hazard analy ses shall be updated and revalidated, based on their completion date

.

(b) The owner or operator shall use one or more of the following methodologies that are appropriate to determine and evaluate the ha zards of the process being analy zed. (1) What-If; (2) Checklist; (3) What- If/Ch ecklist; (4) Hazard and Operability Study (HAZ OP); (5) Failure Mode and Effects Ana lysis (FMEA); (6) Fault Tree Analy sis; or (7 ) A n a pp ro pr ia te eq ui va le nt me th od ol og y.

(c) The process hazard a naly sis shall a ddress: (1) The hazards of the proc ess; (2) The i dentific ation of a ny previous i ncident w hich had a likely potentia l for ca tastroph ic consequences.

(3) Eng ineerin g and a dministra tive cont rols appl icable to the hazar ds and the ir interre lationship s such as a ppropria te applic ation of d etection methodolo gies to provide e arly warning of releases. (Ac ceptable detection methods might include process monitoring a nd control instrumentation with alarms, and detection hardware such a s hydrocar bon sensors.); (4) Conse quence s of failu re of en gineer ing and administr ative co ntrols; (5) St ation ary source siti ng; (6) Human factors; and (7) A qualitative evaluation of a range of the possible safety a nd health effects of failure of controls

.

(d) The process hazard analy sis shall be performed by a team with expertise in engineering and process operations, and the team shall include at least one employ ee who has experience and knowledg e specif ic to the p rocess b eing ev aluated . Also, one member o f the tea m must beknowledgeable in the specific proc ess hazard analy sis methodology being used. (e) The owner or operator sha ll establish a system to promptly address the team's findings and recommendations; assure that the recommendations are r esolved in a timely manner and that the resolution is documented; document what actions are to be taken; complete ac tions as soon as possible; develop a written schedule of when these actions ar e to be completed; communicate the actions to operating, maintenance and other e mployees whose wor k assignments are in the process and who ma y be affec ted by the rec ommendat ions or actions. (f) At least every five (5) ye ars after the completion of the initial process hazard analy sis, the process hazard a naly sis shall be updated a nd reval idated by a team me eting th e requir ements in paragraph (d) of this section, to assure that the process hazard analy sis is consistent with the

### current process. Updated and reva lidated process hazard analy ses completed to comply with 29 CFR 1910.119(e) are acceptable to mee t the requirements of this paragraph. (g) The owner or opera tor shall retain process hazards analy ses and updates or revalidations for each process covere d by this section, as well as the doc umented resolution of
recomme ndations d escribe d in para graph (e) of th is section for the li fe of the process

. § 68.69 Op erating procedu res. (a) The owner or operator sha ll develop and implement written operating procedure s that provide c lear inst ructions for saf ely conducti ng acti vities invo lved in ea ch cove red proc ess consiste nt with the process safety informat ion and sha ll addre ss at leas t the follo wing el ements. (1) Steps for each operating pha se: (i) Initial startup; (ii) Nor mal oper ations; (iii) Tem porary operati ons; (iv) Eme rgenc y sh utdown inc luding th e conditi ons under which eme rgenc y sh utdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. (v) Emer gency operati ons; (vi) Normal shutdown; and, (vii) Startup following a turnaround, or after an e mergency shutdown. (2) Ope rating limits: (i) Consequences of deviation; and (ii) Steps required to correct or avoid deviation. (3) Safe ty a nd health consider ations: (i) Prope rties of, and hazar ds prese nted by , the che micals use d in the pr ocess; (ii) Precautions necessary to prevent exposure, including engineering controls, administrative controls , and per sonal pro tective e quipment;

(iii) Contr ol measur es to be ta ken if phy sical co ntact or airborn e exposure occurs; (iv) Quality control for raw materials and control of hazardous chemical inventor y levels; and, (v) Any special or unique hazards. (4) Safe ty s yst ems and th eir functions. (b) Operating procedure s shall be readily a ccessible to employe es who work in or maintain a process

.

(c) The operating proce dures shall be reviewed as often as nec essary to assur e that they re flect
curren t operat ing pra ctice, in cluding chang es that re sult from c hange s in proce ss chemic als, technolo gy , and equ ipment, a nd chang es to stati onary sources . The own er or ope rator sh all certify a nnually that these oper ating procedures are c urrent and accurate. (d) The owner or operator shall deve lop and implement safe work practices to provide for the control of hazards during operations such as lockout/tag out; confined space entry ; opening process equipment or piping; and control over entranc e into a stationary sourc e by maintenanc e, contractor, labo ratory , or other support pe rsonnel. These sa fe work practic es shall a pply to employ ees and c ontract or employ ees. § 68.7 1 Trai ning.

### (a) Initial training. ( 1) Each employee presently involved in operating a process, and eac h employee be fore being involved in operating a ne wly assigne d process, shall be trained in an overvie wof the p rocess a nd in the op erating procedu res as sp ecified in § 68.69. The trai ning sha ll include emphasis on the specific safety and health hazards, emergency operations including shutdown, and safe work pra ctices a pplicabl e to the e mploy ee's jo b tasks. (2) In lieu of initial training for those employees a lready involved in oper ating a process on June 21, 1999 an owner or operator may certify in wr iting that the employee has the required knowledg e, skills, a nd abilitie s to safe ly c arry out the dut ies and r esponsibi lities as s pecifie d in the oper ating pr ocedure s. (b) Refresher training. Refre sher training shall be provided at least every three ye ars, and more often if necessary , to each employe e involved in operating a process to assure that the e mployee understands and adheres to the current oper ating procedures of the proce ss. The owner or operator, in consultation with the employe es involved in operating the process, shall determine the ap propr iate f requen cy of refres her tr ainin g. (c) Training documentation. The owner or operator shall ascertain that each e mployee involved i n operat ing a pr ocess ha s recei ved and u nderstoo d the tra ining re quired by this paragraph. The owner or operator shall prepare a re cord which contains the identity of the employee, the da te of training, and the means used to verify that the employee unde rstood the train ing. § 6 8. 73 Me ch an ic al in te gr it y.

(a) App lication. Parag raphs (b ) throug h (f) of this secti on apply to the foll owing pr ocess equipmen t: (1) Pres sure ves sels and s torage tanks; (2) Piping systems (including piping components such as valves); (3) Relie f and ven t sy stems and devices ; (4) Emer gency shutdown s yst ems; (5) Controls (including monitoring devices and sensors, alar ms, and interlocks) and, (6) Pumps. (b) Written procedures. The owner or oper ator shall establish and implement written procedu res to mai ntain the on-goin g integ rity of proce ss equipme nt. (c) Training for process maintena nce activities. The owner or operator shall tra in each employee involved in maintaining the on-going integrity of process equipment in an overview of that process and its hazards and in the procedures applicable to the employee' s job tasks to assure that the employee c an perform the job tasks in a safe manner.

(d) I nspectio n and test ing. (1) Insp ections a nd tests sh all be pe rformed on proce ss equipme nt. (2) Inspection and testing procedures shall follow recognized and g enerally a ccepted good engine ering practice s.

(3) The f requenc y of inspections and tes ts of proc ess equip ment shall be consis tent with appli cable m anufac turer s' recommendations and good enginee ring practices, and more fre quently if determined to be necessary by prior opera ting experience. (4) The owner or operator shall document e ach inspection and test that has been performed on process equipmen t. The doc umentation shall ide ntify the date of the ins pection o r test, the name

### of the person who performed the inspection or test, the seria l number or other identifier of the equipmen t on which the inspe ction or te st was per formed, a descr iption of th e inspec tion or tes t perfor med, and t he resul ts of the in spection or test. (e) Equipment deficiencies. The owner or operator shall correct deficienc ies in equipment that are outside acceptable limits (defined by the process safety information in § 68.65) before further use or in a safe and timely manner when necessary means are taken to assure safe ope ration. (f) Quality a ssurance. (1) I n the construction of new plants and equipment, the owner or operator shall assure that equipment as it is fabricated is suitable for the process application for which they will be used.

(2) Appropriate checks and inspections shall be per formed to assure that equipment is installed properl y a nd consist ent with de sign spe cificat ions and th e manufa cturer 's instr uctions. (3) The owner or operator shall assure that maintenance materials, spare parts and e quipment are suitable for the process application for whic h they will be used. § 68.75 Management of chang e.

(a) The owner or operator sha ll establish and implement written procedures to manage cha nges (except for ``re placements in kind'') to process che micals, technology , equipment, and procedu res; and , chang es to stati onary sources that aff ect a co vered pr ocess. (b) The procedures shall assure that the following considerations are addressed prior to any change:

(1) The technical basis for the proposed cha nge; (2) Impact of cha nge on safety and health; (3) Modif ications t o operat ing proc edures; (4) Necessary time period for the change; and, (5) Authorization requirements for the proposed chang e. (c) Empl oye es involve d in opera ting a pr ocess an d mainten ance an d contra ct employ ees whos e job tasks will be affected by a change in the process shall be infor med of, and trained in, the chang e prior to start-up of the pr ocess or affec ted part of the pr ocess. (d) If a cha nge covered by this paragraph results in a chang e in the process safety information
re qu ir ed by § 68 .6 5 o f t hi s p ar t, su ch in fo rm at io n s ha ll be up da te d a cc or di ng ly.

(e) If a c hange covered by this paragraph results in a chang e in the operating procedures or pr ac ti ce s r eq ui re d b y § 6 8. 69 , s uc h p ro ce du re s o r p ra ct ic es sh al l b e u pd at ed ac co rd in gl y. § 68.77 Pre-startup review.

(a) The owner or operator sha ll perform a pre-startup safety review for new stationary sources and for modified stationary sources when the modification is significant enough to r equire a change in the process safety information. (b) The pre-startup safety review shall confirm that prior to the introduction of regulate d substanc es to a pr ocess: (1) Constr uction an d equipme nt is in acc ordance with desig n specif ications; (2) Safety, ope rating, maintenance, and emerg ency proc edures are in place and are adequate; (3) For new stationary sources, a process hazard analy sis has been performed and recommendations have been resolved or implemented be fore startup; and modified stationary

### sources meet the requirements contained in manag ement of change, § 68.75. (4) Training of each employ ee involved in operating a process has be en completed. § 68.79 Comp liance a udits. (a) The owner or operator sha ll certify that they have evaluated compliance with the provisions of this subpart at least every three ye ars to verify that procedures and practices deve loped under this subpart are adequate and are be ing followed.

(b) The compliance audit shall be conducted by at least one person knowledgeable in the process

.

(c) A report of the findings of the a udit shall be developed. (d) The owner or operato r shall pr omptly determine and doc ument an a ppropria te respo nse to each of the findings of the compliance a udit, and document that deficiencies have been cor rected. (e) The owner or operato r shall re tain the two (2) most r ecent c omplianc e audit r eports. [61 FR 31722, June 20, 1996, as amended at 64 FR 979, Jan. 6, 1999] § 68.81 Incident investigation.

(a) The owner or operato r shall inv estiga te each incident which re sulted in, or could reasonably have resulted in a catastrophic release of a regulated substance. (b) An incident investigation shall be initiated as promptly as possible, but not later than 48 hours fol lowing th e incide nt. (c) An incident investigation team shall be established and consist of at lea st one person knowledgeable in the process involved, including a contract employe e if the incident involved work of th e contra ctor, an d other pe rsons with appropr iate know ledge a nd experie nce to thoroug hly investig ate and a naly ze the inc ident. (d) A re port shal l be prep ared at the conc lusion of th e investig ation whic h include s at a minimum:

(1) Date of incide nt; (2) Date investigation began; (3) A de scription of the inc ident; (4) The factors that contributed to the incident; and, (5) Any re commendations resulting from the investigation. (e) The owner or operator sha ll establish a system to promptly address and resolve the incident report findings and recommendations. Resolutions and correc tive actions shall be documented. (f) The report shall be reviewed w ith all affected personnel whose job tasks are re levant to the incident findings including contract employ ees where applicable. (g) I ncident i nvestig ation re ports sha ll be reta ined for five y ears. § 68.83 Employee par ticipation. (a) The owner or operator sha ll develop a written plan of action regar ding the implementation of the employee participation required by this section. (b) The owner or operator shall consult with employ ees and their representatives on the

### conduct and development of process hazards analy ses and on the development of the other elements of process safety management in this rule. (c) The owner or operato r shall pr ovide to e mploy ees and t heir re present atives a ccess to process hazard analy ses and to all other information required to be developed under this rule. § 68.85 Ho t work pe rmit. (a) The owner or operator sha ll issue a hot work permit for hot work operations conducted on
or near a cover ed proce ss. (b) The permit shall docu ment that t he fire prevent ion and prot ection requi rements in 2 9 CFR 1910.252( a) have been impl emented prior to b eginnin g the ho t work ope rations; i t shall indi cate the date(s) authorized for hot work; and identify the object on which hot work is to be performed. The per mit shall be kept on fi le until co mpletion of the hot wo rk opera tions. § 68.87 Con tractor s. (a) Application. This section applies to contractors performing maintenance or repair, turnaround, major renovation, or specialty work on or adjacent to a covered proc ess. It does not apply to contractors providing incidental services which do not influence proc ess safety, suc h as janitoria l work, fo od and dr ink servi ces, lau ndry , deliver y or other sup ply service s. (b) Owner or operator responsibilities. (1) The owne r or operator, when selecting a contractor, shall obta in and eva luate inf ormation r egard ing the c ontract owner or operato r's saf ety perfor mance a nd prog rams. (2) The owner or operator shall inform contra ct owner or operator of the known potential fire, explosion, o r toxic rel ease ha zards re lated to th e contra ctor's work and the proc ess. (3) The owner or operato r shall expl ain to the contract owner o r opera tor the a pplicabl e provision s of subpa rt E of this part. (4) The owner or operator shall deve lop and implement safe work practices consistent with § 68.69(d), to control the entrance, presence , and exit of the contract owner or operator and contract employ ees in co vered pr ocess ar eas. (5) The owner or operator shall periodica lly evaluate the pe rformance of the contract owner or operator in fulfilling their obligations as specified in par agraph (c) of this section. (c) Contract owner or operator re sponsibilities. (1) The contract owner or operator shall assure that each contract employ ee is trained in the work practices nece ssary to safe ly perform his/her job.

(2) The contract owner or opera tor shall assure that each contract employ ee is instructed in the known pote ntial fir e, explosio n, or toxic r elease hazards r elated to his/her jo b and the p rocess, and the applicable provisions of the emergenc y action plan. (3) The contract owner or opera tor shall document that each contract employ ee has received and understood the training required by this section. The contract owner or operator shall pre pare a record which contains the identity of the contract employ ee, the date of training, and the mea ns used t o veri fy that th e empl oyee under stoo d the t raini ng.

(4) The c ontract owner or operato r shall as sure tha t each c ontract employ ee follo ws the saf ety rules of the stationary source including the safe work pra ctices required by § 68.69(d). (5) The contract owner or opera tor shall advise the owner or operator of any unique hazards

### presented by the contract owner or operator' s work, or of any hazards found by the c ontract owner or operator's work. Subpart E - Emerg ency Response Source: 61 FR 31725, June 20, 1996, unless otherwise noted. § 6 8. 90 Ap pl ic ab il it y.

(a) Except as provided in paragraph ( b) of this section, the owner or operator of a stationary source with Program 2 and Progra m 3 processes shall comply with the r equirements of § 68.95. (b) The owner or operator of stationar y source w hose employees w ill not respond to accidental releases of regulated substanc es need not comply with § 68.95 of this par t provided that they meet t he fol lowi ng:

(1) For stationary sources with any r egulated toxic substance held in a process above the threshold quantity, the stationary source is included in the community eme rgency response plan developed under 42 U.S.C. 11003;

(2) For stationary sources with only re gulated flammable substances held in a proce ss above the threshold quantity, the owner or operator has coordinated response a ctions with the local fire department; and

(3) Appropriate mechanisms are in place to notify emergency responders when there is a need for a response. § 68.95 Eme rgenc y r esponse p rogra m. (a) The owner or operator sha ll develop and implement an emergency response program for the purpose of protecting public health and the environme nt. Such program shall include the following elements : (1) An emergency response plan, which shall be maintained at the stationary source and contain a t least the following elements : (i) Procedures for informing the public and loca l emergency response agencies about accide ntal rele ases; (ii) Documentation of proper first-aid and emerg ency medic al treatment necessary to treat accidental human exposures; and

(iii) Procedures and measures for emer gency response after an accidental r elease of a regulated substance;

(2) Procedures for the use of emer gency response equipment and for its inspection, testing, and maintenance;

(3) Training for all employ ees in relevant procedures; and (4) Procedures to review and update, a s appropriate, the emergenc y response plan to r eflect chang es at the stationar y so urce an d ensure that employe es are i nformed of chang es. (b) A wr itten plan that comp lies with o ther Fe deral c ontinge ncy plan reg ulations o r is consistent with the approach in the National Response Team's I ntegrated Contingency Plan Guidanc e (`` One Plan' ') and that, amo ng othe r matter s, include s the ele ments pro vided in paragraph (a) of this section, shall satisfy the requireme nts of this section if the owner or operator

### also complies with paragraph (c) of this section. (c) The emergenc y response plan de veloped under paragraph ( a)(1) of this section shall be coordinated with the community eme rgency response plan developed under 42 U.S.C. 11003. Upon request of the local emerge ncy planning committee or emergency response officials, the owner or operator shall promptly provide to the local emergency response officials information necessary for developing and implementing the community emergency response plan. Subpart F - Regulated Substances for Acc idental Release Prevention

Source: 59 FR 4493, Jan. 31, 1994, unless otherwise noted. Redesignated at 61 FR 31717, June 20, 1996. § 68.100 Purpose. This subpart designates substances to be listed under section 112(r) (3), (4), and (5) of the Clean Air Act, as a mended, i dentifie s their thr eshold qua ntities, a nd establ ishes the require ments for petit ioning to add or de lete subs tances f rom the lis t. § 68.115 Threshold determination.

(a) A threshold quantity of a regulated substance listed in § 68.130 is present at a stationary source if the total quantity of the regulated substance contained in a pr ocess exceeds the threshold.

(b) For the purposes of determining whe ther more than a threshold quantity of a regulated
su bs ta nc e i s p re se nt at th e s ta ti on ar y so ur ce , t he fo ll ow in g e xe mp ti on s a pp ly:

(1) Conc entrations of a re gulate d toxic substa nce in a m ixture. I f a reg ulated su bstance is present in a mixture and the concentration of the substance is below one pe rcent by we ight of the mixture, the amount of the substance in the mixture need not be considered when determining whether more tha n a thres hold quan tity is prese nt at the st ationar y so urce. E xcept for oleum, toluene 2,4-diisocyana te, toluene 2,6-diisocya nate, and toluene diisocy anate (unspecified isomer), if the concentration of the reg ulated substance in the mixture is one percent or greate r by weight, but the owner or operator ca n demonstrate that the partial pressure of the reg ulated substance in the mixture (solution) under handling or storage conditions in any portion of the process is less than 10 millimeters of mercury (mm Hg), the amount of the substance in the mixture in that portion of the process need not be considered when determining whether more than a thr eshold qua ntity is prese nt at the st ationar y so urce. T he owner or opera tor shall document this partial pressure measurement or estimate.

(2) Concentrations of a regulated f lammable substance in a mixture. (i) General provision. I f a regulated substance is present in a mixture and the conce ntration of the substance is below one percent by weight of the mixture, the mixture need not be considered when determining whether more than a threshold quantity of the regulated substance is present at the stationar y source. Except as provided in paragraph (b)(2) (ii) and (iii) of this section, if the concentration of the substance is one percent or gre ater by we ight of the mixture, then, for purposes of determining whether a threshold quantity is present at the stationary source, the entire weight of the mixture shall be treated as the regulated substanc e unless the owner or operator can de monstrate that the

### mixture itself does not have a National Fire Protection Association flammability hazard rating of 4. The de monstrati on shall be in accor dance w ith the de finition of flammabi lity hazard r ating 4 i n the NFPA 704, Standard System for the Identification of the Hazar ds of Materials for Emergency Response, National Fire Protection Association, Quincy , MA, 1996. Available from the National Fire Protection Association, 1 Battery march Park, Quincy , MA 02269-9101. This incorporation by r efere nce was approve d by the Dire ctor of th e Fede ral Reg ister in a ccorda nce with 5 U.S.C. 552(a) a nd 1 CFR pa rt 51. Copie s may be inspec ted at the Environme ntal Prote ction Ag ency Air Docket (6102), Attn: Docket No. A-96-O8, Waterside Mall, 401 M. St. SW., Washington DC; or at the Of fice of Feder al Regis ter at 80 0 North Ca pitol St., NW, Suite 700, Wa shington , DC. Boiling point and flash point shall be defined and determined in ac cordance with NFPA 30, Flammable and Combustible Liquids Code, National Fire Protection Association, Quincy, MA, 19 96 . A va il ab le fr om th e N at io na l F ir e P ro te ct io n A ss oc ia ti on , 1 Ba tt er yma rc h P ar k, Qu in cy, MA 02269-9101. This incorporation by r eference was approve d by the Director of the Federal Register in accordance with 5 U.S.C. 552(a) a nd 1 CFR part 51. Copies may be inspec ted at the Environmental Protection Agency Air Docket (6102), Attn: Docket No. A-96-O8, Waterside Mall, 401 M. St. SW., Washington DC; or at the Office of Federal Register a t 800 North Capitol St., NW., Suite 700, Washington, DC. The owner or operator shall document the National Fire Prot ectio n Asso ciati on fla mmabi lity haz ard rat ing.

(ii) Gas oline. Reg ulated su bstance s in gaso line, whe n in distrib ution or r elated s torage for use as fuel for internal combustion engines, need not be c onsidered when determining whether more than a threshold quantity is prese nt at a stationary sourc e. (iii) Naturally occ urring hy drocarbon mixtures. Prior to entry into a natur al gas processing plant or a petroleum refining process unit, reg ulated substances in naturally occurring hyd rocarb on mixtures need not be consider ed when d etermini ng whet her more than a thr eshold quantity is present at a stationar y source. N aturally occ urringhy drocarbon mixtures include any combination of the following: condensate, crude oil, field g as, and produced water, each a s defined in § 68.3 of this part. (3) Articles. Regulated substances containe d in articles need not be considered when determining whether more than a threshold quantity is present at the stationary source. (4) Uses. Regulated substances, when in use f or the following purposes, need not be included in determining whether more than a threshold quantity is present at the stationary source: (i) Use as a structural component of the stationary source; (ii) Use of products for routine janitorial maintenance; (iii) Use by employ ees of foods, drugs, cosmetics, or other personal items containing the regulated substance; and

(iv) Use of regulated substances pr esent in process water or non-contact cooling water as drawn f rom the e nvironme nt or munic ipal sour ces, or u se of re gulate d substanc es prese nt in air used either as compressed air or as par t of combustion. (5) Activities in laboratories. If a regulated substance is manufacture d, processed, or used in a laboratory a t a stationary sourc e under the supervision of a technically qualified individual as defined in § 720.3( ee) of t his chapt er, the q uantity of the sub stance n eed not be consider ed in determining whether a threshold quantity is present. This exemption does not apply to: (i) Specialty che mical production; (ii) Manufacture, processing, or use of substances in pilot plant scale operations; and (i ii ) A ct iv it ie s c on du ct ed ou ts id e t he la bo ra to ry.

### [59 FR 449 3, Jan. 3 1, 1994. R edesignated at 61 FR 31717 , June 20 , 1996, as am ended at 63 FR 645, Jan. 6, 1998] § 68.120 Pe tition proc ess. (a) Any person may pe tition the Administrator to modify, by addition or deletion, the list of regulated substances identified in § 68.130. Base d on the information presented by the petitioner, the Administrator may g rant or deny a petition. (b) A sub stance m ay be adde d to the list if, in the c ase of a n accide ntal rele ase, it is k nown to cause or may be reasonably anticipated to cause death, injury , or serious adverse effects to human health or the envir onment. (c) A substance may be deleted from the list if adequate data on the hea lth and environmental effects of the substance are a vailable to determine that the substance, in the case of an a ccidental release, is not known to cause and may not be reasonably anticipated to cause death, injury , or serious a dverse e ffects t o human he alth or the environm ent. (d) No substance for which a national primary ambient air quality standar d has been establish ed shall b e added to the list. No substa nce reg ulated un der title VI of the Clean Air Act, as amend ed, shall be adde d to the list

. (e) The burden of proof is on the petitioner to demonstrate that the c riteria for addition and deletion are met. A petition will be denied if this demonstration is not made.

(f) The Administrator will not accept additional petitions on the same substance following publication of a final notice of the decision to grant or de ny a petition, unless new data becomes available that could significantly affect the basis for the decision. (g) Pet itio ns to modi fy the lis t of re gulate d subs tances must conta in th e foll owing: (1) Name and address of the petitioner and a brief description of the organization(s) that the petitioner represents, if applicable;

(2) Name, address, and telephone number of a contact person for the petition; (3) Common chemical name(s), common sy nonym(s), Chemical Abstra cts Service number, and chemical formula and structure;

(4) Action requested (add or delete a substance); (5) Ratio nale supp orting t he petitioner's p osition; tha t is, how the substanc e meets th e criter ia for addition and deletion. A short summary of the rationale must be submitted along with a more detailed narrative; and

(6) Suppo rting da ta; that is , the peti tion must inc lude suff icient inf ormation t o scientif ically support the request to modify the list. Such information shall include:

(i) A list o f all supp ort docum ents; (ii) Documentation of literature searches c onducted, including, but not limited to, identific ation of th e databa se(s) se arched , the sea rch stra tegy , dates c overed, and print ed resul ts; (iii) Effects data (animal, human, and environmental test data) indicating the potential for death, injury, or ser ious adverse human and environmental impacts from acute e xposure following an accidental release ; printed copies of the data sources, in English, should be provided; and

(iv) Exposure data or previous accident history data, indicating the potential for serious adverse human health or environmental effe cts from an accidental release. The se data may include, but are not limited to, physical and c hemical properties of the substance, such as vapor

### -------------- -------------- -------------- -------------- -------------- -------------- -------------- -----

-------------- -------------- -------------- -------------- -------------- -------------- -------------- ----- pressure; modeling results, including data and assumptions used and model doc umentation; and historica l accide nt data, c iting da ta sourc es. (h) Within 18 months of receipt of a petition, the Administrator shall publish in the Federal Regis ter a no tice e ither denying th e peti tion or grant ing th e peti tion and pr oposi ng a lis ting. § 68.125 Exe mptions. Agric ultural nu trients. A mmonia use d as an ag ricultur al nutrie nt, when h eld by farmer s, is exempt fro m all provi sions of th is part. § 68.126 Exclusion.
Flammab le Substan ces Use d as Fue l or Held f or Sale a s Fuel at Retail Fa cilities. A flamma ble substanc e listed in Tables 3 a nd 4 of § 68 .130 is nev erthele ss exclude d from all provision s of this pa rt wh en th e s ub st an ce is us ed as a f ue l o r h el d f or sa le as a f ue l a t a re ta il fa ci li ty. [65 FR 13250, Mar. 13, 2000] § 68.130 L ist of subst ances. (a) Regulated toxic and flammable substances under se ction 112(r) of the Clean Air Act are the substa nces liste d in Table s 1, 2, 3, a nd 4. Thre shold quan tities for listed toxic and flam mable substanc es are s pecifie d in the ta bles. (b) The basis for placing toxic and flammable substances on the list of re gulated substances are explained in the note s to the list

. Table 1 to § 68.130 - List of Regulate d Toxic Substances and Threshold Quantities for Accidental Release Prevention [Alphabet ical Ord er - 77 Sub stances ]

CAS No. Thresho ld Basis for Chemical name quantity listing (lbs)
Acrolei n [2-Prope nal] 107-02-8 5,000 b Acrylonitrile [2- Propenenitrile] 107-13-1 20,000 b Acryly l chloride [2-Propenoyl chloride] 814-68-6 5,000 b Ally l alcohol [2-Propen -l-ol] 107-18-61 15,000 b Allylamine [2-Propen-l-amine] 107-11-9 10,000 b Ammonia ( anhy drous) 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, trichloro-] 10294-34-5 5,000 b Boron trifluoride [Borane, trifluoro-] 7637-07-2 5,000 b

### Bo ro n t ri fl uo ri de co mp ou nd wi th me th yl 353-42-4 15,000 b ethe r (1: 1) [B oron , trif luoro [oxy bis [me tane ]]-, 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 oxide (ClO2)] 10049-04-4 1,000 c Chloroform [Methane, trichloro-] 67-66-3 20,000 b Chloromethyl ether [Methane, 542-88-1 1,000 b oxy bis[c hloro -] Chloromethyl methy l ether [Methane, 107-30-2 5,000 b chloromethoxy-] Crotonald ehy de [2-Bu tenal] 4170-30-3 20,000 b Crotonaldehyde, (E )- [2-Butenal, (E)-] 123-73-9 20,000 b Cyanoge n chloride 506-77-4 10,000 c Cyclohexy lamine [Cyclohexanamine] 108-91-8 15,000 b Diborane 19287-45-7 2,500 b Dimethyldichlorosilane [Silane, 75-78-5 5,000 b dichlorodimethyl-] 1,1-Dimethylhy drazine [Hydrazine, 57-14-7 15,000 b 1,1-dimethyl-] Epichlorohydrin [Oxirane, (chloromethy l)-] 106-89-8 20,000 b Ethylenediamine [1,2- Ethanedia mine] 107-15-3 20,000 b Ethyleneimine [Aziridine] 151-56-4 10,000 b Ethylene oxide [Oxirane] 75-21-8 10,000 a, b Fluorine 7782-41-4 1,000 b Formaldehy de (solution) 50-00-0 15,000 b Furan 110-00-9 5,000 b Hydrazine 302-01-2 15,000 b Hydrochloric acid (conc 37% or grea ter) 7647-01-0 15,000 d Hy drocy anic ac id 74-90-8 2,500 a, b Hy droge n chlorid e (anhy drous) 7647-01-0 5,000 a [Hy droc hlori c ac id]. Hy droge n fluorid e/Hy drofluor ic acid 7664-39-3 1,000 a, b (conc 50% or greater ) [Hydrofluoric ac id] Hydrog en selenide 7783-07-5 500 b Hydrog en sulfide 7783-06-4 10,000 a, b Iro n, pe nt ac ar bo nyl - [ Iro n c ar bo nyl 13463-40-6 2,500 b (Fe(CO)5), (TB-5-11)- ] Isobuty ronitrile [Propanenitrile, 78-82-0 20,000 b 2-methyl-] Isop ropy l chlorof ormate [Ca rbonoch loridic 108-23-6 15,000 b acid, 1- methylethy l ester] Methacry lonitrile [2- Propenenitrile, 126-98-7 10,000 b 2-methyl-] Methyl chloride [Methane, c hloro-] 74-87-3 10,000 a

### Methy l chlorof ormate [Ca rbonoch loridic 79-22-1 5,000 b acid , meth yl este r] Methyl hy drazine [Hydrazine, methy l-] 60-34-4 15,000 b Methyl isocy anate [Methane, isocy anato-] 624-83-9 10,000 a, b Methy l mercap tan [Metha nethiol] 74-93-1 10,000 b Methyl thiocy anate [Thiocyanic acid, 556-64-9 20,000 b methyl ester] Methyltrichlorosilane [Silane, 75-79-6 5,000 b tric hloro methy l-]. Ni ck el ca rb on yl 13463-39-3 1,000 b Nitric acid (conc 80% or gre ater) 7697-37-2 15,000 b Nitric oxide [Nitrogen oxide (NO)] 10102-43-9 10,000 b Oleum (Fuming Sulfuric acid) 8014-95-7 10,000 e [Su lfu ric a cid , mi xt ure w ith sul fur t rio xi de] \1\. Peracetic acid [Ethaneperoxoic acid] 79-21-0 10,000 b Perchloromethylmerc aptan 594-42-3 10,000 b [Methanesulfenyl chloride, tr ichloro-] Phosgene [Carbonic dichloride] 75-44-5 500 a, b Phosphine 7803-51-2 5,000 b Ph os ph or us ox ych lo ri de [P ho sp ho ryl 10025-87-3 5,000 b chloride] Phosphorus trichloride [Phosphorous 7719-12-2 15,000 b tric hlori de]. Piperidine 110-89-4 15,000 b Propionitrile [Propanenitrile] 107-12-0 10,000 b Propy l chlorof ormate [Ca rbonoch loridic 109-61-5 15,000 b acid, propyleste r] Propyleneimine [Aziridine, 2-methy l-] 75-55-8 10,000 b Propylene oxide [Oxirane, methy l-] 75-56-9 10,000 b Sulfur dio xide (anhy drous) 7446-09-5 5,000 a, b Sulfur tetrafluoride [Sulfur fluoride 7783-60-0 2,500 b (SF4), (T-4)-] Sulfur trioxide 7446-11-9 10,000 a, b Tetramethyllea d [Plumbane, tetramethyl-] 75-74-1 10,000 b Tetranitromethane [Methane, tetranitro-] 509-14-8 10,000 b Titanium tetrachloride [Titanium chloride 7550-45-0 2,500 b (TiCl4) (T- 4)-] Toluene 2,4-diisocya nate [Benzene, 584-84-9 10,000 a 2,4 -di iso cyanat o-1 -met hyl-] \1\. Toluene 2,6-diisocya nate [Benzene, 91-08-7 10,000 a 1,3 -di iso cyanat o-2 -met hyl-] \1\. Toluene diisocyana te (unspecified 26471-62-5 10,000 a iso mer) [Ben zen e, 1, 3-d iis ocyana tom eth yl-] \1 \. Trimethylchlorosilane [Silane, 75-77-4 10,000 b chlorotrimethyl-]

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-------------- -------------- -------------- -------------- -------------- -------------- ------------ Viny l aceta te monome r [Acetic 108-05-4 15,000 b acid ethe ny l este r].
\1\ The mixture exemption in § 68.115( b)(1) do es not app ly to the substance.

Note: Basis for List ing: a Mandat ed for lis ting by Congre ss. b On EHS list, vapor pressure 10 mmHg or grea ter. c Toxic g as. d Toxicity of hy droge n chlorid e, potent ial to rel ease hy droge n chlorid e, and history of acci dents. e Toxicity of sulfur trioxide and sulfuric acid, potential to rele ase sulfur trioxide, and history of accide nts.

Table 2 to § 68.130 - List of Regulate d Toxic Substances and Threshold Quantities for Accidental Release Prevention [CAS Number Order -77 Substances]
Chemical name Threshold Basis for CAS No. quantity list ing (lbs)

50-00-0 Formaldehy de (solution) 15,000 b 57-14-7 1,1-Dimethylhy drazine 15,000 b [Hydrazine, 1,1-dimethy l-] 60-34-4 Methyl hy drazine [Hy drazi ne, m ethy l-]. 15,000 b

67-66-3 Chloroform 20,000 b [Methane, trichloro-] 74-87-3 Methyl chloride 10,000 a
74-90-8 [Meth ane, chlo ro-]. Hy drocy anic ac id 2,500 a, b 74-93-1 Methyl merca ptan 10,000 b

75-15-0 [Methanethiol] Carbon disulfide 20,000 b 75-21-8 Ethylene oxide 10,000 a, b [Oxira ne]. 75-44-5 Phosgene 500 a, b

75-55-8 [Carb onicdich lorid e] Propyleneimine 10,000 b [Aziridine, 2-methyl-] 75-56-9 Propylene oxide 10,000 b [Oxirane, methyl-] 75-74-1 Tetramethyllea d 10,000 b

### [Plumbane, tetramethyl-] 75-77-4 Trimethylchlorosilane 10,000 b [Silane, chlorotrimethyl-] 75-78-5 Dimethyldichlorosilane 5,000 b [Silane, dichlorodimethyl-] 75-79-6 Methyltrichlorosilane 5,000 b [Silane, trichloromethyl-] 78-82-0 Isob uty ronitrile 20,000 b [Propanenitrile, 2- methyl-] 79-21-0 Peracetic acid 10,000 b [Etha nepe roxoic acid ]. 79-22-1 Methyl chloroforma te 5,000 b [Carb onoc hlori dic acid, methy leste r]. 91-08-7 Toluene 2,6-diiso cy anate 10,000 a [Ben zen e, 1, 3-d iis ocyana to- 2-m eth yl-]\1 \. 106-89-8 Epichlor ohy drin 20,000 b [Oxirane, (chloromethyl)-] 107-02-8 Acrolei n [2-Prope nal] 5,000 b 107-11-9 Allylamine 10,000 b [ 2-Propen-1- amine] 107-12-0 Propionitrile [Propanenitrile] 10,000 b

107-13-1 Acry lonitrile 20,000 b [2- Propenenitrile] 107-15-3 Ethylenediamine 20,000 b [1,2- Ethanediamine] 107-18-6 Ally l alcohol [2- Propen -1-ol] 15,000 b

107-30-2 Chloromethyl methy l ether 5,000 b [Methane, chloromethoxy-] 108-05-4 Vinyl aceta te monomer 15,000 b [Acetic acid etheny l ester] 108-23-6 Isopropy l chloroformate 15,000 b [Carbonochloridic acid, 1-methyle thyl ester] 108-91-8 Cyclohexy lamine 15,000 b [Cyclohexanamine] 109-61-5 Propy l chlorof ormate 15,000 b [Carbonochloridic acid, propyle ster] 110-00-9 Furan 5,000 b 110-89-4 Piperidine 15,000 b 123-73-9 Crotonaldehyde, (E )- 20,000 b [2-Butenal, (E)-] 126-98-7 Methacr ylo nitrile 10,000 b [2-Pr open enitr ile, 2 - met hy l-]. 151-56-4 Ethyleneimine 10,000 b

### [Aziridine] 302-01-2 Hydrazine 15,000 b 353-42-4 Boron trifluoride compound 15,000 b with methyl ether (1:1) [Bor on, trifluoro[oxybis[methane]]-, T-4-] 506-77-4 Cyanoge n chloride 10,000 c 509-14-8 Tetranitromethane 10,000 b [Methane, tetranitro-] 542-88-1 Chloromethyl ether 1,000 b [Methane, oxybis[chloro-] 556-64-9 Methyl thiocy anate 20,000 b [Thiocyanic acid, methy l ester] 584-84-9 Toluene 2,4- diisocya nate 10,000 a [Benzene, 2,4-diisocya nato-1-methyl-]\ 1\ 594-42-3 Perchloromethylmerc aptan 10,000 b [Methanesulfenyl chloride, tr ichloro-] 624-83-9 Methyl isocy anate 10,000 a, b [Methane, isocyanato- ] 814-68-6 Acryly l chloride 5,000 b

[2- Propenoyl chloride] 4170-30-3 Crotonaldehyde 20,000 b [2-Butenal] 7446-09-5 Sulfur dioxide (anhydrous) 5,000 a, b 7446-11-9 Sulfur trioxide 10,000 a, b 7550-45-0 Titanium tetrachloride 2,500 b [Titanium chloride (TiCl4) (T-4)-] 7637-07-2 Boron trifluoride 5,000 b [Borane, trifluoro-] 7647-01-0 Hy drochlor ic acid 15,000 d (conc 37% or greater ). 7647-01-0 Hydrog en chloride 5,000 a (anhydrous) [Hydrochloric ac id] 7664-39-3 Hy droge n fluorid e/ 1,000 a, b Hydrofluoric a cid (conc 50% or greate r) [Hydrofluoric a cid] 7664-41-7 Ammonia ( anhy drous) 10,000 a, b 7664-41-7 Ammonia (conc 20% or 20,000 a, b greater) 7697-37-2 Nitric acid (conc 80% 15,000 b or greater) 7719-12-2 Phosphorus trichloride 15,000 b [Phosphorous trichloride] 7726-95-6 Bromine 10,000 a, b 7782-41-4 Fluorine 1,000 b 7782-50-5 Chlorine 2,500 a, b 7783-06-4 Hydrog en sulfide 10,000 a, b 7783-07-5 Hydrog en selenide 500 b

### -------------- -------------- -------------- -------------- -------------- -------------- -------------- ------

-------------- -------------- -------------- -------------- -------------- -------------- -----------

-------------- -------------- -------------- -------------- -------------- -------------- ----------- 7783-60-0 Sulfur tetrafluoride 2,500 b [Sulfur fluoride (SF4), (T-4)-] 7784-34-1 Arsenous trichloride 15,000 b 7784-42-1 Arsine 1,000 b 7803-51-2 Phosphine 5,000 b 8014-95-7 Oleum 10,000 e (Fuming Sulfuric acid) [Sulfuric acid, mixture with sulfur trioxide]\1\ 10025-87-3 Phosphorus oxychloride 5,000 b [Phosphoryl chloride] 10049-04-4 Chlorine dioxide 1,000 c [Chlorine o xide (ClO 2 

### )] 10102-43-9 Nitric oxide 10,000 b [Nitrogen oxide (NO)] 10294-34-5 Boron trichloride 5,000 b [Borane, trichloro-] 13463-39-3 Ni ck el ca rb on yl 1,000 b 13463-40-6 Iron, pentacar bonyl- 2,500 b [Iron carbony l (Fe(CO) 5 

### ), (TB-5-11)-] 19287-45-7 Diborane 2,500 b 26471-62-5 Toluene diisocy anate 10,000 a (unspecified isomer) [Benzene, 1,3-diisocy anatomethyl-1]\ 1\ \1\ The mixture exemption in § 68.115(b)(1) does not apply to the substance. Note: Basis for List ing: a Mandat ed for lis ting by Congre ss. b On EHS list, vapor pressure 10 mmHg or grea ter. c Toxic g as. d Toxicity of hy droge n chlorid e, potent ial to rel ease hy droge n chlorid e, and history of acci dents. e Toxicity of sulfur trioxide and sulfuric acid, potential to rele ase sulfur trioxide, and history of accide nts

Table 3 to § 68.130 - List of Regulate d Flammable Substances \1\ and Threshold Quantities for Accidental Release Prevention [Alphabet ical Ord er - 63 Sub stances ]

CAS No. Thresho ld Basis for Chemical name quantity listing (lbs) Acetaldehy de 75-07-0 10,000 g Acetylene [Ethyne] 74-86-2 10,000 f Bromotrifluorethy lene 598-73-2 10,000 f [Ethene, bromotrifluoro-] 1,3-Butadiene 106-99-0 10,000 f

### Butane 106-97-8 1-Butene 106-98-9 2-Butene 107-01-7 Butene 25167-67-3 2-Bute ne-cis 2-Butene-trans [2-Butene, (E)] Carbon oxysulfide [Carbon oxide sulfide (COS)] Chlorine monoxide [Chlorine oxide] 2-Chloropropylene [1-Propene, 2- chloro-] 1-Chloropropylene [1-Propene, 1- chloro-] Cyanoge n [Ethanedinitrile] Cyclopropane Dichlorosilane [Silane, dichloro-] Difluoroethane [Ethane, 1,1- difluoro-] Dimethylamine [Methanamine, N- methyl-] 2,2-Dimethylpropane [Propane, 2,2-dimethyl-] Ethane Ethyl acety lene [1-Butyne] Ethylamine [Ethanamine] Ethyl chloride [Ethane, chloro- ] Ethylene [Ethene] Ethyl ether [Ethane, 1,1' -oxybis-] Ethy l mercap tan [Ethan ethiol] Ethy l nitrite [Nitrous acid, ethyl ester] Hydrog en Isob utane [Pro pane, 2- methy l] Isopentane [Butane, 2-me thyl-] Isoprene [1,3-Butadinene, 2-methy l-] Isopropy lamine [2-Propanamine] Isopropy l chloride [Propane, 2- chloro-] Methane Methylamine [Methanamine] 3-Methyl-1-butene 2-Methyl-1-butene Methyl ether [Methane, oxy bis-] 590-18-1 624-64-6 463-58-1

7791-21-1

557-98-2

590-21-6

460-19-5 75-19-4 4109-96-0 75-37-6

124-40-3

463-82-1

74-84-0 107-00-6 75-04-7 75-00-3 74-85-1 60-29-7 75-08-1 109-95-5

1333-74-0 75-28-5 78-78-4 78-79-5

75-31-0 75-29-6

74-82-8 74-89-5 563-45-1 563-46-2 115-10-6 10,000 f 10,000 f 10,000 f 10,000 f 10,000 f 10,000 f 10,000 f
10,000 f
10,000 g 10,000 g 10,000 f 10,000 f 10,000 f 10,000 f
10,000 f
10,000 f
10,000 f 10,000 f 10,000 f 10,000 f 10,000 f 10,000 g 10,000 g 10,000 f
10,000 f 10,000 f 10,000 g 10,000 g 10,000 g 10,000 g 10,000 f 10,000 f 10,000 f 10,000 g 10,000 f

### -------------- -------------- -------------- -------------- -------------- -- Methy l formate 107-31-3 10,000 g

[Formic acid, methyl ester ] 2-Methylpropene 115-11-7 10,000 f [1-Propene, 2- methyl-] 1,3-Pentadinene 504-60-9 10,000 f Pentane 109-66-0 10,000 g 1-Pentene 109-67-1 10,000 g 2-Pentene, (E)- 646-04-8 10,000 g 2-Pentene, (Z)- 627-20-3 10,000 g Propadiene [1,2-Propadiene] 463-49-0 10,000 f Propane 74-98-6 10,000 f Propylene [1-Propene] 115-07-1 10,000 f Propyne [1-Propy ne] 74-99-7 10,000 f Silane 7803-62-5 10,000 f Tetrafluoroethy lene 116-14-3 10,000 f [Ethene, tetrafluoro-] Tetramethylsilane 75-76-3 10,000 g [Silane, tetramethyl-] Trichlorosilane 10025-78-2 10,000 g [Silane, trichloro-] Trifluorochloroethy lene 79-38-9 10,000 f [Ethene, chlorotrifluoro-] Trimethylamine 75-50-3 10,000 f [Methanamine, N,N-dimethyl-] Vinyl acety lene [1-Buten-3-y ne] 689-97-4 10,000 f Vinyl chloride [Ethene, chloro- ] 75-01-4 10,000 a, f Vinyl ethy l ether [Ethene, ethoxy-] 109-92-2 10,000 g Vinyl fluoride [Ethene, fluoro-] 75-02-5 10,000 f Vinylidene chloride 75-35-4 10,000 g [Ethene, 1,1-dichloro-] Vinylidene fluoride 75-38-7 10,000 f [Ethene,1,1-difluoro-] Vinyl methy l ether 107-25-5 10,000 f [Ethe ne, m etho xy- ].
\1\ A flamma ble substa nce whe n used as a fuel or h eld for s ale as a fuel at a retail f acility is excluded from all provisions of this part (see § 68.126).

Note: Basis for List ing: a Mandat ed for lis ting by Congre ss. f Flamma ble gas

. gVolatile flammable liquid. Table 4 to § 68.130 - List of Regulate d Flammable Substances \1\ and Threshold Quantities for Accidental Release Prevention

### -------------- -------------- -------------- -------------- -------------- -------------- -------------- --------------

-------------- -------------- -------------- -------------- -------------- -------------- -------------- -------------- [CAS Number Order -63 Substances]
Thresho ld Basis for CAS No. Chemical name quantity listing (lbs)

60-29-7 Ethyl ether 10,000 g [Ethane,1,1[prime]-oxybis-] 74-82-8 Methane 10,000 f 74-84-0 Ethane 10,000 f 74-85-1 Ethylene [Ethene] 10,000 f 74-86-2 Acetylene [Ethyne] 10,000 f 74-89-5 Methylamine 10,000 f [Methanamine] 74-98-6 Propane 10,000 f 74-99-7 Propyne 10,000 f [1-Propyne] 75-00-3 Ethyl chloride 10,000 f [Ethane, chloro-] 75-01-4 Vinyl chloride 10,000 a, f [Ethene, chloro-] 75-02-5 Vinyl fluoride 10,000 f [Ethene, fluoro-] 75-04-7 Ethylamine 10,000 f [Ethanamine] 75-07-0 Acetaldehy de 10,000 g 75-08-1 Ethyl mercapta n 10,000 g [Ethaneth iol] 75-19-4 Cyclopropane 10,000 f 75-28-5 Isobutane 10,000 f [Propane, 2-methy l] 75-29-6 Isopropy l chloride 10,000 g [Propane, 2-chloro-] 75-31-0 Isopropy lamine 10,000 g [2-Propanamine] 75-35-4 Vinylidene chloride 10,000 g [Ethene, 1,1-dichloro-] 75-37-6 Difluoroethane 10,000 f [Ethane, 1,1-difluoro-] 75-38-7 Vinylidene fluoride 10,000 f [Ethene,1,1-difluoro-] 75-50-3 Trimethylamine 10,000 f [Methanamine, N, N-dimethyl-] 75-76-3 Tetramethylsilane 10,000 g [Silane, tetramethyl-]

### 78-78-4 Isopentane 10,000 g [Butane, 2-methyl-] 78-79-5 Isoprene 10,000 g [1,3,-Butadiene, 2- methy l-] 79-38-9 Trifluorochloroethy lene 10,000 f [Ethene, chlorotrifluoro-] 106-97-8 Butane 106-98-9 1-Butene 196-99-0 1,3-Butadiene 107-00-6 Ethyl acety lene [1-Butyne] 107-01-7 2-Butene 107-25-5 Vinyl methy l ether [Ethene, methoxy-] 107-31-3 Methy l formate 10,000 f 10,000 f 10,000 f 10,000 f
10,000 f 10,000 f
10,000 g [Formic acid, methyl ester ] 109-66-0 Pentane 10,000 g 109-67-1 1-Pentene 10,000 g 109-92-2 Vinyl ethy l ether 10,000 g [Ethene, ethoxy-] 109-95-5 Ethy l nitrite 10,000 f [Nitrous acid, ethyl ester] 115-07-1 Propylene [1-Propene] 115-10-6 Methyl ether [Meth ane, oxy bis-] 115-11-7 2-Methylpropene 10,000 f
10,000 f
10,000 f [1-Propene, 2-methyl-] 116-14-3 Tetrafluoroethy lene 10,000 f [Ethene, tetrafluoro-] 124-40-3 Dimethylamine 10,000 f [Methanamine, N-methyl-] 460-19-5 Cyanoge n 10,000 f [Ethanedinitrile] 463-49-0 Propadiene 10,000 f [1,2- Propa dien e] 463-58-1 Carbon oxysulfide 10,000 f [Carbon oxide sulfide (COS)] 463-82-1 2,2-Dimethylpropane 10,000 f [Propane, 2,2-dimethyl-] 504-60-9 1,3-Pentadiene 10,000 f 557-98-2 2-Chloropropylene 10,000 g [1-Propene, 2-chloro-] 563-45-1 3-Methyl-1-butene 10,000 f 563-46-2 2-Methyl-1-butene 10,000 g

### -------------- -------------- -------------- -------------- -------------- -------------- -------------- -------------- 590-18-1 2-Bute ne-cis 10,000 f 590-21-6 1-Chloropropylene 10,000 g [1-Propene, 1-chloro-] 598-73-2 Bromotrifluorethy lene 10,000 f [Ethene, bromotrifluoro-] 624-64-6 2-Butene-trans 10,000 f [2-B uten e, (E )] 627-20-3 2-Pentene, (Z)- 10,000 g 646-04-8 2-Pentene, (E)- 10,000 g 689-97-4 Vinyl acety lene 10,000 f [1-Buten-3-yne ] 1333-74-0 Hydrog en 10,000 f 4109-96-0 Dichlorosilane 10,000 f [Silane, dichloro-] 7791-21-1 Chlorine monoxide 10,000 f [Chlorine oxide] 7803-62-5 Silane 10,000 f 10025-78-2 Trichlorosilane 10,000 g [Silane,trichloro-] 25167-67-3 Butene 10,000 f
\1\ A flamma ble substa nce whe n used as a fuel or h eld for s ale as a fuel at a retail f acility is excluded from all provisions of this part (see § 68.126).

Note: Basis for List ing: a Mandat ed for lis ting by Congre ss. f Flamma ble gas

. g Volatile flammable liquid. [59 FR 4493, Jan. 31, 1994. Redesignated at 61 FR 31717, June 20, 1996, as amend ed at 62 F R 45132, Au g. 25, 19 97; 63 FR 64 5, Jan. 6, 19 98; 65 FR 13250, Mar. 13, 2000] Subpart G - Risk Management Plan Source: 61 FR 31726, June 20, 1996, unless otherwise noted. § 68.150 Submission.

(a) The owner or operator sha ll submit a single RMP that includes the information required by §§68.155 through 68.185 for all covered proce sses. The RMP shall be submitted in the method and format to the central point specified by EPA as of the date of submission. (b) The owner or operator shall submit the first RMP no later than the latest of the f ollowing dates:

(1) June 21, 1999;

### (2) Three y ears after the date on which a re gulated substance is first listed under § 68.130; or (3) The date on which a reg ulated substance is first present above a threshold quantity in a process

.

(c) The owner or operator of any stationary source for which an RMP was submitted before June 21, 2004, shall revise the RMP to include the information required by §68.160(b)(6) and (14) by June 21, 2004 in the manner spec ified by EPA prior to that date. A ny such submission shall also include t he infor mation re quired by §68.160( b)(20) ( indicatin g that th e submission is a correction to include the information required by §68.160(b)(6) and (14) or an update under §68.190).

(d) RMPs sub mitted unde r this sec tion shall b e update d and cor rected in accor dance w ith §§68.190 and 68.195.

(e) Notwithstanding the provisions of Sec.§ 68.155 to 68.190, the RMP shall exclude classified information. Subject to appropriate procedures to protec t such information from public disclosure, classified data or information excluded from the RMP may be made available in a classified annex to the RMP for review by Federal and state represe ntatives who have received the appr opriate security cleara nces. (f) Procedures for asserting that information submitted in the RMP is entitled to protection as confidential business information are set forth in Sec.§ 68.151 and 68.152. [61 FR 31726, June 20, 1996, as amended at 64 FR 979, Jan. 6, 1999 and 69 FR 18819, April 9, 2004] § 68.151 Assertion of claims of confidential business information.

(a) Except as provided in paragraph ( b) of this section, an owner or operator of a stationar y source required to report or otherwise pr ovide information under this part may make a claim of confidential business information for any such information that meets the criteria set forth in 40 CFR 2.301.

(b) Notwithstanding the provisions of 40 CFR part 2, an owner or oper ator of a stationary source subject to this part may not claim as confidential business information the following information:

(1) Registration data required by § 68.160(b)(1) through (b)(6) and (b)(8), ( b)(10) through (b)(13) and NAI CS code and Program level of the process set forth in § 68.160(b)(7);

(2) Offsite consequence analy sis data required by § 68.165(b)(4), (b)(9), (b)(10), (b) (11), and (b)(12).

(3) Accident history data required by § 68.168; (4) Prevention program data require d by § 68.170(b), (d) , (e)(1), (f) through (k) ; (5) Prevention program data require d by § 68.175(b), (d) , (e)(1), (f) through (p) ; and (6) Emergency response program data require d by § 68.180. (c) Notwithstanding the procedures spec ified in 40 CFR part 2, an owner or operator asser ting a claim of CBI with resp ect to inf ormation c ontained in its RMP, sha ll submit to E PA at the ti me it su bmit s the R MP th e foll owing:

(1) The information claimed confidential, provided in a format to be spe cified by EPA; (2) A sanitized (redacted) copy of the RMP, with the notation ``CBI '' substituted for the

### information claimed confidential, except that a generic category or class name shall be substituted for any che mical name or identity cla imed confidential; and (3) The d ocument o r docume nts substa ntiating each cl aim of co nfidentia l business information, as described in § 68.152. [64 FR 979, Jan. 6, 1999] § 68.152 Substantiating claims of confidential business information.

(a) An o wner or operato r claimin g that in formatio n is confi dential b usiness in formatio n must substantiate that claim by providing documentation that demonstrates that the claim meets the substantivecriteria set forth in 40 CFR 2.301.

(b) Information that is submitted as part of the substantiation may be claimed confidential by marking it as confidential business information. I nformation not so marked will be treated as public and may be disclose d without notice to the submitter. If information that is submitted as part of the substantiation is claimed confidential, the owner or operator must provide a sanitized and unsanitized version of the substantiation.

(c) The owner, operator, or se nior official with management responsibility of the stationary source shall sign a certification that the signe r has personally examined the information submitted and that based on inquiry of the pe rsons who compiled the information, the information is true, accurate, and complete, and that those por tions of the substantiation claimed as confidential business information would, if disclosed, reveal trade sec rets or other confidential business information. [64 FR 980, Jan. 6, 1999] § 6 8. 15 5 E xe cu ti ve su mm ar y. The owner or operator shall provide in the RMP an executive summary that includes a brief descrip tion of the following elements : (a) The accidental relea se prevention and emergency response policies at the stationary source; (b) The stationary source and regulated substance s handled; (c) The gener al acci dental r elease prevent ion prog ram and c hemical- specific prevent ion steps; (d ) T he fi ve -ye ar ac ci de nt hi st or y;

(e) The emergenc y response pr ogram; and (f ) P la nn ed ch an ge s t o i mp ro ve sa fe ty. [61 FR 31726, June 20, 1996, as amended at 69 FR 18819, April 9, 2004] § 68.160 Registration.

(a) The owner or operato r shall co mplete a s ingle r egistr ation for m and incl ude it in the RMP. The form shall cov er all re gulate d substanc es handle d in cover ed proce sses. (b) The registration shall include the following da ta: (1) Stationary sourc e name, street, city , county, state, zip code, latitude and long itude, method

### for obtaining latitude and longitude, and description of loca tion that latitude and longitude repres ent;

(2) The stationary source Dun and Bradstreet number; (3 ) N am e a nd Du n a nd Br ad st re et nu mb er of th e c or po ra te pa re nt co mp an y; (4) The name, telephone number, and mailing a ddress of the owner or operator; (5) The n ame and t itle of the person or position wi th overa ll respon sibility for RMP ele ments and imple mentation , and (op tional) th e e-mail address for that p erson or position; (6) The name, title, telephone number, 24-hour telephone numbe r, and, as of June 21, 2004, the e-ma il addre ss (if an e -mail add ress exists ) of the e merge ncy contact ; (7) For each co vered pr ocess, th e name a nd CAS numbe r of eac h regu lated sub stance h eld above the threshold quantity in the pr ocess, the maximum quantity of each re gulated substance or mixture in the process (in pounds) to two significant digits, the five- or six-digit NAI CS code that most c losely corres ponds to the process , and the P rogra m level of the proc ess; (8) The stationary source EPA identifier; (9) The number of full-time employ ees at the stationary source; (10) Whether the stationary source is subject to 29 CFR 1910.119; (11) Whether the stationary source is subject to 40 CFR part 355; (12) If the stationary source has a CAA Title V operating per mit, the permit number; and (13) The date of the last safety inspection of the stationary sour ce by a Federal, state, or local go ve rn me nt ag en cy a nd th e i de nt it y of th e i ns pe ct in g e nt it y. (14) As of June 21, 2004, the name, the mailing address, and the telephone number of the contractor who prepared the RMP (if any ); (15) Source or Parent Company E-Mail Address (Optional); (16) Sour ce Home page a ddress ( Optional) (17) Phone number at the source for public inquiries (Optional); (18) Local Emerg ency Planning Committee (Optional); (19) OSHA Voluntary Protection Program status (Optional); (20) As o f June 21, 20 04, the ty pe of and reason f or any chang es being made to a previous ly submitted R MP; the ty pes of ch anges to RMP are c ategor ized as fo llows: (i) Updates and re-submissions required under §68.190(b); (ii) Corr ections u nder §68 .195 or fo r purpose s of corr ecting minor cle rical er rors, updating administr ative inf ormation, providing missing d ata ele ments or r eflecti ng fac ility ownersh ip chang es, and w hich do no t require an update and re- submission a s specif ied in §68.190(b); (iii) De-registrations required under §68.190(c); and (iv) Withdr awals of an RMP for any facility that was e rroneou sly consider ed subjec t to this part 68. [61 FR 31726, June 20, 1996, as amended at 64 FR 980, Jan. 6, 1999 and 69 FR 18819, April 9, 2004] § 68.165 O ffsite c onseque nce ana lys is. (a) The owner or operator sha ll submit in the RMP information: (1) One worst-case release scenario for each Progr am 1 process; and

### (2) For Program 2 and 3 proce sses, one worst-case release sce nario to represent all regulated toxic substa nces hel d above th e thresh old quanti ty a nd one wor st-case releas e scena rio to represent all regulated flammable substances held above the threshold quantity . If additional
wo rs t- ca se sc en ar io s f or to xi cs or fl am ma bl es ar e r eq ui re d b y § 68.25(a)(2)(iii), the owner or operator shall submit the same information on the additional scenario(s). The owner or opera tor of Program 2 and 3 processes shall also submit information on one alt ernativ e relea se scena rio for e ach reg ulated to xic substance held a bove the t hreshold quantity and one a lternati ve rele ase sce nario to r eprese nt all reg ulated f lammable substanc es held ab ov e t he th re sh ol d q ua nt it y.

(b) The owner or operator shall submit the following da ta: (1) Chemical name; (2) Percentage weig ht of the chemical in a liquid mixture (toxics only); (3) Physical state (toxics only ); (4) Basis of results (give model name if use d); (5) Scenario (explosion, fire, toxic gas release, or liquid spill and evapora tion); (6) Qua ntity releas ed in pounds; (7) Release rate; (8) Release duration; (9) Wind speed and atmospheric stability c lass (toxics only); (10) Topography (toxics only); (11) Dist ance to e ndpoint; (12) Public and environmental receptors within the distance; (13) Passive mitigation considered; and (14) Active mitigation considered (alternative r eleases only) ; [61 FR 31726, June 20, 1996, as amended at 64 FR 980, Jan. 6, 1999] § 6 8. 16 8 F iv e- yea r a cc id en t h is to ry.

The owner or operator shall submit in the RMP the information provided in § 68.42(b) on each accident covered by § 68.42(a). § 68.170 Prevention program/Program 2.

(a) For each Progr am 2 process, the owner or operator shall provide in the RMP the information indicated in paragraphs (b) throug h (k) of this section. If the same infor mation applies to more than one covered process, the owne r or operator may provide the information only once, bu t shall indi cate to w hich proc esses the informat ion applie s. (b) The f ive- or s ix-digit N AICS c ode that most close ly c orrespo nds to the process. (c) The name(s) of the chemica l(s) covered. (d) The date of the most recent review or revision of the safety information and a list of Feder al or stat e regu lations or industry -specif ic desig n codes a nd standa rds used t o demonstr ate compliance with th e safet y in formatio n requir ement. (e) The date of completion of the most recent hazar d review or update. (1) The expected date of completion of any changes resulting from the hazar d review;

### (2) Major hazards identified; (3) Process controls in use; (4) Mitigation systems in use; (5) Monitoring and detection sy stems in use; and (6) Changes since the last hazard review

. (f) The date of t he most re cent re view or r evision of operati ng proc edures. (g) Th e date of the most re cent re view or r evision of training progra ms; (1) The type of training provided - classroom, classroom plus on the job, on the job; and (2) The type of competency testing used. (h) The date of the most recent review or revision of maintenance procedures and the date of the most recent equipment inspection or test and the equipment inspected or tested.

(i) The date of the most recent compliance a udit and the expected date of completion of any chang es resul ting fr om the com pliance audit. (j) The date of the most recent incident investigation and the expected date of completion of any cha nges resulting from the investigation. (k) The d ate of th e most rec ent chan ge that trigg ered a r eview or revision of safe ty infor mati on, t he haz ard rev iew, o perati ng or ma inten ance pr ocedu res, o r trai ning. [61 FR 31726, June 20, 1996, as amended at 64 FR 980, Jan. 6, 1999] § 68.175 Prevention program/Program 3.

(a) For each Progr am 3 process, the owner or operator shall provide the information indicated in paragraphs (b) throug h (p) of this section. If the same infor mation applies to more than one
covere d proces s, the own er or ope rator ma y pr ovide the informat ion only once, bu t shall indi cate to which p rocesse s the info rmation a pplies. (b) The f ive- or s ix-digit N AICS c ode that most close ly c orrespo nds to the process. (c) The name(s) of the substance( s) covered. (d) The date on which the safety information was last reviewed or revised. (e) The date of completion of the most recent PHA or upda te and the technique used. (1) The expected date of completion of any changes resulting from the PHA; (2) Major hazards identified; (3) Process controls in use; (4) Mitigation systems in use; (5) Monitoring and detection sy stems in use; and (6) Changes since the last PHA. (f) The date of t he most re cent re view or r evision of operati ng proc edures. (g) Th e date of the most re cent re view or r evision of training progra ms; (1) The type of training provided - classroom, classroom plus on the job, on the job; and (2) The type of competency testing used. (h) The date of the most recent review or revision of maintenance procedures and the date of the most recent equipment inspection or test and the equipment inspected or tested.

(i) The date of the most recent chang e that triggered manag ement of change procedur es and the date of t he most re cent re view or r evision of manage ment of c hange procedu res. (j) The date of the most recent pre-star tup review.

### (k) The date of the most recent compliance a udit and the expected date of completion of any chang es resul ting fr om the com pliance audit; (l) The date of the most recent incident investigation and the expected date of completion of any cha nges resulting from the investigation;

(m) The d ate of th e most rec ent revi ew or re vision of e mploy ee part icipation plans; (n) The d ate of th e most rec ent revi ew or re vision of h ot work pe rmit proc edures; (o) The date of the most recent review or revision of contractor safety procedures; and (p) The date of the most recent evaluation of c ontractor safety performance. [61 FR 31726, June 20, 1996, as amended at 64 FR 980, Jan. 6, 1999] § 68.180 Em ergen cy response progra m. (a) The owner or operator sha ll provide in the RMP the following information: (1) Do you ha ve a written emergency response plan? (2) Does the plan include specific actions to be taken in re sponse to an accidental releases of a regulated substance?

(3) Doe s the plan include p rocedur es for in forming the public and loca l agenc ies resp onsible for res ponding to accid ental re leases? (4) Does the plan include information on emerge ncy hea lth care? (5) The date of the most recent review or update of the emergency response plan; (6) The d ate of th e most rec ent emer gency response training for emplo ye es. (b) The owner or operator shall provide the na me and telephone number of the local ag ency with which emergency response activities and the emergenc y response plan is c oordinated. (c) The owner or operato r shall lis t other F ederal or state e merge ncy plan req uiremen ts to which the stationar y so urce is s ubject. [61 FR 31726, June 20, 1996, as amended at 64 FR 980, Jan. 6, 1999] § 68.185 Certification.

(a) For Program 1 proce sses, the owner or operator shall submit in the RMP the certification statement provided in § 68.12(b)(4).

(b) For all other covere d proces ses, the o wner or operato r shall sub mit in the RMP a single certification that, to the best of the signer' s knowledge, information, and belief formed a fter reasonable inquiry , the information submitted is true, accurate, and complete. § 68.190 U pdates. (a) The owner or operato r shall re view and update th e RMP as spe cified in parag raph (b) of this section and submit it in the method and format to the central point specified by EPA as of the date of submission.

(b) The owner or operator of a stationary source shall revise and update the RMP submitted under § 6 8.150 as f ollows:

### (1) At le ast once every five y ears fr om the dat e of its ini tial submis sion or mos t recen t update required by paragraphs (b)(2) throug h (b)(7) of this section, whichever is later. For pur poses of determining the date of initial submissions, RMPs submitted before June 21, 1999 are considered to have been submitted on that date.

(2) No later than three y ears after a newly regulated substance is first listed by EPA; (3) No later than the date on which a new r egulated substance is first present in an alre ady
co ve re d p ro ce ss ab ov e a th re sh ol d q ua nt it y;

(4) No la ter than the date on which a regula ted substa nce is fir st prese nt above a threshol d quantity in a new p rocess; (5) Within six months of a change that requires a revised PHA or hazard re view; (6) Within six months of a change that requires a revised offsite conseque nce analy sis as provided in § 68.36; and

(7) Within six months of a change that alters the Program level that applied to any covered process

.

(c) I f a statio nary source i s no long er subje ct to this pa rt, the ow ner or op erator shall submi t a de-registration to EPA within six months indicating that the stationary source is no longer covered. [61 FR 31727, June 20, 1996, as amended at 69 FR 18819, April 9, 2004] §68.195 Re quired c orrect ions. The owner or operator of a stationary source for which a RMP was submitted shall correct the RMP as follo ws:

(a) New accident history information – For any accidental release meeting the five-ye ar accide nt history reportin g crite ria of §6 8.42 and o ccurri ng afte r [insert d ate of pu blication of this final rule], the owner or operator shall submit the data required unde r §§68.168, 68.170(j), and 68.175(l) with resp ect to tha t accide nt within six mo nths of the releas e or by the time th e RMP is updated under §68.190, whichever is earlier.

(b) Emergency contact information – Beginning June 21, 2004, within one month of any change in the emerge ncy contac t information required under §68.160 (b)(6), the owner or operator shall submit a correction of that information. [69 FR 18819, April 9, 2004] Subpart H - Other R equirem ents Source: 61 FR 31728, June 20, 1996, unless otherwise noted. § 68.2 00 Rec ordke eping. The owner or operator shall maintain recor ds supporting the implementation of this part for five y ears unl ess other wise prov ided in sub part D of this part. § 68.210 Availability of information to the public.

### (a) The RMP required under subpart G of this part shall be a vailable to the public under 42 U.S.C. 7414(c).

(b) The disclosure of classified information by the Department of Defense or other F ederal agencies or contractors of such agencies shall be controlled by applicable laws, regulations, or executive orders concerning the re lease of classified information. § 68.215 Pe rmit conte nt and air permittin g autho rity or desig nated ag ency require ments. (a) These requirements apply to any stationary source subject to this part 68 and parts 70 or 71 of this chapter. The 40 CFR part 70 or part 71 permit for the stationar y source sha ll contain: (1) A sta tement lis ting this p art as a n applica ble requ irement; (2) Condit ions that r equire t he sourc e owner or opera tor to submi t: (i) A compliance schedule for meeting the requirements of this part by the date provided in § 68.10(a) or;

(ii) As part of the compliance certification submitted under 40 CFR 70.6(c )(5), a certification statement that the source is in compliance with all requirements of this part, including the regist ration a nd submission of the RMP

. (b) The owner or operato r shall sub mit any additiona l releva nt informa tion requ ested by the air pe rm it ti ng au th or it y or de si gn at ed ag en cy.

(c) For 40 CFR part 70 or part 71 permits issued prior to the dea dline for registering and submitting the RMP and which do not contain permit conditions described in paragraph ( a) of this section, the owner or operator or air permitting a uthority shall initiate permit revision or reopening according to the procedures of 40 CFR 70.7 or 71.7 to incorporate the ter ms and conditions consistent with paragraph (a) of this section.

(d) The state may delegate the authority to implement and enforce the requirements of paragraph (e) of this section to a state or local agency or agencies other than the air pe rmitting authority . An up-to -date c opy of any delega tion instru ment shall be mainta ined by the air permitting authority. The state may enter a written agreement with the Administrator under which EPA will implement and enforce the requirements of par agraph (e) of this section. (e) The air permitting authority or the agency designated by delegation or agree ment under parag raph (d) of this sec tion shall, at a minimu m: (1) Verify that the source owner or operator has r egistered and submitted an RMP or a revised plan whe n requir ed by this part; (2) Ver ify that the so urce ow ner or op erator has submitt ed a sour ce cer tification or in its absence has submitted a compliance schedule consistent with para graph (a)(2) of this section; (3) For some or a ll of the so urces su bject to th is section , use one or more me chanisms such as, but not limite d to, a com pletene ss check , source audits, r ecord r eviews, or faci lity inspectio ns to ensure that permitted sources are in compliance w ith the requirements of this part; and (4) Initiate enforc ement action based on paragra phs (e)(1) and (e)(2) of this section as appropriate. § 68.220 A udits. (a) In addition to inspections for the purpose of regulatory development and enforcement of the Act, the implementing agency shall periodically audit RMPs submitted under subpart G of this part t o review the adeq uacy of such RMPs and req uire re visions of RMPs when n ecessa ry

to

### ensure c omplianc e with subp art G of t his part. (b) The implementing agency shall select stationary sour ces for audits based on any of the following criteria:

(1) Accident history of the stationary sourc e; (2 ) A cc id en t h is to ry o f o th er st at io na ry s ou rc es in th e s am e i nd us tr y;

(3) Quantity of r egulated substances present at the stationary source; (4) Location of the stationary source and its proximity to the public and environmental recept ors; (5) The p resenc e of spec ific reg ulated su bstance s; (6) The hazards identified in the RMP; and (7) A pla n providin g for ne utral, ra ndom over sight. (c) Ex empti on fro m audi ts. A s tati onary sou rce wit h a St ar or Me rit ra nkin g under OSHA's voluntary protection program shall be exempt from audits under parag raph (b)(2) and (b)(7) of this section.

(d) The implementing agency shall have access to the stationary source, supporting documentation, and any area where an acc idental release could occur. (e) Based on the audit, the implementing ag ency may issue the owner or operator of a stationary source a written preliminary determination of necessary revisions to the stationary source's RMP to ensure that the RMP meets the criteria of subpart G of this part. The preliminary determination shall include an explanation for the basis for the revisions, reflecting industry standards and guidelines (such as AI ChE/CCPS guidelines and ASME and API standards) to the extent that such stan dards an d guide lines are applica ble, and shall inclu de a timet able for their implementation.

(f) Writte n respons e to a pre liminary determination. (1 ) The owner or ope rator sh all respond in writing to a preliminary determination made in accordance with para graph (e) of this section. The response shall state the owner or operator will implement the revisions containe d in the preliminary dete rmination in accordance with the timetable included in the preliminary determin ation or s hall state that the o wner or operato r rejec ts the rev isions in whole or in p art. For each rejected re vision, the owner or operator shall explain the basis for rejecting suc h revision . Such expla nation ma y include sub stitute re visions. (2) The written response under parag raph (f)(1) of this section shall be receive d by the implementing agency within 90 days of the issue of the pr eliminary deter mination or a shorter period of time as the implementing agency specifies in the preliminary determination as necessary to protect public health and the environment. Prior to the written response being due and upon w ritten re quest fr om the own er or ope rator, th e impleme nting ag ency may provide i n writing additional time for the response to be receive d.

(g) Af ter providing the owner or operato r an oppo rtunity to respon d under p aragr aph (f) of this section, the implementing agency may issue the owner or operator a written final determination of necessary revisions to the stationary source 's RMP. The final determination may adopt or modify the revi sions cont ained in t he preli minary determin ation unde r parag raph (e ) of this section or may a dopt or modify the substitute revisions provided in the response unde r paragraph (f) of this section. A final determination that adopts a revision rejecte d by the owner or operator shall include an explanation of the basis for the revision. A final determination that fails to adopt a substitute revision provided under paragraph ( f) of this section shall include an explanation of the basis for finding such substitute revision unreasonable.

### -------------- -------------- -------------- -------------- -------------- --------------

-------------- -------------- -------------- -------------- -------------- --------------

(h) Thir ty d ay s after c ompletion o f the ac tions deta iled in the implement ation sch edule se t in the final determination under paragra ph (g) of this secti on, the ow ner or op erator shall be in violation o f subpar t G of this p art and t his section unless the owner or operator revises the RMP prepar ed under subpart G of this part as required by the final determination, and submits the revised RMP as required under § 68.150. (i) The public shall have access to the preliminary determinations, responses, and final determinations under this section in a manner consistent with § 68.210.

(j) Nothing in this section shall preclude, limit, or interfere in any way with the authority of EPA or the state to exercise its enforcement, investigatory , and information gathering authorities
concer ning this part unde r the Act

. Appendix A t o Part 68 -;Table of Toxic Endpo ints [As define d in § 68.22 of this pa rt]
Toxic CAS No. Chemical name endpoint (mg /L)

107-02-8 Acrolei n [2-Prope nal] 0.0011 107-13-1 Acry lonitrile 0.076 [2- Propenenitrile] 814-68-6 Acryly l chloride 0.00090

[2-Propenoyl chloride] 107-18-6 Allyl alcohol 0.036 [2-Propen -1-ol] 107-11-9 Allylamine 0.0032 [2-Propen-1-amine] 7664-41-7 Ammonia ( anhy drous) 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 0.010 [Borane, trichloro-] 7637-07-2 Boron trifluoride 0.028 [Borane, trifluoro-] 353-42-4 Boron trifluoride compound 0.023 with methyl ether (1:1) B oron, 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 0.0028 [Chlorine oxide (ClO2)] 67-66-3 Chloroform 0.49

### [Methane, trichloro-] 542-88-1 Chloromethyl ether 0.00025 [Methane, oxybis[chloro-] 107-30-2 Chloromethyl methy l ether 0.0018 [Methane, chloromethoxy-] 4170-30-3 Crotonald ehy de [2-Bu tenal] 0.029 123-73-9 Crotonaldehyde, (E )-, 0.029 [2- Butenal, (E)-] 506-77-4 Cyanoge n chloride 0.030 108-91-8 Cyclohexy lamine 0.16 [Cyclohexanamine] 19287-45-7 Diborane 0.0011 75-78-5 Dimethyldichlorosilane 0.026 [Silane, dichlorodimethyl-] 57-14-7 1,1-Dimethylhy drazine 0.012 [Hydrazine, 1,1-dimethy l-] 106-89-8 Epichlor ohy drin 0.076 [Oxirane, (chloromethyl)-] 107-15-3 Ethylenediamine 0.49 [1,2-Ethanediamine] 151-56-4 Ethyleneimine [Aziridine] 0.018 75-21-8 Ethylene oxide [Oxirane] 0.090 7782-41-4 Fluorine 0.0039 50-00-0 Formaldehy de (solution) 0.012 110-00-9 Furan 0.0012 302-01-2 Hydrazine 0.011 7647-01-0 Hy drochlor ic acid 0.030 (conc 37% or greater ) 74-90-8 Hy drocy anic ac id 0.011 7647-01-0 Hy droge n chlorid e (anhy drous) 0.030 [Hydrochloric ac id] 7664-39-3 Hydrog en fluoride/ 0.016 Hydrofluoric a cid (conc 50% or greate r) [Hydrofluoric a cid] 7783-07-5 Hydrog en selenide 0.00066 7783-06-4 Hydrog en sulfide 0.042 13463-40-6 Iron, pentacar bonyl- 0.00044 [Iron carbony l (Fe(CO)5), (TB-5-11)- ] 78-82-0 Isob uty ronitrile 0.14 [Propanenitrile, 2-methyl-] 108-23-6 Isop ropy l chlorof ormate 0.10 [Carbonochloride acid, 1-methy lethyl ester] 126-98-7 Methacr ylo nitrile 0.0027 [2-Propenenitrile, 2-methyl-] 74-87-3 Methyl chloride 0.82 [Methane, chloro-]

### 79-22-1 Methy l chlorof ormate 0.0019 [Carbonochloridic acid, methylester ] 60-34-4 Methyl hy drazine 0.0094 [Hydrazine, methy l-] 624-83-9 Methy l isocy anate 0.0012 [Methane, isocyanato- ] 74-93-1 Methyl merca ptan 0.049 [Methanethiol] 556-64-9 Methyl thiocy anate 0.085 [Thiocyanic acid, methy l ester] 75-79-6 Methyltrichlorosilane 0.018 [Silane, trichloromethyl-] 13463-39-3 Ni ck el ca rb on yl 0.00067 7697-37-2 Nitric acid (conc 80% or gre ater) 0.026 10102-43-9 Nitric oxide 0.031 [Nitr ogen oxide (NO) ]. 8014-95-7 Oleum (Fuming Sulfuric acid) 0.010 [Sulfuric acid, mixture with sulfur trioxide] 79-21-0 Peracetic acid 0.0045 [Ethaneperoxoic acid] 594-42-3 Perchloromethylmerc aptan 0.0076 [Methanesulfenyl chloride, tr ichloro-] 75-44-5 Phosgene [Carbonic dichloride] 0.00081 7803-51-2 Phosphine 0.0035 10025-87-3 Phosphorus oxychloride 0.0030 [Phosphoryl chloride] 7719-12-2 Phosphorus trichloride 0.028 [Phosphorous trichloride] 110-89-4 Piperidine 0.022 107-12-0 Propionitrile [Propanenitrile] 0.0037 109-61-5 Propy l chlorof ormate 0.010 [Carb onoc hlori dic a cid, prop yl este r]. 75-55-8 Propyleneimine 0.12 [Aziridine, 2- methyl-] 75-56-9 Propylene oxide 0.59 [Oxirane, methyl-] 7446-09-5 Sulfur dio xide (anhy drous) 0.0078 7783-60-0 Sulfur tetrafluoride 0.0092 [Sulfur fluoride (SF4), (T-4)-] 7446-11-9 Sulfur trioxide 0.010 75-74-1 Tetramethyllea d 0.0040 [Plumbane, tetramethyl-] 509-14-8 Tetranitromethane 0.0040 [Methane, tetranitro-] 7750-45-0 Titanium tetrachloride 0.020

### -------------- -------------- -------------- -------------- -------------- -- [Titanium chloride (TiCl4) (T- 4)-] 584-84-9 Toluene 2,4-diiso cy anate 0.0070 [Benzene, 2,4-diisocya nato-1-methyl-] 91-08-7 Toluene 2,6-diiso cy anate 0.0070 [Benzene, 1,3-diisocya nato-2-methyl-] 26471-62-5 Toluene diisocy anate 0.0070 (unspecified isomer) [Benzene, 1,3-diisocy anatomethyl-] 75-77-4 Trimethylchlorosilane 0.050 [Silane, chlorotrimethyl-] 108-05-4 Vinyl aceta te monomer 0.26 [Acetic acid etheny l ester]

[61 FR 31729, June 20, 1996, as amended at 62 FR 45132, Aug. 25, 1997]

## A PPENDIX B: SELECTED 2002 NAICS CODES

## Selected 2002 NA ICS Co des

Visit http://www.census.gov/epcd/www/naics.html f or a complete listing of 2002 NAICS Codes

11 Agriculture, Forestry, Fi shing and Hunting 11194 Hay Fa rming 111940 Hay Fa rming 111 Crop Production 11199 All Othe r Crop Farm ing 1111 Oilseed a nd Grain Fa rming 111991 Sugar Bee t Farmi ng 11111 Soybean F arming 111992 Peanut Farm ing 111110 Soybean F arming 111998 All Othe r Miscell aneous Crop Fa rming 11112 Oilseed ( except S oybean) Farming 112 Anima l Production 111120 Oilseed ( except S oybean) Farming 1121 Cattle Ra nching and Fa rming 11113 Dry Pea and Bean Fa rming 11211 Beef C attle Ra nching and Fa rming, including 111130 Dry Pea and Bean Fa rming Feedlots 11114 Wheat Fa rming 112111 Beef C attle Ra nching and Fa rming 111140 Wheat Fa rming 112112 Cattle Fe edlots 11115 Corn Farm ing 11212 Dairy Cattle a nd Milk Production 111150 Corn Farm ing 112120 Dairy Cattle a nd Milk Production 11116 Rice Far ming 11213 Dual-Purpose C attle Ra nching and Fa rming 111160 Rice Far ming 112130 Dual-Purpose C attle Ra nching and Fa rming 11119 Other G rain Farm ing 1122 Hog and Pig Fa rming 111191 Oilseed a nd Grain C ombination Fa rming 11221 Hog and Pig Fa rming 111199 All Othe r Grain Farming 112210 Hog and Pig Fa rming 1112 Vegetable and Melon Far ming 1123 Poultry and Eg g Production 11121 Vegetable and Melon Far ming 11231 Chicken Eg g Production 111211 Potato Farm ing 112310 Chicken Eg g Production 111219 Other Vege table (ex cept Potato) a nd Melon 11232 Broilers and Other Meat Type Chicken Farming Production 1113 Fruit and Tr ee Nut Far ming 112320 Broilers and Other Meat Type Chicken 11131 Orange Groves Production 111310 Orange Groves 11233 Turkey Production 11132 Citrus (except Orange) Groves 112330 Turkey Production 111320 Citrus (except Orange) Groves 11234 Poultry Hatcheries 11133 Noncitrus Fr uit and Tre e Nut Farm ing 112340 Poultry Hatcheries 111331 Apple Or chards 11239 Other Poultry Production 111332 Grape Vine yards 112390 Other Poultry Production 111333 Strawbe rry Fa rming 1124 Sheep and G oat Farm ing 111334 Berry (except Strawbe rry) Fa rming 11241 Sheep Farm ing 111335 Tree N ut Farmi ng 112410 Sheep Farm ing 111336 Fruit and Tr ee Nut Com bination Farm ing 11242 Goat Far ming 111339 Other Nonci trus Fruit Fa rming 112420 Goat Far ming 1114 Greenhous e, Nurser y, and Flor iculture 1125 Anima l Aquacul ture Production 11251 Anima l Aquacul ture 11141 Food Crops Grown Under Cover 112511 Finfish Farming and Fish Hatcheries 111411 Mushroom Product ion 112512 Shellfis h Farming 111419 Other Food Crops Grown Under Cover 112519 Other A nimal A quaculture 11142 Nursery and Floricult ure Production 1129 Other A nimal Product ion 111421 Nursery and Tree Production 11291 Apiculture 111422 Floriculture Production 112910 Apiculture 1119 Other Crop Fa rming 11292 Horses a nd Other Equine Production 11191 Tobacco F arming 112920 Horses a nd Other Equine Production 111910 Tobacco F arming 11293 Fur-Bearing Anima l and Rabbit Produc tion 11192 Cotton Farm ing 112930 Fur-Bearing Anima l and Rabbit Produc tion 111920 Cotton Farm ing 11299 All Othe r Anim al Production 11193 Sugarcane Farming 112990 All Othe r Anim al Production 111930 Sugarcane Farming 113 Forestry and Logg ingAppendix B Selected 2002 NAICS Codes B-2

1131 Timbe r Tract Operations 11311 Timbe r Tract Operations 113110 Timbe r Tract Operations 1132 Forest Nurseries and Gathering of Forest Products 11321 Forest Nurseries and Gathering of Forest Products 113210 Forest Nurseries and Gathering of Forest Products 1133 Logging 11331 Logging 113310 Logging 114 Fishing, Hunti ng and Tra pping 1141 Fishing 11411 Fishing 114111 Finfish Fis hing 114112 Shellfis h Fishing 114119 Other Mari ne Fishing 1142 Hunting and T rapping 11421 Hunting and T rapping 114210 Hunting and T rapping 115 Support Acti vities f or Agri culture and F orestry 1151 Support Acti vities f or Crop Production 11511 Support Acti vities f or Crop Production 115111 Cotton Ginning 115112 Soil Preparati on, Planting, and C ultivating 115113 Crop Harv esting, Prim arily by Machi ne 115114 Postharvest Crop Act ivities ( except C otton Ginning) 115115 Farm L abor Contrac tors and Cre w Lea ders 115116 Farm Management Service s 1152 Support Acti vities f or Anim al Production 11521 Support Acti vities f or Anim al Production 115210 Support Acti vities f or Anim al Production 1153 Support Acti vities f or Forestry 11531 Support Acti vities f or Forestry 115310 Support Acti vities f or Forestry

21 Mining

211 Oil and G as Extra ction 2111 Oil and G as Extra ction 21111 Oil and G as Extra ction 211111 Crude Petroleum and Natura l Gas E xtraction 211112 Natural G as Liquid E xtraction 212 Mining (except Oil and Gas) 2121 Coal Mining 21211 Coal Mining 212111 Bituminous Coal and L ignite Surf ace Mining 212112 Bituminous Coal Underg round Mining 212113 Anthraci te Mining 2122 Metal Ore Mining 21221 Iron Ore Mini ng 212210 Iron Ore Mini ng 21222 Gold Ore and Silver Ore Mining 212221 Gold Ore Mining 212222 Silver Or e Mining 21223 212231 212234 21229 212291 212299 2123 21231 212311 212312 Copper, Nick el, Lea d, and Zinc Mining Lead Or e and Zinc O re Mining Copper Ore and Nicke l Ore Mining Other Meta l Ore Mining Uranium- Radium-Va nadium Or e Mining All Othe r Metal Or e Mining Nonmeta llic Minera l Mining and Q uarrying Stone Mining a nd Quarry ing Dimens ion Stone Mining and Quarry ing Crushed and B roken Li mestone Mining and Quarry ing 212313 Crushed and B roken G ranite Mining and Quarry ing 212319 Other Crus hed and Broke n Stone Mining a nd Quarry ing 21232 Sand, Gra vel, Cla y, and Ce ramic and Refr actory Minerals Mi ning and Quar rying 212321 Construction Sa nd and Gra vel Mining 212322 Industrial Sa nd Mining 212324 Kaolin and Ba ll Clay Mining 212325 Clay a nd Ceram ic and Ref ractory Minerals Mining 21239 Other Nonm etallic Mineral Mining and Quarry ing 212391 212392 212393 212399 213 2131 21311 213111 213112 213113 213114 213115 Potash, Soda, and B orate Miner al Mining Phosphate Rock Mining Other Chem ical and Fe rtilizer Mineral Mining All Othe r Nonmet allic Mine ral Mining Support Acti vities f or Mining Support Acti vities f or Mining Support Acti vities f or Mining Drilling O il and Ga s Wells Support Acti vities f or Oil and G as Opera tions Support Acti vities f or Coal Mining Support Acti vities f or Metal Mini ng Support Acti vities f or Nonmet allic Mine rals (except Fuels)

22 Utilities

221 Utilities 2211 Electric Power Generation, T ransmis sion and Distribution 22111 221111 221112 221113 221119 22112 Electric Power Generation Hydroel ectric Pow er Gene ration Fossil Fuel Electric Power Ge neration Nuclear Electric Power Ge neration Other Elec tric Power Genera tion Electric Power Tr ansmis sion, Control, a nd Distribution 221121 221122 2212 22121 221210 2213 22131 Electric Bulk Power Transm ission and Cont rol Electric Power Dis tribution Natural G as Distr ibution Natural G as Distr ibution Natural G as Distr ibution Water, Sewage an d Oth er Syst ems Water S upp ly and I rriga tion SystemsAppend ix B B-3 Select ed 2002 NA ICS Codes

221310 Water S upp ly and I rriga tion Systems 22132 Sewage Treatm ent Facilities 221320 Sewage Treatm ent Facilities 22133 Steam and Air-C onditioning Supply 221330 Steam and Air-C onditioning Supply

23 Construction
236 Constru ction o f Buildin gs 2361 Residentia l Building Cons truction 23611 Residentia l Building Cons truction 236115 New Sing le-Fam ily Hous ing Construc tion (except Operative Builders) 236116 New Mult ifam ily Hous ing Construc tion (exce pt Operative Builders) 236117 New Hous ing Opera tive Builde rs 236118 Residentia l Remode lers 2362 Nonresidenti al Building Construction 23621 Industrial B uilding Constr uction 236210 Industrial B uilding Constr uction 23622 Comm ercial a nd Institutional Building Construction 236220 Comm ercial a nd Institutional Building Construction 237 Heavy and Civil E ngineering Construction 2371 Utility Syste m Construc tion 23711 Water and Sewer Line and Related Structures Construction 237110 Water and Sewer Line and Related Structures Construction 23712 Oil and Gas Pipeline and Related Structures Construction 237120 Oil and Gas Pipeline and Related Structures Construction 23713 Power and Communication Line and Related Structures Construction 237130 Power and Communication Line and Related Structures Construction 2372 Land Subdivi sion 23721 Land Subdivi sion 237210 Land Subdivi sion 2373 Highwa y, Stre et, and Bridg e Construct ion 23731 Highwa y, Stre et, and Bridg e Construct ion 237310 Highwa y, Stre et, and Bridg e Construct ion 2379 Other Hea vy and Civil Engi neering C onstruction 23799 Other Hea vy and Civil Engi neering C onstruction 237990 Other Hea vy and Civil Engi neering C onstruction 238 Specialty Trade C ontractors 2381 Foundation, Struct ure, and Buildi ng Exter ior Contractors 23811 Poured Concrete Foundation and Str ucture Contractors 238110 Poured Concrete Foundation and Str ucture Contractors 23812 Structural S teel and Prec ast Concre te Contrac tors 238120 Structural S teel and Prec ast Concre te Contrac tors 23813 Framing Contractors 238130 Framing Contractors 23814 Masonry Contractors 238140 Masonry Contractors 23815 Glass and Glaz ing Contrac tors 238150 Glass and Glaz ing Contrac tors 23816 Roofing Cont ractors 238160 Roofing Cont ractors 23817 Siding Contra ctors 238170 Siding Contra ctors 23819 Other Foundati on, Structure,and Building Exterior C ontractors 238190 Other Foundati on, Structure,and Building Exterior C ontractors 2382 Building Equipm ent Contrac tors 23821 Electric al Contrac tors 238210 Electric al Contrac tors 23822 Plumbing, He ating, and A ir-Conditioning Contractors 238220 Plumbing, He ating, and A ir-Conditioning Contractors 23829 Other Building Equipment Contractors 238290 Other Building Equipment Contractors 2383 Building Finis hing Contrac tors 23831 Dryw all and Insul ation Contrac tors 238310 Dryw all and Insul ation Contrac tors 23832 Painting and W all Cover ing Contrac tors 238320 Painting and W all Cover ing Contrac tors 23833 Flooring Contra ctors 238330 Flooring Contra ctors 23834 Tile and T errazzo Contractors 238340 Tile and T errazzo Contractors 23835 Finish Carpe ntry Contr actors 238350 Finish Carpe ntry Contr actors 23839 Other Building Finishing Cont ractors 238390 Other Building Finishing Cont ractors 2389 Other Spec ialty T rade Contra ctors 23891 Site Prepara tion Contract ors 238910 Site Prepara tion Contract ors 23899 All Othe r Specialt y Tra de Contract ors 238990 All Othe r Specialt y Tra de Contract ors
31-33 Manufacturing
311 Food Manufac turing 3111 Anima l Food Manufa cturing 31111 Anima l Food Manufa cturing 311111 Dog and Ca t Food Manufa cturing 311119 Other A nimal Food M anufact uring 3112 Grain a nd Oilseed M illing 31121 Flour Milling a nd Malt Manuf acturing 311211 Flour Milling 311212 Rice Milli ng 311213 Malt Manuf acturing 31122 Starch and Ve getable Fats and Oi ls Manufact uring 311221 Wet Corn Milling 311222 Soybean Proc essingAppendix B Selected 2002 NAICS Codes B-4

311223 Other Oils eed Process ing 311225 Fats and Oi ls Refi ning and Ble nding 31123 Breakf ast Cere al Manufa cturing 311230 Breakf ast Cere al Manufa cturing 3113 Sugar and C onfectione ry Product Ma nufacturi ng 31131 Sugar Manuf acturing 311311 Sugarcane Mills 311312 Cane Suga r Refini ng 311313 Beet Suga r Manufac turing 31132 Chocolate a nd Confect ionery Ma nufacturi ng from C acao Bea ns 311320 Chocolate a nd Confect ionery Ma nufacturi ng from C acao Bea ns 31133 Confectionery Manufacturing from Purchased Chocolate 311330 Confectionery Manufacturing from Purchased Chocolate 31134 Nonchocolate Confect ionery Ma nufacturi ng 311340 Nonchocolate Confect ionery Ma nufacturi ng 3114 Fruit and Vege table Prese rving and S pecialty Food Manufac turing 31141 Frozen Food Manuf acturing 311411 Frozen Fruit, Juice, and Vegetable Manufact uring 311412 Frozen Spec ialty F ood Manufac turing 31142 Fruit and Vege table Canni ng, Pickling , and Drying 311421 Fruit and Vege table Canni ng 311422 Specialty Canning 311423 Dried and D ehydrat ed Food Manufa cturing 3115 Dairy Product Manufa cturing 31151 Dairy Product (exc ept Frozen) Manufact uring 311511 Fluid Milk Ma nufacturi ng 311512 Cream ery But ter Manuf acturing 311513 Cheese Ma nufacturi ng 311514 Dry, Condensed, and Evaporated Dairy Product Manufact uring 31152 Ice Crea m and Froz en Desse rt Manufa cturing 311520 Ice Crea m and Froz en Desse rt Manufa cturing 3116 Anima l Slaughter ing and Proces sing 31161 Anima l Slaughter ing and Proces sing 311611 Anima l (exce pt Poultry) Sl aughtering 311612 Meat Processed from Carcasses 311613 Rendering and Meat By product Process ing 311615 Poultry Proces sing 3117 Seafood Product Preparation a nd Packagi ng 31171 Seafood Product Preparation a nd Packagi ng 311711 Seafood Ca nning 311712 Fresh and Froz en Seaf ood Processing 3118 Bakerie s and Tortilla Manuf acturing 31181 Bread and B akery Product Manufa cturing 311811 Retail Bakeries 311812 Commercial Bake ries 311813 Frozen Cakes, Pies, and Other Pastries 311822 Flour Mixes and Dough Ma nufacturi ng from Purchased Flour 311823 Dry Past a Manufa cturing 31183 Tortilla Manufact uring 311830 Tortilla Manufact uring 3119 Other Food Manuf acturing 31191 Snack Food Ma nufacturi ng 311911 Roasted Nut s and Peanut But ter Manuf acturing 311919 Other Snac k Food Manufa cturing 31192 Coffe e and Te a Manufa cturing 311920 Coffe e and Te a Manufa cturing 31193 Flavoring Syrup and Concentrate Manufac turing 311930 Flavoring Syrup and Concentrate Manufac turing 31194 Seasoning a nd Dressing Manufac turing 311941 Mayonnaise, Dressing, and Other Prepared Sauce Manufact uring 311942 31199 311991 311999 312 3121 31211 312111 312112 312113 31212 312120 31213 312130 31214 312140 3122 31221 312210 31222 312221 312229 313 3131 31311 313111 313112 313113 3132 31321 313210 31322 Spice and Ex tract Manuf acturing All Othe r Food Manufa cturing Perishable Pre pared Food Manuf acturing All Othe r Miscell aneous Food Manuf acturing Bevera ge and T obacco Product Ma nufacturi ng Bevera ge Manuf acturing Soft Drink and Ice Ma nufacturi ng Soft Drink Manufac turing Bottled Wa ter Manuf acturing Ice Manuf acturing Breweries Breweries Wineries Wineries Distilleries Distilleries Tobacco Ma nufacturi ng Tobacco S temm ing and Redr ying Tobacco S temm ing and Redr ying Tobacco Produc t Manufac turing Cigaret te Manufa cturing Other Toba cco Product Manuf acturing Textil e Mills Fiber, Yar n, and Threa d Mills Fiber, Yar n, and Threa d Mills Yarn Spinning Mills Yarn Te xturizing , Throwi ng, and Tw isting Mill s Thread Mi lls Fabric Mills Broadwov en Fabric Mi lls Broadwov en Fabric Mi lls Narrow Fabric Mills and Schiff li Machine Embroider y 313221 Narrow Fabric Mills 313222 Schiff li Machine E mbroidery 31323 Nonwoven Fabric Mills 313230 Nonwoven Fabric Mills 31324 Knit Fabric Mills Manufact uring 313241 Weft Knit Fabric Mills 31182 Cookie, Cr acker, and Pasta Manuf acturing 313249 Other Knit F abric and L ace Mills 311821 Cookie and C racker Manufac turing 3133 Textil e and Fabric Finishing a nd Fabric Coa tingAppend ix B B-5 Select ed 2002 NA ICS Codes

Mills 31331 Textil e and Fabric Finishing Mil ls 313311 Broadwov en Fabric Fi nishing Mills 313312 Textile and Fabric Finishing (except Broadwoven Fabric) Mills 31332 Fabric Coa ting Mills 313320 Fabric Coa ting Mills 314 Textil e Product Mills 3141 Textil e Furnishings Mills 31411 Carpet and Rug Mills 314110 Carpet and Rug Mills 31412 Curtain and L inen Mills 314121 Curtain and D rapery Mills 314129 Other House hold Texti le Product Mills 3149 Other Te xtile Product Mills 31491 Textil e Bag a nd Canvas Mills 314911 Textil e Bag Mil ls 314912 Canvas a nd Related Produc t Mills 31499 All Othe r Text ile Product Mills 314991 Rope, Cordag e, and Tw ine Mills 314992 Tire Cor d and Tire Fabric Mill s 314999 All Othe r Miscell aneous Te xtile Product Mills Manufact uring

322 Paper Manufa cturing 3221 Pulp, Paper, and Paperboa rd Mills 32211 Pulp Mills 322110 Pulp Mills 32212 Paper Mills 322121 Paper (exc ept New sprint) Mills 322122 Newspr int Mills 32213 Paperboard Mills 322130 Paperboard Mills 3222 Converted Paper Product Manuf acturing 32221 Paperboard Conta iner Manuf acturing 322211 Corrugate d and Solid Fiber Box Manuf acturing 322212 Folding Paperboa rd Box Manuf acturing 322213 Setup Paperboard Box Manuf acturing 322214 Fiber Can, T ube, Drum , and Simi lar Products Manufact uring 322215 Nonfolding Sanitary Food Container Manufact uring 32222 Paper Bag and Coated and Treated Paper Manufact uring 322221 Coated and L aminate d Packagi ng Paper and Plastics Fil m Manuf acturing 322222 Coated and L aminate d Paper Manuf acturing 322223 Plastics, Foil, and Coated Paper Bag Manufact uring 322224 Uncoated Paper and Multiwall Bag Manufact uring 322225 Lami nated Al uminum Foil Manufa cturing f or Flexible Packaging Uses 322226 Surface -Coated Paper board Manufa cturing 32223 Stationery Product Manufa cturing 322231 Die-Cut Paper and Paperboard Office Supplies Manufact uring 322232 Envelope Ma nufacturi ng 322233 Stationery, Tablet, and Related Product Manufact uring 32229 Other Conve rted Paper Product Manufac turing 322291 Sanitary Paper Product Manuf acturing 322299 All Other Converted Paper Product Manufact uring 323 Printing and Related Suppo rt Activities 3231 Printing and Related Suppo rt Activities 32311 Printing 323110 Comm ercial L ithographic Printing 323111 Comm ercial G ravure Print ing 323112 Comm ercial Fl exographi c Printing 323113 Comm ercial Sc reen Printing 323114 Quick Printing 323115 Digital Print ing 323116 Manifold Bus iness Form s Printing 323117 Books Printing 323118 Blankbook, Looseleaf Binders, and Devices Manufact uring 323119 Other Com merci al Printing 32312 Support Acti vities f or Printing 323121 Tradebinding and Relate d Work 323122 Prepress Services 324 Petroleum a nd Coal Products Ma nufacturi ng 3241 Petroleum a nd Coal Products Ma nufacturi ng 32411 Petroleum Refineries 324110 Petroleum Refineries 32412 Asphalt Pav ing, Roofi ng, and Satur ated Mate rials Manufact uring 324121 Asphalt Paving Mixture and Block Manufact uring 324122 Asphalt S hingle and C oating Mate rials Manufact uring 32419 Other Petrole um and Coa l Products Manufact uring 324191 Petroleum Lubricating Oil and Grease Manufact uring 324199 All Othe r Petroleum and Coal Products Manufact uring 325 Chemic al Manufa cturing 3251 Basic Che mical Manufact uring 32511 Petrochem ical Manuf acturing 325110 Petrochem ical Manuf acturing 32512 Industrial G as Manuf acturing 325120 Industrial G as Manuf acturing 32513 Synthetic Dye a nd Pigment M anufact uring 325131 Inorganic D ye and Pig ment Ma nufacturi ng 325132 Synthetic Organic Dye a nd Pigment Manufact uring 32518 Other Bas ic Inorgani c Chem ical Manuf acturing 325181 Alkali es and Chlori ne Manufa cturing 325182 Carbon Blac k Manufa cturing 325188 All Other Basic Inorganic Chemical Manufact uring 32519 Other Bas ic Orga nic Chem ical Manuf acturing 325191 Gum a nd Wood Chem ical Manuf acturingAppendix B Selected 2002 NAICS Codes B-6

325192 Cyclic Crude and Int ermedi ate Manuf acturing 325193 Ethyl A lcohol Manuf acturing 325199 All Othe r Basic O rganic C hemica l Manufac turing 3252 Resin, Sy nthetic Rubbe r, and Art ificial Syntheti c Fibers and Fi laments Manufac turing 32521 Resin and Sy nthetic Rubbe r Manufac turing 325211 Plastics Ma terial a nd Resin Manuf acturing 325212 Synthetic Rubber Manuf acturing 32522 Artif icial and Sy nthetic Fibe rs and Filam ents Manufact uring 325221 Cellulosic Organic Fiber Manuf acturing 325222 Noncellulosi c Organi c Fiber Manuf acturing 3253 Pesticide, Fertilizer, and Other Agricultural Chemic al Manufa cturing 32531 Fertilize r Manufac turing 325311 Nitrogenous Fertilize r Manufac turing 325312 Phosphatic Fert ilizer Ma nufacturi ng 325314 Fertilize r (Mixing Only) Ma nufacturi ng 32532 Pesticide and Other Agricultural Chemical Manufact uring 325320 Pesticide and Other Agricultural Chemical Manufact uring 3254 Pharmace utical and Me dicine Manuf acturing 32541 Pharmace utical and Me dicine Manuf acturing 325411 Medicinal a nd Botanical Manufac turing 325412 Pharmace utical Prepa ration Manuf acturing 325413 In-Vitro Diag nostic Substa nce Manuf acturing 325414 Biological Product (except Diagnostic) Manufact uring 3255 Paint, Coating , and Adhes ive Manuf acturing 32551 Paint and Coating Manufac turing 325510 Paint and Coating Manufac turing 32552 Adhesiv e Manufa cturing 325520 Adhesiv e Manufa cturing 3256 Soap, Cleaning Compound, and Toilet Preparation Ma nufacturi ng 32561 Soap and Clea ning Compound Manufact uring 325611 Soap and Other Deterg ent Manufa cturing 325612 Polish and Other Sanitation G ood Manufac turing 325613 Surface Activ e Age nt Manufac turing 32562 Toilet Prepa ration Manuf acturing 325620 Toilet Prepa ration Manuf acturing 3259 Other Chem ical Product a nd Preparation Manufact uring 32591 Printing Ink Ma nufacturi ng 325910 Printing Ink Ma nufacturi ng 32592 Explosive s Manufa cturing 325920 Explosive s Manufa cturing 32599 All Othe r Chemi cal Product and Preparation Manufact uring 325991 Custom C ompounding of Purchased Re sins 325992 Photographic Film, Paper, P late, and Chemical Manufact uring 325998 All Othe r Miscell aneous Chem ical Product a nd Preparation Ma nufacturi ng 326 Plastics a nd Rubber Products M anufact uring 3261 Plastics Product Manufac turing 32611 Plastics Packaging Materials and Unlaminated Film and S heet Manuf acturing 326111 Plastics Ba g Manufa cturing 326112 Plastics Pac kaging Film and S heet (incl uding Lami nated) Manuf acturing 326113 Unlamina ted Plastics Film and Sheet (ex cept Packaging ) Manufac turing 32612 Plastics Pipe, Pipe Fit ting, and Unlaminated Profile Shape Manufac turing 326121 Unlamina ted Plastics Profile Shape Manufact uring 326122 Plastics Pipe a nd Pipe Fitting Ma nufacturi ng 32613 Lami nated Plastic s Plate, Shee t (exce pt Packaging ), and Shape M anufact uring 326130 Lami nated Plastic s Plate, Shee t (exce pt Packaging ), and Shape M anufact uring 32614 Polysty rene Foam Product Manufa cturing 326140 Polysty rene Foam Product Manufa cturing 32615 Urethane a nd Other Foam Product (exc ept Polysty rene) Manuf acturing 326150 Urethane a nd Other Foam Product (exc ept Polysty rene) Manuf acturing 32616 Plastics Bot tle Manuf acturing 326160 Plastics Bot tle Manuf acturing 32619 Other Plasti cs Product Manuf acturing 326191 Plastics Plum bing Fixture Manufac turing 326192 Resilient Floor Cover ing Manufa cturing 326199 All Othe r Plastics Product Manufa cturing 3262 Rubber Product Manuf acturing 32621 Tire Ma nufacturi ng 326211 Tire Manufact uring (excep t Retreadi ng) 326212 Tire Re treading 32622 Rubber and Plast ics Hose s and Belti ng Manufact uring 326220 Rubber and Plast ics Hose s and Belti ng Manufact uring 32629 Other Rubber Product Manufa cturing 326291 Rubber Product Manu facturing for Mechanical Use 326299 All Othe r Rubber Product Ma nufacturi ng 327 Nonmeta llic Minera l Product Manufa cturing 3271 Clay Produc t and Ref ractory Manufac turing 32711 Pottery, C eramics, and Plum bing Fixture Manufact uring 327111 Vitreous China Plumbing Fix ture and China and Earthenw are Bathr oom Ac cessorie s Manufa cturing 327112 Vitreous China, Fine Earthenware, and Other Pottery Product Manufac turing 327113 Porcelain Ele ctrical Supply Manuf acturing 32712 Clay Building Material and Refractories Manufact uring 327121 Brick a nd Structural Clay T ile Manuf acturing 327122 Ceram ic Wall and Floor Ti le Manufa cturing 327123 Other Struc tural Clay Product Manufa cturing 327124 Clay R efrac tory Manuf acturing 327125 Nonclay Refra ctory Ma nufacturi ng 3272 Glass and Glas s Product Manuf acturingAppend ix B B-7 Select ed 2002 NA ICS Codes

32721 Glass and Glas s Product Manuf acturing 327211 Flat Gla ss Manufa cturing 327212 Other Press ed and Blow n Glass and Glas sware Manufact uring 327213 Glass Container Ma nufacturi ng 327215 Glass Product Manufacturing Made of Purchased Glass 3273 Cement and Concret e Product Manuf acturing 32731 Cement Manufac turing 327310 Cement Manufac turing 32732 Ready- Mix Concre te Manufa cturing 327320 Ready- Mix Concre te Manufa cturing 32733 Concrete Pipe , Brick, a nd Block Manuf acturing 327331 Concrete B lock and Br ick Manuf acturing 327332 Concrete Pipe Manufac turing 32739 Other Concr ete Product Ma nufacturi ng 327390 Other Concr ete Product Ma nufacturi ng 3274 Lime and Gy psum Product Ma nufacturi ng 32741 Lime Manufac turing 327410 Lime Manufac turing 32742 Gyps um Product Manuf acturing 327420 Gyps um Product Manuf acturing 3279 Other Nonmetallic Mineral Product Manufact uring 32791 Abrasiv e Product Manuf acturing 327910 Abrasiv e Product Manuf acturing 32799 All Other Nonmetallic Mineral Product Manufact uring 327991 Cut Stone and St one Product Manuf acturing 327992 Ground or T reated Mine ral and Ear th Manufact uring 327993 Mineral W ool Manufac turing 327999 All Other Miscellaneous Nonmetallic Mineral Product Manufa cturing 331 Primary Metal Manuf acturing 3311 Iron and Stee l Mills and Fe rroalloy Manufact uring 33111 Iron and Stee l Mills and Fe rroalloy Manufact uring 331111 Iron and Stee l Mills 331112 Electrometallurgical Ferroalloy Product Manufact uring 3312 Steel Product Manufacturing from Purchased Steel 33121 Iron and Stee l Pipe and Tube Manufac turing from Purchased Steel 331210 Iron and Stee l Pipe and Tube Manufac turing from Purchased Steel 33122 Rolling and Drawing of Purchased Steel 331221 Rolled Stee l Shape Manuf acturing 331222 Steel Wi re Draw ing 3313 Alumi na and Alum inum Production a nd Processing 33131 Alumi na and Alum inum Production a nd Processing 331311 Alumi na Refi ning 331312 Primary Alumi num Production 331314 Secondary Smelting and Alloy ing of A luminum 331315 Alumi num Sheet , Plate, and Foil Manufac turing 331316 Alumi num Extr uded Product Manuf acturing 331319 Other A luminum Rolling and D rawing 3314 Nonferrous Metal (e xcept A luminum ) Production and Processing 33141 Nonferrous Metal (e xcept A luminum ) Smelt ing and Refi ning 331411 Primary Smelting and Refining of Copper 331419 Primary Smelting and Refi ning of Nonf errous Metal (excep t Cop per an d Alumi num) 33142 Copper Rolling , Drawi ng, Extruding , and Alloy ing 331421 Copper Rolling , Drawi ng, and Ext ruding 331422 Copper Wir e (exce pt Mechanic al) Draw ing 331423 Secondary Smelting , Refining , and Alloy ing of Copper 33149 Nonferrous Metal (e xcept Coppe r and Alumi num) Rolling , Drawi ng, Extruding , and Alloy ing 331491 Nonferrous Metal (e xcept Coppe r and Alumi num) Rolling , Drawi ng, and Ext ruding 331492 Secondary Smelting , Refining , and Alloy ing of Nonfe rrou s Meta l (exce pt Co pper and Al uminu m) 3315 Foundries 33151 Ferrous Metal Foundries 331511 Iron Foundries 331512 Steel Investment Foundries 331513 Steel Foundrie s (exce pt Investm ent) 33152 Nonferrous Metal Foundries 331521 Aluminum Die-Casting Foundries 331522 Nonferrous (except Alumi num) Die -Casting Foundries 331524 Aluminum Fou ndries (e xcept Die-Ca sting) 331525 Copper Found ries (except Die-Castin g) 331528 Other Non ferrous Fo undri es (except Die- Casting) 332 Fabricate d Metal Product M anufact uring 3321 Forging and Stamping 33211 Forging and Stamping 332111 Iron and Stee l Forging 332112 Nonferrous Forging 332114 Custom R oll Forming 332115 Crown and C losure Manuf acturing 332116 Metal Stam ping 332117 Powder Meta llurgy Part Manufa cturing 3322 Cutlery and Handtool Ma nufacturi ng 33221 Cutlery and Handtool Ma nufacturi ng 332211 Cutlery and Flatware (except Precious) Manufact uring 332212 Hand and Edge Tool Manuf acturing 332213 Saw Bla de and Hands aw Manuf acturing 332214 Kitchen Ut ensil, Pot, and Pan M anufact uring 3323 Archite ctural and S tructural Me tals Manufact uring 33231 Plate Work and Fabricated Structural Product Manufact uring 332311 Prefabric ated Meta l Building a nd Component Manufact uringAppendix B Selected 2002 NAICS Codes B-8

332312 Fabricate d Structural Metal Manuf acturing 332313 Plate Work Manufac turing 33232 Orname ntal and A rchitectur al Metal Produc ts Manufact uring 332321 Metal Wi ndow and Door Manufact uring 332322 Sheet Meta l Work Ma nufacturi ng 332323 Orname ntal and A rchitectur al Metal W ork Manufact uring 3324 Boiler, Tank, and Shipping Container Manufact uring 33241 Power Boile r and Heat Exchang er Manufa cturing 332410 Power Boile r and Heat Exchang er Manufa cturing 33242 Metal Ta nk (Heav y Ga uge) Manuf acturing 332420 Metal Ta nk (Heav y Ga uge) Manuf acturing 33243 Metal Can, Box, and Other Metal Container (Light G auge) Ma nufacturi ng 332431 Metal Can Manufact uring 332439 Other Meta l Container M anufact uring 3325 Hardwa re Manufa cturing 33251 Hardwa re Manufa cturing 332510 Hardwa re Manufa cturing 3326 Spring and W ire Product Manuf acturing 33261 Spring and W ire Product Manuf acturing 332611 Spring (He avy G auge) Ma nufacturi ng 332612 Spring (Li ght Gaug e) Manufa cturing 332618 Other Fabri cated W ire Product Manuf acturing 3327 Mach ine S hop s; Tur ned P rodu ct; an d Scr ew, Nut, and Bolt M anufact uring 33271 Machine Shops 332710 Machine Shops 33272 Turned Product a nd Screw , Nut, and Bolt Manufact uring 332721 Precision T urned Product Manuf acturing 332722 Bolt, Nut, Screw, Rivet, and Washer Manufact uring 3328 Coating, Engraving, Heat Treating, and Allied Activities 33281 Coating, Engraving, Heat Treating, and Allied Activities 332811 Metal He at Trea ting 332812 Metal Coat ing, Engra ving (ex cept Jew elry a nd Silverw are), and A llied Serv ices to Ma nufacture rs 332813 Electrop lating, P lating, P olishi ng, Anodi zing, and Coloring 3329 Other Fabri cated Met al Product Manuf acturing 33291 Metal Valv e Manufa cturing 332911 Industrial Va lve Manuf acturing 332912 Fluid Power Val ve and Hos e Fitting Manufact uring 332913 Plumbing Fix ture Fitting and Trim Manufact uring 332919 Other Meta l Valve a nd Pipe Fitting Manufact uring 33299 All Other Fabricated Metal Product Manufact uring 332991 Ball and Rol ler Bear ing Manufa cturing 332992 Small A rms A mmunit ion Manufac turing 332993 Amm unition (exc ept Sma ll Arm s) Manufa cturing 332994 Small A rms Ma nufacturi ng 332995 Other Ordna nce and A ccessor ies Manuf acturing 332996 Fabricate d Pipe and Pipe Fitting Manufac turing 332997 Industrial Patt ern Manufa cturing 332998 Enamele d Iron and Meta l Sanitary Ware Manufact uring 332999 All Other Miscellaneous Fabricated Metal Product Manufa cturing 333 Machinery Manufac turing 3331 Agric ulture, Constr uction, and Mining Machinery Manufac turing 33311 Agric ultural Im plement Manufact uring 333111 Farm Ma chinery and Equipme nt Manufac turing 333112 Lawn a nd Garden Tractor and Home Lawn and Garden E quipment Ma nufacturi ng 33312 Construction Ma chinery Manufac turing 333120 Construction Ma chinery Manufac turing 33313 Mining and Oi l and Gas Field Machi nery Manufact uring 333131 Mining Machi nery a nd Equipment Manufact uring 333132 Oil and G as Field Ma chinery and Equipme nt Manufact uring 3332 Industrial Ma chinery Manufac turing 33321 Sawm ill and Woodw orking Mac hinery Manufact uring 333210 Sawm ill and Woodw orking Mac hinery Manufact uring 33322 Plastics a nd Rubber Industr y Machi nery Manufact uring 333220 Plastics a nd Rubber Industr y Machi nery Manufact uring 33329 Other Industr ial Machine ry Manuf acturing 333291 Paper Industry Machinery Manufac turing 333292 Textil e Machiner y Manuf acturing 333293 Printing Machine ry and Equi pment Manufact uring 333294 Food Product Machine ry Manuf acturing 333295 Semiconduc tor Machiner y Manuf acturing 333298 All Othe r Industrial Machinery Manufac turing 3333 Comm ercial a nd Service Industry Machinery Manufact uring 33331 Comm ercial a nd Service Industry Machinery Manufact uring 333311 Automa tic Vending Ma chine Manuf acturing 333312 Comm ercial L aundry, D rycle aning, and Pre ssing Machine Manuf acturing 333313 Offic e Machiner y Manuf acturing 333314 Optical Ins trument a nd Lens Ma nufacturi ng 333315 Photographic and Photocopying E quipment Manufact uring 333319 Other Com merci al and Serv ice Industr y Machinery Manufac turing 3334 Ventilation, He ating, A ir-Conditioning , and Comm ercial R efrige ration Equipm ent Manufa cturing 33341 Ventilation, He ating, A ir-Conditioning , andAppend ix B B-9 Select ed 2002 NA ICS Codes

Comm ercial R efrige ration Equipm ent Manufa cturing 333411 Air Purif ication Equipm ent Manufa cturing 333412 Industrial and Commercial Fan and Blower Manufact uring 333414 Heating Equipment (except Warm A ir Furnaces) Manufact uring 333415 Air-Condit ioning and W arm A ir Heating Equipment a nd Comm ercial a nd Industrial R efrige ration Equipment Ma nufacturi ng 3335 Metalwor king Mac hinery Ma nufacturi ng 33351 Metalwor king Mac hinery Ma nufacturi ng 333511 Industrial Mol d Manufac turing 333512 Machine Tool (Metal Cutting Types) Manufact uring 333513 Machine Tool (Metal Forming Types) Manufact uring 333514 Special D ie and Tool, Die Set, J ig, and Fix ture Manufact uring 333515 Cutting Tool and Machine Tool Ac cessory Manufact uring 333516 Rolling Mill Machinery and Equipme nt Manufact uring 333518 Other Meta lworking Machinery Manufac turing 3336 Engine, T urbine, and Powe r Transm ission Equipment Ma nufacturi ng 33361 Engine, T urbine, and Powe r Transm ission Equipment Ma nufacturi ng 333611 Turbine and Turbine G enerator Se t Units Manufact uring 333612 Speed Chang er, Industria l High-Spee d Drive, a nd Gear Ma nufacturi ng 333613 Mechanica l Power T ransmis sion Equipme nt Manufact uring 333618 Other Engi ne Equipme nt Manufac turing 3339 Other G eneral Purpose Machinery Manufac turing 33391 Pump and Com pressor Ma nufacturi ng 333911 Pump and Pumping Equipment Manufact uring 333912 Air and G as Compr essor Manuf acturing 333913 Measuring and Dispens ing Pump Manuf acturing 33392 Material Handling Equipm ent Manufa cturing 333921 Elevator and Moving St airway Manufac turing 333922 Convey or and Convey ing Equipme nt Manufact uring 333923 Overhea d Trave ling Crane , Hoist, and M onorail System Manufac turing 333924 Industrial Truck, Tractor, Trailer, and Stacker Machinery Manufac turing 33399 All Othe r Gener al Purpose Mac hinery Manufact uring 333991 Power-Driv en Handtool Ma nufacturi ng 333992 Welding a nd Soldering Equi pment Manufact uring 333993 Packaging Machinery Manufac turing 333994 Industrial Process Furnace and Oven Manufact uring 333995 Fluid Power Cy linder and A ctuator Manufact uring 333996 Fluid Power Pum p and Motor Manuf acturing 333997 Sca le an d Ba lan ce (e xcep t Lab ora tor y) Manufact uring 333999 All Other Miscellaneous General Purpose Machinery Manufac turing 334 Computer and Electroni c Product Manuf acturing 3341 Computer and Peripheral Equipment Manufact uring 33411 Computer and Peripheral Equipment Manufact uring 334111 Electronic Computer Manufac turing 334112 Computer Storage D evice M anufact uring 334113 Computer Term inal Manuf acturing 334119 Other Com puter Periphera l Equipment Manufact uring 3342 Comm unications Equi pment Ma nufacturi ng 33421 Telephone Apparatus Manufac turing 334210 Telephone Apparatus Manufac turing 33422 Radio and Television Broadcasting and Wireless Comm unications Equi pment Ma nufacturi ng 334220 Radio and Television Broadcasting and Wireless Comm unications Equi pment Ma nufacturi ng 33429 Other Com municati ons Equipme nt Manufact uring 334290 Other Com municati ons Equipme nt Manufact uring 3343 Audio and Video Equipment Ma nufacturi ng 33431 Audio and Video Equipment Ma nufacturi ng 334310 Audio and Video Equipment Ma nufacturi ng 3344 Semiconduc tor and Other Electronic Component Manufact uring 33441 Semiconduc tor and Other Electronic Component Manufact uring 334411 Electron T ube Manufa cturing 334412 Bare Printed Circuit Boa rd Manufac turing 334413 Semiconductor and Related Device Manufact uring 334414 Electronic Capacitor Manufac turing 334415 Electronic Resistor Manufact uring 334416 Electronic Coil, Tra nsform er, and Othe r Inductor Manufact uring 334417 Electronic Connector Ma nufacturi ng 334418 Pr int ed C irc uit Assemb ly (E lect ron ic As semb ly) Manufact uring 334419 Other Elec tronic Com ponent Manufa cturing 3345 Naviga tional, Meas uring, Elec tromedic al, and Control Instrum ents Manuf acturing 33451 Naviga tional, Meas uring, Elec tromedic al, and Control Instrum ents Manuf acturing 334510 Electrom edical and Electrothe rapeutic A pparatus Manufact uring 334511 Search, Detection, Navigation, Guidance, Aeronauti cal, and Na utical Sy stem a nd Instrume nt Manufact uring 334512 Automa tic Environm ental Control Manufac turing for Residential, Commercial, and Appliance Use 334513 Instrume nts and Rela ted Products Manuf acturingAppendix B Selected 2002 NAICS Codes B-10
for Measuring, Displaying, and Controlling Industrial Process Variables 334514 Totalizing Fluid Meter and Counting Device Manufact uring 334515 Instrume nt Manufac turing for Measuring and Testing Electric ity and E lectrica l Signals 334516 Analy tical L aboratory Instrume nt Manufac turing 334517 Irradiation Apparatus Manufac turing 334518 Watch, C lock, and Par t Manufac turing 334519 Other Measuring and Controlling Device Manufact uring 3346 Manufact uring and Re producing Mag netic and Optical Me dia 33461 Manufact uring and Re producing Mag netic and Optical Me dia 334611 Softwa re Reproduci ng 334612 Prerecorded C ompact D isc (ex cept Soft ware) , Tape, a nd Record Re producing 334613 Magnetic and Optica l Recording Media Manufact uring 335 Electric al Equipme nt, Applianc e, and Com ponent Manufact uring 3351 Electric Lighting Equipment Manufact uring 33511 Electric Lam p Bulb and Part Ma nufacturi ng 335110 Electric Lam p Bulb and Part Ma nufacturi ng 33512 Lighting Fixture Ma nufacturi ng 335121 Residentia l Electric Lighting Fixture Manufact uring 335122 Comm ercial, I ndustrial, a nd Institutional Electric Lighting Fixture Ma nufacturi ng 335129 Other Li ghting Equipm ent Manufa cturing 3352 Household A ppliance Ma nufacturi ng 33521 Small El ectrica l Applianc e Manufa cturing 335211 Electric Housewares and Household Fan Manufact uring 335212 Household Vacuum Cleaner Manufact uring 33522 Major Appli ance Manuf acturing 335221 Household Cook ing Applia nce Manuf acturing 335222 Household Refrigerator and Home Freezer Manufact uring 335224 Household La undry Equipm ent Manufa cturing 335228 Other Major Household Appliance Manufact uring 3353 Electric al Equipme nt Manufac turing 33531 Electric al Equipme nt Manufac turing 335311 Power, Distribution, and Specialty Transformer Manufact uring 335312 Motor and Ge nerator Manuf acturing 335313 Switchg ear and Sw itchboard A pparatus Manufact uring 335314 Relay and Industria l Control Manuf acturing 3359 Other Elec trical Equipm ent and Com ponent Manufact uring 33591 Battery Manufac turing 335911 Storage B attery Manufac turing 335912 Primary Battery Manufac turing 33592 Comm unication and E nergy Wire a nd Cable Manufact uring 335921 Fiber Optic Cable Manuf acturing 335929 Other Com municati on and Energy Wire Manufact uring 33593 Wiring D evice M anufact uring 335931 Current-Ca rrying Wiring D evice M anufact uring 335932 Noncurrent-Carrying Wiring Device Manufact uring 33599 All Othe r Electri cal Equipm ent and Com ponent Manufact uring 335991 Carbon and G raphite Product M anufact uring 335999 All Othe r Miscell aneous Elec trical Equipm ent and Compone nt Manufac turing 336 Transporta tion Equipme nt Manufac turing 3361 Motor Vehicle Manufact uring 33611 Automobi le and Lig ht Duty Mot or Vehicle Manufact uring 336111 Automobi le Manufa cturing 336112 Light T ruck and U tility Ve hicle Manuf acturing 33612 Heavy Duty T ruck Manuf acturing 336120 Heavy Duty T ruck Manuf acturing 3362 Motor Vehicle Body and T railer Ma nufacturi ng 33621 Motor Vehicle Body and T railer Ma nufacturi ng 336211 Motor Vehicle Body Manuf acturing 336212 Truck T railer Ma nufacturi ng 336213 Motor Home Manufac turing 336214 Trave l Traile r and Cam per Manufa cturing 3363 Motor Vehicle Parts Manuf acturing 33631 Motor Vehicle Gasoline Engine and E ngine Parts Manufact uring 336311 Carburet or, Pi ston, P iston Ri ng, and V alve Manufact uring 336312 Gasoline Engine and E ngine Parts M anufact uring 33632 Motor Vehicle Electric al and Elec tronic Equipment Ma nufacturi ng 336321 Vehicular L ighting Equipm ent Manufa cturing 336322 Other Motor Ve hicle Elec trical a nd Electronic Equipment Ma nufacturi ng 33633 Motor Vehicle Steering and Suspension Components (except Spring) Manuf acturing 336330 Motor Vehicle Steering and Suspension Components (except Spring) Manuf acturing 33634 Motor Vehicle Brake Sy stem Ma nufacturi ng 336340 Motor Vehicle Brake Sy stem Ma nufacturi ng 33635 Motor Vehicle Transm ission and Pow er Trai n Parts Manuf acturing 336350 Motor Vehicle Transm ission and Pow er Trai n Parts Manuf acturing 33636 Motor Vehicle Seating a nd Interior T rim Manufact uring 336360 Motor Vehicle Seating a nd Interior T rim Manufact uring 33637 Motor Vehicle Metal Stam ping 336370 Motor Vehicle Metal Stam ping 33639 Other Motor Ve hicle Parts Manufact uring 336391 Motor Vehicle Air-Condit ioning Manuf acturing 336399 All Othe r Motor Vehicle Parts Manuf acturingAppend ix B B-11 Select ed 2002 NA ICS Codes

3364 Aerospa ce Product and Par ts Manufa cturing 33641 Aerospa ce Product and Par ts Manufa cturing 336411 Aircra ft Manuf acturing 336412 Aircra ft Engine and Engine Par ts Manufa cturing 336413 Other A ircraf t Parts and A uxiliary Equipment Manufact uring 336414 Guided Mis sile and Spa ce Vehicle Manufact uring 336415 Guided Mis sile and Spa ce Vehicle Propulsion Unit and Propulsion U nit Parts Manuf acturing 336419 Other G uided Missile and Space Ve hicle Parts and Auxil iary E quipment Ma nufacturi ng 3365 Railroad Rol ling Stock Manufac turing 33651 Railroad Rol ling Stock Manufac turing 336510 Railroad Rol ling Stock Manufac turing 3366 Ship and Boat B uilding 33661 Ship and Boat B uilding 336611 Ship Building a nd Repairing 336612 Boat Building 3369 Other Tr ansportation E quipment Ma nufacturi ng 33699 Other Tr ansportation E quipment Ma nufacturi ng 336991 Motorcyc le, Bicy cle, and Part s Manufa cturing 336992 Military Arm ored Vehicle , Tank, a nd Tank Component Ma nufacturi ng 336999 All Othe r Transpor tation Equipm ent Manufact uring

42 Wholesale Trade

424 Merchant W holesaler s, Nondurable Goods 4244 Grocer y and Re lated Product W holesaler s 42441 Genera l Line G rocery Merchant W holesaler s 424410 Genera l Line G rocery Merchant W holesaler s 42442 Package d Frozen Food Me rchant Whol esalers 424420 Package d Frozen Food Me rchant Whol esalers 42443 Dairy Product (exc ept Dried or Canned) Merchant W holesaler s 424430 Dairy Product (exc ept Dried or Canned) Merchant W holesaler s 42444 Poultry and Poultry Product Mercha nt Wholesal ers 424440 Poultry and Poultry Product Mercha nt Wholesal ers 42445 Confecti onery Me rchant Whol esalers 424450 Confecti onery Me rchant Whol esalers 42446 Fish and Sea food Mercha nt Wholesa lers 424460 Fish and Sea food Mercha nt Wholesa lers 42447 Meat and Me at Product Merc hant Wholes alers 424470 Meat and Me at Product Merc hant Wholes alers 42448 Fresh Fruit a nd Vegetable Merchant W holesaler s 424480 Fresh Fruit a nd Vegetable Merchant W holesaler s 42449 Other G rocery and Relate d Products Merc hant Wholesal ers 424490 Other G rocery and Relate d Products Merc hant Wholesal ers 4245 Farm Product Raw Ma terial Me rchant Wholesal ers 42451 Grain a nd Field Bea n Merchant W holesaler s 424510 Grain a nd Field Bea n Merchant W holesaler s 42452 Livest ock Merc hant Wholes alers 424520 Livest ock Merc hant Wholes alers 42459 Other Farm Product Raw Material Merchant Wholesal ers 424590 Other Farm Product Raw Material Merchant Wholesal ers 4246 Chemic al and Al lied Products Me rchant Wholesal ers 42461 Plastics Materials and Basic Forms and Shapes Merchant W holesaler s 424610 Plastics Materials and Basic Forms and Shapes Merchant W holesaler s 42469 Other Chem ical and A llied Products Me rchant Wholesal ers 424690 Other Chem ical and A llied Products Me rchant Wholesal ers 4247 Petroleum a nd Petroleum Products Mercha nt Wholesal ers 42471 Petroleum Bulk Stations and Term inals 424710 Petroleum Bulk Stations and Term inals 42472 Petroleum a nd Petroleum Products Mercha nt Wholesalers (except Bulk Stations and Terminals) 424720 Petroleum a nd Petroleum Products Mercha nt Wholesalers (except Bulk Stations and Terminals) 4248 Beer, Wine, and Disti lled Alcoh olic Beverage Merchant W holesaler s 42481 Beer and A le Mercha nt Wholesa lers 424810 Beer and A le Mercha nt Wholesa lers 42482 Wine and D istilled A lcoholic Be verage Merchant Wholesal ers 424820 Wine and D istilled A lcoholic Be verage Merchant Wholesal ers 4249 Miscella neous Nondurable Goods Mer chant Wholesal ers 42491 Farm Suppli es Mercha nt Wholesa lers 424910 Farm Suppli es Mercha nt Wholesa lers 42492 Book, Periodica l, and New spaper Mer chant Wholesal ers 424920 Book, Periodica l, and New spaper Mer chant Wholesal ers 42493 Flower, Nursery Stock, and Florists' Supplies Merchant W holesaler s 424930 Flower, Nursery Stock, and Florists' Supplies Merchant W holesaler s 42494 Tobacco a nd Tobacco Product Merchant Wholesal ers 424940 Tobacco a nd Tobacco Product Merchant Wholesal ers 42495 Paint, Varnish, a nd Supplies Mer chant Wholesal ers 424950 Paint, Varnish, a nd Supplies Mer chant Wholesal ers 42499 Other Misc ellaneous N ondurable G oods Merchant W holesaler s 424990 Other Misc ellaneous N ondurable G oodsAppendix B Selected 2002 NAICS Codes B-12

Merchant W holesaler s 484230 Specialized Freight (except Used Goods) Trucking, Long-Distance 44-45 Retail Trade
4451 Grocery Stores 44511 Supermar kets and O ther Groc ery (e xcept Convenience) Stores 445110 Supermar kets and O ther Groc ery (e xcept Convenience) Stores 45291 Warehouse Clubs and Super centers 452910 Warehouse Clubs and Super centers 45299 All Other General Merchandise Stores 452990 All Other General Merchandise Stores 45431 Fuel Deal ers 454311 Heating Oil Deal ers 454312 Liquefi ed Petroleum Gas (B ottled Ga s) Deale rs 454319 Other Fuel D ealers

48-49 Transportation and Warehousing
482 Rail Tra nsportation 4821 Rail Tra nsportation 48211 Rail Tra nsportation 482111 Line-Ha ul Railroads 482112 Short Line R ailroads 483 Water T ransportati on 4831 Deep Sea, Coastal, and Great Lakes Water Transporta tion 48311 Deep Sea, Coastal, and Great Lakes Water Transporta tion 483111 Deep Sea Freight T ransportati on 483112 Deep Sea Passenge r Transpor tation 483113 Coastal a nd Great Lake s Freight Transporta tion 483114 Coastal and Great Lakes Passenger Transporta tion 4832 Inland Wat er Trans portation 48321 Inland Wat er Trans portation 483211 Inland Wat er Freig ht Transpor tation 483212 Inland Wat er Passeng er Trans portation 484 Truck T ransportati on 4841 Genera l Freight T rucking 48411 General Freight Trucking, Local 484110 General Freight Trucking, Local 48412 General Freight Trucking, Long-Distance 484121 General Freight Trucking, Long-Distance, Truckload 484122 General Freight Trucking, Long-Distance, Le ss Than Truckload 4842 Specialized Freight Trucki ng 48421 Used House hold and Off ice Goods Moving 484210 Used House hold and Off ice Goods Moving 48422 Specialized Freight (except Used Goods) Trucking, Local 484220 Specialized Freight (except Used Goods) Trucking, Local 48423 Specialized Freight (except Used Goods) Trucking, Long-Distance 486 Pipeline Tra nsportation 4861 Pipeline Tra nsportation of Crude Oil 48611 Pipeline Tra nsportation of Crude Oil 486110 Pipeline Tra nsportation of Crude Oil 4862 Pipeline Transportation of Natural Gas 48621 Pipeline Transportation of Natural Gas 486210 Pipeline Transportation of Natural Gas 4869 Other Pipeline Transport ation 48691 Pipeline Tra nsportation of Refine d Petroleum Products 486910 Pipeline Tra nsportation of Refine d Petroleum Products 48699 All Othe r Pipeline Tr ansportation 486990 All Othe r Pipeline Tr ansportation 488 Support Acti vities f or Transpor tation 4881 Support Acti vities f or Air T ransportati on 48811 Airport O perations 488119 Other A irport Opera tions 48819 Other Support A ctivitie s for A ir Trans portation 488190 Other Support A ctivitie s for A ir Trans portation 4882 Support Acti vities f or Rail T ransportati on 48821 Support Acti vities f or Rail T ransportati on 488210 Support Acti vities f or Rail T ransportati on 4883 Support Acti vities f or Water Transport ation 48831 Port and Harbor O perations 488310 Port and Harbor O perations 48832 Marine Ca rgo Handling 488320 Marine Ca rgo Handling 48833 Naviga tional Serv ices to Shippi ng 488330 Naviga tional Serv ices to Shippi ng 48839 Other Support Activities for Water Transporta tion 488390 Other Support Activities for Water Transporta tion 4884 Support Acti vities f or Road Tra nsportation 48841 Motor Vehicle Towing 488410 Motor Vehicle Towing 48849 Other Support A ctivitie s for Roa d Transport ation 488490 Other Support A ctivitie s for Roa d Transport ation 4885 Freight T ransportati on Arrang ement 48851 Freight T ransportati on Arrang ement 488510 Freight T ransportati on Arrang ement 4889 Other Support A ctivitie s for T ransportati on 48899 Other Support A ctivitie s for T ransportati on 488991 Packing a nd Crating 488999 All Othe r Support Ac tivities for Tr ansportation 493 Warehousi ng and Sto rage 4931 Warehousi ng and Sto rage 49311 General Wareho using and Storage 493110 General Wareho using and Storage 49312 Refrigerated War ehousi ng and Sto rage 493120 Refrigerated War ehousi ng and Sto rage 49313 Farm Prod uct Wareho using and Storage 493130 Farm Prod uct Wareho using and Storage 49319 Other Wareho using and StorageAppend ix B B-13 Select ed 2002 NA ICS Codes

493190 Other Wareho using and Storage 561710 Exterminating and Pest Control Services 56172 Janitorial Services 56 Adm inistra tive an d Supp ort an d Was te 561720 Janitorial Services Management a nd Rem ediation Services 56173 Landscaping Services 561730 Landscaping Services 561 Administrative and Support Services 56174 Carpet and Upholstery Cleaning Services 5611 Office Adm inistrative Services 561740 Carpet and Upholstery Cleaning Services 56111 Office Adm inistrative Services 56179 Other Servi ces to Buil dings and Dwellings 561110 Office Adm inistrative Services 561790 Other Servi ces to Buil dings and Dwellings 5612 Facilities Support Services 5619 Other Support Services 56121 Facilities Support Services 56191 Packaging and Labeling Services 561210 Facilities Support Services 561910 Packaging and Labeling Services 5613 Employment Services 56192 Convention and Trade Show Organiz ers 56131 Employment Placement A gencies 561920 Convention and Trade Show Organiz ers 561310 Employment Placement A gencies 56199 All Other Support Services 56132 Temporary Help Service s 561990 All Other Support Services 561320 Temporary Help Service s 562 Waste Management and Rem ediation Services 56133 Professiona l Employ er Orga nizations 5621 Waste Collection 561330 Professiona l Employ er Orga nizations 56211 Waste Collection 5614 Business Support Services 562111 Solid Wast e Collect ion 56141 Document Preparation Services 562112 Hazardous Waste Collection 561410 Document Preparation Services 562119 Other Wa ste Collec tion 56142 Telephone Call Cente rs 5622 Waste Treatm ent and Disposal 561421 Telephone Answering Services 56221 Waste Treatm ent and Disposal 561422 Telem arketing Bureaus 562211 Hazardous Waste Treatm ent and Disposal 56143 Business Se rvice C enters 562212 Solid Wast e Landf ill 561431 Private Ma il Centers 562213 Solid Wast e Combust ors and Incine rators 561439 Other Busine ss Servi ce Cente rs (including Copy 562219 Other Nonhaz ardous Waste Tre atment and Shops) Disposal 56144 Collection Agencies 5629 Remedi ation and Othe r Waste Managem ent 561440 Collection Agencies Services 56145 Credit Bure aus 56291 Remediation Services 561450 Credit Bure aus 562910 Remediation Services 56149 Other Business Support Services 56292 Materials Recovery Facilities 561491 Repossession Services 562920 Materials Recovery Facilities 561492 Court Reporting and Stenotype Services 56299 All Other Waste Managem ent Services 561499 All Other Business Support Services 562991 Septic Tank and Related Services 5615 Travel Arrangem ent and Reservation Services 562998 All Othe r Miscell aneous Wa ste Manag ement 56151 Travel Agencies Services 561510 Travel Agencies 56152 Tour Opera tors 92 Public Administration 561520 Tour Opera tors 56159 Other Tr avel A rrangem ent and Res ervation 927 Space Researc h and Techn ology Services 9271 Space Researc h and Techn ology 561591 Convention and Visitors Bure aus 92711 Space Researc h and Techn ology 561599 All Othe r Trav el Arra ngeme nt and Rese rvation 927110 Space Researc h and Techn ology Services 928 National Se curity and Internat ional Af fairs 5616 Investigation and Security Services 9281 National Se curity and Internat ional Af fairs 56161 Investigation, Guard, and Armored Car Services 92811 National Se curity 561611 Investigation Services 928110 National Se curity 561612 Security Guards and Patrol Services 561613 Armored Car Services 56162 Security Systems Services 561621 Security Systems Services (except Locksm iths) 561622 Locksm iths 5617 Services to Buildi ngs and Dwell ings 56171 Exterminating and Pest Control Services

## A PPENDIX C: TECHN ICA L A SSIST A NCE

## A PPENDIX C: TECHN ICA L A SSIST A NCE

WHERE CA N I GET HEL P?
This appendix provides points of contact for the res ources that are available to facilities in complyin g with 40 CF R part 68 from EPA, OSHA , and several oth er entities involve d in process safety and risk mana gement issue s.


### U.S. Environmental Protection Agency
� Office of Emergency Prevention, Preparedness, an d Response 1200 Pennsylvania Ave., NW (Mail code 5104A) Washington, DC 20460 (202) 564-86 00 www.epa.g ov/swercepp OEPPR (form erly CEPPO) administers the RMP program at the national level. The OEPPR hom epage on the I nternet provides access to downloadable v ersions of numerous risk managem ent program documents, m any of which a re also available upon reque st from the Nation al Service Center fo r Environm ental Publications

S see below.


### � EPCRA/Superfund/RCR A/CAA Call C enter Toll-Free: (800) 42 4-9346 Local: (703) 412- 9810 TDD: (800) 553- 7672 TDD Local: (703) 412 -3323 Monday - Friday, 9:00 a m - 5:00 pm EST
www.e pa.go v/epa oswer/h otline/i ndex.h tm Questions or com ments: epacallcenter@ bah.com

EPA’s RCRA, Superf und, an d EPCR A Call Center is a pub licly a ccessib le service that prov ides up-to- date information on EPA program s. The Call Center responds to factual questions on a variety of federal EPA reg ulations, including those developed u nder Clean Air Act s ection 112(r). The Call C enter also responds to requests for in dividual copies of d ocuments. 

### � National Service Cen ter for Environmental Publications P.O. Box 424 19 Cincinnati, OH 452 42 Phone: (800) 490- 9198 Fax: (513) 489- 8695
www.e pa.go v/nc epi hom/
Order size m ay be restricted due to limited supply . As supplies are dep leted you will be referred to the N ational Envir onme ntal Pu blicatio ns I nternet Site (NEPIS) N ational Technical Inform ation Service (NTI S), the Govern mentAppendix C Technical Assistance C-2 Printing Office ( GPO), or the Educatio nal Resource Information Cent er (ERIC) to obtain your do cuments at cost.


### � National Technical In formation Service Technology Ad ministration U.S. Departm ent of Comm erce 5285 Port Royal Road Springfield, VA 221 61 Phone: (800) 553- 6847 (toll-free) Phone: (703) 605- 6000 (l ocal) Monday - Friday, 8:00 a m - 6:00 pm EST Fax: (703) 605- 6900 www.nti s.gov/ E-Mail: orders@ ntis.gov
The National Technical I nformation Serv ice is the official resource for government -sponsor ed U.S. an d world wide sc ienti fic, t echni cal, en gineer ing, and business-rela ted information. Documents not available through the EPA Hotline are often av ailable from NTI S. You can plac e your order by telephone, mail, fax, or e-mail. NTIS also offers onli ne ordering using NTIS OrderNow.


### � EPA Small Business Assistance Program www.epa.g ov/ttn/sbap/
The Clean Air Act Am endments of 19 90 requires that all States d evelop a program to assist small businesses in meeting the requirements of the Act. EPA has established its own S mall Business A ssistance Program (SBAP) to prov ide technical assistance to these S tate small business p rograms. This s ite has been devel oped to allow S tate and EPA p rogram s to sha re infor matio n about their small business assistan ce materials and ac tivities.


### � EPA Small Business Hotline Small Business Ombudsm an Office (800) 368-58 88


### � Office of Air Quality Planning and Standard s www.epa.g ov/oar/oaqps/ The Office of Air Quality Planning and S tandards administers E PA’s operating permit program

. Permits incorporate terms and conditions to assure that the
source comp lies wit h all ap plicable require ments

. The R MP reg ulation s are considered to be applicable requirements.Appendix C C-3 Technical Assistance 

### Occupational Safety and Health Administration (OSHA)

OSHA adm inisters the Process Safety Management Standard (29 CFR 1910.119), which mandates actions sim ilar to that of EPA’s pre vention progra m. I n about half of the states (see Appendix D), OSHA progra ms are run by state agencies.


### � Occupational Safety and Health Administration U.S. Departm ent of Labor 200 Constituti on Avenue, NW Washington, DC 20210 (800) 321-OSHA www.osha.g ov 

### � OSHA Process Safety Management Homepage
www.o sha. gov/S LTC/ proc ess saf etyma nage ment/ inde x.ht ml The PSM homepag e on the In ternet provides access to downloadable v ersions of numerous process safety manag ement docum ents.


### � OSHA Consultation Serv ices htt p:/ /www .osh a.gov /dc sp/ small busi ness /co nsul t.ht ml Using a free cons ultation service larg ely funded by OSHA, em ployers can find out abo ut poten tial haz ards at their wo rk site s, im prove their o ccupati onal saf ety and health mana gement sy stems, and ev en qualify for a on e-year ex emption from routine OSHA inspect ions. P rimar ily tar geted for sm aller bu sinesse s, this safety and health consul tation program is completel y separate from the OSHA inspect ion effort.


### � OSHA Office of Training & Education OSHA Training Ins titute 2020 South Arling ton Heights Roa d Arlington Heig hts, Illinois 60 005-4102 (847) 297-49 13
www.o sha. gov/f so/ ote /tr ain ing/ tra ini ng_r esou rce s.ht ml
The OSH A Offic e of Tr ainin g and Educ ation offer s short -term trai ning thr ough the OSHA Training Institute. The O ffice also administers the OSHA Training Inst itute Ed ucation Center s prog ram, in whic h desig nated n onprofi t organizations in each federal region o ffer the most frequen tly requested courses for the privat e sector and oth er Fede ral ag ency s taff.


### � OSHA Volu ntar y Pro tect ion P rogr am (V PP) Office of Partnerships and Recognition (202) 693-22 13
www.o sha. gov/d csp/ vpp/ inde x.ht mlAppendix C Technical Assistance C-4
OSHA Voluntar y Pro tection Progr ams a re desig ned to r ecogn ize and prom ote effective safety an d health manag ement. I n the VPP, ma nagement, labor, and OSHA establish a c ooperative relationship at a workplace that h as implemented a strong prog ram. 

### � OSHA Publications

U.S. Department of Labor/OSHA OSHA Publications P.O. Box 375 35, Washington, D.C. 20013- 7535 Telephone: (202) 693- 1888 or by Fax: (202 ) 693-2498 Or download on line at: www.osha.gov/pls/publications/pubinde x.list The Publications Office prov ides copies of variou s OSHA docum ents.



### Other Or ganizatio ns � American Institute of Chemical E ngineers 3 Park Av enue New York, NY 10016- 5991 (212) 591-73 38 www.aic he.org/ AIChE p rovides educational an d training prog rams and an an nual Publications Catalog from which docum ents can be purchased.

Center for Chem ical Proc ess Safet y Park Av enue New York, NY 10016- 5991 (212) 591-73 19 www.aiche.org /ccps


### � Small Busine ss Administrat ion (SBA) 409 Third Street, SW Washington, DC 20416 (800) 827-57 22 www.sba .gov/

SBA w as creat ed to he lp Am erica' s entrepreneurs form succes sful sm all enterprises. SBA' s program offices in every state offer financing, train ing and advocac y for small firms. In add ition , the SBA wo rks with thousa nds of l endin g, educational, and training institutions nationwide.Appendix C C-5 Technical Assistance 

### � U.S. Government Printing Office 732 N. Capitol Stree t, NW Mail Stop: SDE Washington, DC 20401 (888) 293-64 98 www.g poac cess .gov/ inde x.ht ml

## APPENDIX D OSH A GUIDANCE ON PSM

## APPENDIX D OSH A GUIDANCE ON PSM

The following text is taken directly from OSHA’s non-mandatory appendix C to the PSM standard (29 CFR 1910.119). The only change has been to rearrange the sections to track the order of part 68.

P ROCESS S AFETY I NFORMATION Complete and accurate written information concerning process chemicals, process technology, and process equipment is essential to an effective process safety management program and to a process hazards analysis. The compiled information will be a necessary resource to a variety of users including the team that will perform the process hazards analysis; those developing the training programs and the operating procedures; contractors whose employees will be working with the process; those conducting the pre-startup reviews; local emergency preparedness planners; and insurance and enforcement officials. The information to be compiled about the chemicals, including process intermediates, needs to be comprehensive enough for an accurate assessment of the fire and explosion characteristics, reactivity hazards, the safety and health hazards to workers, and the corrosion and erosion effects on the process equipment and monitoring tools. Current material safety data sheet (MSDS) information can be used to help meet this requirement, which must be supplemented with process chemistry information including runaway reaction and over pressure hazards if applicable. Process technology information will be a part of the process safety information package and it is expected that it will include diagrams as well as employer established criteria for maximum inventory levels for process chemicals; limits beyond which would be considered upset conditions; and a qualitative estimate of the consequences or results of deviation that could occur if operating beyond the established process limits. Employers are encouraged to use diagrams which will help users understand the process. A block flow diagram is used to show the major process equipment and interconnecting process flow lines and show flow rates, stream composition, temperatures, and pressures when necessary for clarity. The block flow diagram is a simplified diagram. Process flow diagrams are more complex and will show all main flow streams including valves to enhance the understanding of the process, as well as pressures and temperatures on all feed and product lines within all major vessels, in and out of headers and heat exchangers, and points of pressure and temperature control. Also, materials of construction information, pump capacities and pressure heads, compressor horsepower and vessel design pressures and temperatures are shown when necessary for clarity. In addition, major components of control loops are usually shown along with key utilities on process flow diagrams. Piping and instrument diagrams (P&IDS) may be the more appropriate type of diagrams to show some of the above details and to display the information for the piping designer and engineering staff. The P&IDS are to be used to describe the relationships between equipment and instrumentation as well as other relevant information that will enhance clarity. Computer software programs which do P&IDS or other diagrams useful to the information package, may be used to help meet this requirement.Appendix D OSHA Guidance on PSM D-2 The information pertaining to process equipment design must be documented. In other words, what were the codes and standards relied on to establish good engineering practice. These codes and standards are published by such organizations as the American Society of Mechanical Engineers, American Petroleum Institute, American National Standards Institute, National Fire Protection Association, American Society for Testing and Materials, National Board of Boiler and Pressure Vessel Inspectors, National Association of Corrosion Engineers, American Society of Exchange Manufacturers Association, and model building code groups. In addition, various engineering societies issue technical reports which impact process design. For example, the American Institute of Chemical Engineers has published technical reports on topics such as two phase flow for venting devices. This type of technically recognized report would constitute good engineering practice. For existing equipment designed and constructed many years ago in accordance with the codes and standards available at that time and no longer in general use today, the employer must document which codes and standards were used and that the design and construction along with the testing, inspection and operation are still suitable for the intended use. Where the process technology requires a design which departs from the applicable codes and standards, the employer must document that the design and construction is suitable for the intended purpose.

P ROCESS H AZARD A NALYSIS A process hazard analysis (PHA), sometimes called a process hazard evaluation, is one of the most important elements of the process safety management program. A PHA is an organized and systematic effort to identify and analyze the significance of potential hazards associated with the processing or handling of highly hazardous chemicals. A PHA provides information which will assist employers and employees in making decisions for improving safety and reducing the consequences of unwanted or unplanned releases of hazardous chemicals. A PHA is directed toward analyzing potential causes and consequences of fires, explosions, releases of toxic or flammable chemicals and major spills of hazardous chemicals. The PHA focuses on equipment, instrumentation, utilities, human actions (routine and non-routine), and external factors that might impact the process. These considerations assist in determining the hazards and potential failure points or failure modes in a process. The selection of a PHA methodology or technique will be influenced by many factors including the amount of existing knowledge about the process. Is it a process that has been operated for a long period of time with little or no innovation and extensive experience has been generated with its use? Or, is it a new process or one which has been changed frequently by the inclusion of innovative features? Also, the size and complexity of the process will influence the decision as to 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.Appendix D D-3 OSHA Guidance on PSM The team conducting the PHA need to understand the methodology 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 members 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 methodology 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 non-routine 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 the 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 operations of varying sizes, complexities, and ages may use different methodologies and team members 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 process hazard analysis criteria in the standard. These process hazard analyses can be done in less time and with a few people being involved. A less complex process generally means that less data, P&IDS, and process information is needed to perform a process hazard analysis. Many small businesses have processes that are not unique, such as cold storage lockers or water treatment facilities. Where employer associations have a number of members with such facilities, a generic PHA, evolved from a checklist or what-if questions, could be developed and used by each employer effectively to reflect his/her particular process; this would simplify compliance for them.Appendix D OSHA Guidance on PSM D-4 When the employer has a number of processes which require a PHA, the employer must set up a priority system of which PHAs to conduct first. A preliminary or gross hazard analysis may be useful in prioritizing the processes that the employer has determined are subject to coverage by the process safety management standard. Consideration should first be given to those processes with the potential of adversely affecting the largest number of employees. This prioritizing should consider the potential severity of a chemical release, the number of potentially affected employees, the operating history of the process such as the frequency of chemical releases, the age of the process and any other relevant factors. These factors would suggest a ranking order and would suggest either using a weighing factor system or a systematic ranking method. The use of a preliminary hazard analysis would assist an employer in determining which process should be of the highest priority and thereby the employer would obtain the greatest improvement in safety at the facility.

O PERATING P ROCEDURES Operating procedures describe tasks to be performed, data to be recorded, operating conditions to be maintained, samples to be collected, and safety and health precautions to be taken. The procedures need to be technically accurate, understandable to employees, and revised periodically to ensure that they reflect current operations. The process safety information package is to be used as a resource to better assure that the operating procedures and practices are consistent with the known hazards of the chemicals in the process and that the operating parameters are accurate. Operating procedures should be reviewed by engineering staff and operating personnel to ensure that they are accurate and provide practical instructions on how to actually carry out job duties safely. Operating procedures will include specific instructions or details on what steps are to be taken or followed in carrying out the stated procedures. These operating instructions for each procedure should include the applicable safety precautions and should contain appropriate information on safety implications. For example, the operating procedures addressing operating parameters will contain operating instructions about pressure limits, temperature ranges, flow rates, what to do when an upset condition occurs, what alarms and instruments are pertinent if an upset condition occurs, and other subjects. Another example of using operating instructions to properly implement operating procedures is in starting up or shutting down the process. In these cases, different parameters will be required from those of normal operation. These operating instructions need to clearly indicate the distinctions between startup and normal operations such as the appropriate allowances for heating up a unit to reach the normal operating parameters. Also the operating instructions need to describe the proper method for increasing the temperature of the unit until the normal operating temperature parameters are achieved. Computerized process control systems add complexity to operating instructions. These operating instructions need to describe the logic of the software as well as the relationship between the equipment and the control system; otherwise, it may not be apparent to the operator. Operating procedures and instructions are important for training operating personnel. The operating procedures are often viewed as the standard operating practices (SOPs) for operations. Control room personnel and operating staff, in general, need to have a full understanding of operating procedures. If workers are not fluent in English then procedures and instructions need to be prepared in a second language understood by the workers. In addition, operating procedures need to be changed when there is a change in the process as a result of the management of change procedures. The consequences of operating procedure changes need to be fully evaluated and the information conveyed to the personnel.Appendix D D-5 OSHA Guidance on PSM For example, mechanical changes to the process made by the maintenance department (like changing a valve from steel to brass or other subtle changes) need to be evaluated to determine if operating procedures and practices also need to be changed. All management of change actions must be coordinated and integrated with current operating procedures and operating personnel must be oriented to the changes in procedures before the change is made. When the process is shutdown to make a change, then the operating procedures must be updated before startup of the process. Training in how to handle upset conditions must be accomplished as well as what operating personnel are to do in emergencies such as when a pump seal fails or a pipeline ruptures. Communication between operating personnel and workers performing work within the process area, such as non-routine tasks, also must be maintained. The hazards of the tasks are to be conveyed to operating personnel in accordance with established procedures and to those performing the actual tasks. When the work is completed, operating personnel should be informed to provide closure on the job.

T RAINING All employees, including maintenance and contractor employees, involved with highly hazardous chemicals need to fully understand the safety and health hazards of the chemicals and processes they work with for the protection of themselves, their fellow employees and the citizens of nearby communities. Training conducted in compliance with 1910.1200, the Hazard Communication standard, will help employees to be more knowledgeable about the chemicals they work with as well as familiarize them with reading and understanding MSDS. However, additional training in subjects such as operating procedures and safety work practices, emergency evacuation and response, safety procedures, routine and non-routine work authorization activities, and other areas pertinent to process safety and health will need to be covered by an employer's training program. In establishing their training programs, employers must clearly define the employees to be trained and what subjects are to be covered in their training. Employers in setting up their training program will need to clearly establish the goals and objectives they wish to achieve with the training that they provide to their employees. The learning goals or objectives should be written in clear measurable terms before the training begins. These goals and objectives need to be tailored to each of the specific training modules or segments. Employers should describe the important actions and conditions under which the employee will demonstrate competence or knowledge as well as what is acceptable performance. Hands-on-training where employees are able to use their senses beyond listening, will enhance learning. For example, operating personnel, who will work in a control room or at control panels, would benefit by being trained at a simulated control panel or panels. Upset conditions of various types could be displayed on the simulator, and then the employee could go through the proper operating procedures to bring the simulator panel back to the normal operating parameters. A training environment could be created to help the trainee feel the full reality of the situation but, of course, under controlled conditions. This realistic type of training can be very effective in teaching employees correct procedures while allowing them to also see the consequences of what might happens if they do not follow established operating procedures. Other training techniques using videos or on-the-job training can also be very effective for teaching other job tasks, duties, or other important information. An effective training program will allow the employee to fully participate in the training process and to practice their skill or knowledge.Appendix D OSHA Guidance on PSM D-6 Employers need to periodically evaluate their training programs to see if the necessary skills, knowledge, and routines are being properly understood and implemented by their trained employees. The means or methods for evaluating the training should be developed along with the training program goals and objectives. Training program evaluation will help employers to determine the amount of training their employees understood, and whether the desired results were obtained. If, after the evaluation, it appears that the trained employees are not at the level of knowledge and skill that was expected, the employer will need to revise the training program, provide retraining, or provide more frequent refresher training sessions until the deficiency is resolved. Those who conducted the training and those who received the training should also be consulted as to how best to improve the training process. If there is a language barrier, the language known to the trainees should be used to reinforce the training messages and information. Careful consideration must be given to assure that employees including maintenance and contract employees receive current and updated training. For example, if changes are made to a process, impacted employees must be trained in the changes and understand the effects of the changes on their job tasks (e.g., any new operating procedures pertinent to their tasks). Additionally, as already discussed the evaluation of the employee's absorption of training will certainly influence the need for training.

M ECHANICAL I NTEGRITY Employers will need to review their maintenance programs and schedules to see if there are areas where "breakdown" maintenance is used rather than an on-going mechanical integrity program. Equipment used to process, store, or handle highly hazardous chemicals needs to be designed, constructed, installed and maintained to minimize the risk of releases of such chemicals. This requires that a mechanical integrity program be in place to assure the continued integrity of process equipment. Elements of a mechanical integrity program include the identification and categorization of equipment and instrumentation, inspections and tests, testing and inspection frequencies, development of maintenance procedures, training of maintenance personnel, the establishment of criteria for acceptable test results, documentation of test and inspection results, 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 andAppendix D D-7 OSHA Guidance on PSM 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, American 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 maximum 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 or 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 and 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. A quality assurance system is needed to help ensure that the proper materials of construction 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 a release. "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. If the quality of parts is a problem, it may be appropriate to conduct audits of the equipment supplier's facilities to better assure proper 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.Appendix D OSHA Guidance on PSM D-8

M ANAGEMENT OF C HANGE To properly manage changes to process chemicals, technology, equipment and facilities, one must define what is meant by change. In this process safety management standard, change includes all modifications to equipment, procedures, raw materials and processing conditions other than "replacement in kind." These changes need to be properly managed by identifying and reviewing them prior to implementation of the change. For example, the operating procedures contain the operating parameters (pressure limits, temperature ranges, flow rates, etc.) and the importance of operating within these limits. While the operator must have the flexibility to maintain safe operation within the established parameters, any operation outside of these parameters requires review and approval by a written management of change procedure. Management of change covers changes in process technology and changes to equipment and instrumentation. Changes in process technology can result from changes in production rates, raw materials, experimentation, equipment unavailability, new equipment, new product development, change in catalyst and changes in operating conditions to improve yield or quality. 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 methods 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. It is 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.

P RE -S TARTUP R EVIEW For new processes, the employer will find a PHA helpful in improving the design and construction of the process from a reliability and quality point of view. The safe operation of the new process will be enhanced by making use of the PHA recommendations before final installations are completed. P&IDsAppendix D D-9 OSHA Guidance on PSM are to be completed along with having the operating procedures in place and the operating staff trained to run the process before startup. The initial startup procedures and normal operating procedures need to be fully evaluated as part of the pre-startup review to assure a safe transfer into the normal operating mode for meeting the process parameters. For existing processes that have been shutdown for turnaround, or modification, etc., the employer must assure that any changes other than "replacement in kind" made to the process during shutdown go through the management of change procedures. P&IDS will need to be updated as necessary, as well as operating procedures and instructions. If the changes made to the process during shutdown are significant and impact the training program, then operating personnel as well as employees engaged in routine and non-routine work in the process area may need some refresher or additional training in light of the changes. Any incident investigation recommendations, compliance audits or PHA recommendations need to be reviewed as well to see what impacts they may have on the process before beginning the startup.

C OMPLIANCE A UDITS 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. The audit should be conducted or led 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, conducting 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 information 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. Team 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, emergency 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, compared 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. Using the auditAppendix D OSHA Guidance on PSM D-10 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 compliance 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 system 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. Corrective action is one of the most important parts of the audit. It includes not only addressing the identified deficiencies, but also planning, follow up, 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 in-depth 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 management. 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.

I NCIDENT I NVESTIGATION 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 toAppendix D D-11 OSHA Guidance on PSM learn from past experiences and thus avoid repeating past mistakes. 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 members should be selected on the basis of their training, knowledge and ability to contribute to a team effort to fully investigate the incident. Employees in the process area where the incident occurred should be consulted, interviewed or made a member of the team. Their knowledge of the events form a significant set of facts about the incident which occurred. The report, its findings and recommendations are to be shared with those who can benefit from the information. The cooperation of employees is essential to an effective incident investigation. The focus of the investigation should be to obtain facts, and not to place blame. The team and the investigation process should clearly deal with all involved individuals in a fair, open and consistent manner.

E MPLOYEE P ARTICIPATION Section 304 of the Clean Air Act Amendments states that employers are to consult with their employees and their representatives regarding the employers efforts in the development and implementation of the process safety management program elements and hazard assessments. Section 304 also requires employers to train and educate their employees and to inform affected employees of the findings from incident investigations required by the process safety management program. Many employers, under their safety and health programs, have already established means and methods to keep employees and their representatives informed about relevant safety and health issues and employers may be able to adapt these practices and procedures to meet their obligations under this standard. Employers who have not implemented an occupational safety and health program may wish to form a safety and health committee of employees and management representatives to help the employer meet the obligations specified by this standard. These committees can become a significant ally in helping the employer to implement and maintain an effective process safety management program for all employees.

H OT W ORK P ERMIT Non-routine work which is conducted in process areas needs to be controlled by the employer in a consistent manner. The hazards identified involving the work that is to be accomplished must be communicated to those doing the work, but also to those operating personnel whose work could affect the safety of the process. A work authorization notice or permit must have a procedure that describes the steps the maintenance supervisor, contractor representative or other person needs to follow to obtain the necessary clearance to get the job started. The work authorization procedures need to reference and coordinate, as applicable, lockout/tagout procedures, line breaking procedures, confined space entry procedures and hot work authorizations. This procedure also needs to provide clear steps to follow once the job is completed to provide closure for those that need to know the job is now completed and equipment can be returned to normal.Appendix D OSHA Guidance on PSM D-12

C ONTRACTORS Employers who use contractors to perform work in and around processes that involve highly hazardous chemicals, will need to establish a screening process so that they hire and use contractors who accomplish the desired job tasks without compromising the safety and health of employees at a facility. For contractors, whose safety performance on the job is not known to the hiring employer, the employer will need to obtain information on injury and illness rates and experience and should obtain contractor references. Additionally, the employer must assure that the contractor has the appropriate job skills, knowledge and certifications (such as for pressure vessel welders). Contractor work methods and experiences should be evaluated. For example, does the contractor conducting demolition work swing loads over operating processes or does the contractor avoid such hazards? Contract employees must perform their work safely. Considering that contractors often perform very specialized and potentially hazardous tasks such as confined space entry activities and non-routine repair activities it is quite important that their activities be controlled while they are working on or near a covered process. A permit system or work authorization system for these activities would also be helpful to all affected employers. The use of a work authorization system keeps an employer informed of contract employee activities, and as a benefit the employer will have better coordination and more management control over the work being performed in the process area. A well run and well maintained process where employee safety is fully recognized will benefit all of those who work in the facility whether they be contract employees or employees of the owner.

## APPENDIX E: Supplemental Risk Management Program Guidance for Ammonia Refrigeration FacilitiesAppendix E

- 2- NH3


## Appendix E: Supplemental Risk Management Program Guidance for Ammonia Refrigeration Facilities

This appendix supplem ents the m a in body of the General Guidance to provide additional inform ation for food processors , food distributors, and refrigerated warehouses who use am m onia as a refrigerant, as well as any other facility that has
an am m onia refrigeration sy stem

. If y ou have other processes that use regulated substances other than am m onia, refer to the m a in body of the General Guidance (and any other applicable industry

- specific a ppendix) for inform ation on com p liance with the rule for those processes. The appendix covers Risk Managem e nt Program elem ents in the sam e general order as t hose elem ents are addressed in the m a in docum ent. However, note that the appendix does not address som e generic RMP elem ents (e.g., Managem e nt Sy stem ). Fo r elem ents not addressed in this appendix, sim p ly refer to the applicable guidance in the m a in docum ent.


### E.1 G eneral Applicability

E XEM PTIO N FO R F AR M S
The rule exem pts am m onia when held by a farm er for use as an agricultural nutrient on a farm

. This exem ption does not apply to agricultural suppliers, fertilizer
m a nufacturers, or the use of am m onia as a refrigerant. It does not apply to farm cooperatives or to groups of farm er s who buy , use, and sell am m onia.
T HRESHO L D Q U A N TI TY The threshold quantity for a nhy drous am m onia is 10,000 pounds.
C O -L OC A T ION OF P RO CESS V ESSELS

For am m onia, a release from a single vessel will not norm a lly lead to a release from others unless the vessel fails catastrophically and explodes, sending m e tal fragm ents into other vessels. Co-located vessels containing am m onia, however, m a y well be involved in a release caused by a fire or explosion that occurs from another source.


### E.2 A pplicability of Program Levels
Q UI CK R ULES FO R D ETERM I NING P R OGR A M 1 E LIGIBILITY If y ou have a process containing m o re than a threshold quantity of am m onia that is not liquefied by refrigeration alone (i.e ., y ou hold it as a gas or liquefied under pressure), the distance to the endpoint estim ated for a worst-case release m a y be several m iles. As a result, the distance to endpoint is unlikely to be less than the distance to public receptors, unless the pr ocess is very rem o te. In som e cases,NH3 -3- A ppendix E however, am m onia in processes contained in enclosed areas m a y be eligible for Program 1. If y ou have a process containing anhy drous am m onia liquefied by refrigeration alone, and y our worst-case release would take place into a diked area, the chances are good that the process m a y be eligible for Progr am 1, unless there are public receptors very close to the process. Even if y ou have m a ny tim es the threshold quantity of
am m onia, the process m a y still be eligible for Program 1.
P R OGR A M 3

Most am m onia refrigeration processes that are not eligible for Program 1 will be subject to Program 3 requirem e nts because they are subject to the OSHA PSM Standard.
P R OGR A M 2

Am m onia refrigeration processes will usually not be eligible for this program level because they are covered by OSHA PSM. If y our am m onia process is not eligible for Program 1, it will generally be subject to Program 3. If y our am m onia refrigeration process is subject to Program 2 require m e nts, this appendix does not contain additional inform ation on prevention program elem ents; consult chapter 6 in the m a in docum ent. 

### E.3 O ffsite Consequence Analy s is
This section gives sim p le guidance on how to perform the hazard assessm ent for anhy drous am m onia in am m onia refrige ration facilities. Additional technical inform ation is provided in a separate docum ent entitled “Technical Background Docum e nt for Offsite Consequence Anal y s is for Anhy drous Am m onia, Aqueous Am m onia, Chlorine and Sulfur Dioxide,” henceforth known as the “Technical Background Docum e nt”. This docum ent is available from EPA’s website at www.epa.gov/em ergencies.


### E.3.1 W orst-Case Release Scenario Analy s is

M A NDA TO RY I NPUTS The following inputs are required by the Risk Managem e nt Program rule: Release Quantity : The worst-case release quantity (lb) shall be the greater of the following:



### — For substances in a vessel, the greatest am ount held in a vessel, taking into account adm i nistrative controls that lim it the m a xim u m quantity ; orAppendix E

- 4- NH3



### — For substances in pipes, the greatest am ount in a pipe, taking into account adm i nistrative controls that lim it the m a xim u m quantity

. Section E.3.3 shows that, for am m onia refrigeration sy stem s, a storage vessel or receiver is the place where the worst-case re lease quantity is expected to reside. Per §68.25(c)(1), because am m onia is a vapor at ambient tem p erature and is handled as a liquid under pressure in m o st parts of a refrigeration sy stem , the release quantity is assum e d to be com p letely released from the vessel over a period of 10 m i nutes. This applies whether the release takes place outside or in a building. Wind speed/atmospheric stability class : The owner or operator shall use a wind speed of 1.5 m e ters per second and F stability class. If the owner or operator can dem onstrate that local m e teorological data show a higher m i nim u m wind speed or a less stable atm o sphere at all tim es during the previous three y ears, these site-specific conditions m a y be used. For sim p licity ’ s sake, the guidance presented below is restricted to a wind speed of 1.5 m e ters per second and F stability class. Toxic Endpoint : The toxic endpoint for am m onia is 200 ppm (0.14 m g /L). This airborne concentration has been publishe d by the Am erican Industrial Hy giene Association (AIHA) and is the m a xim u m airborne concentration below which it is believed that nearly all individuals can be exposed for up to one hour without experiencing or developing irre versible or other serious health effects or sy m p tom s which could im pair an individual' s ability to take protective action. The rule requires y ou to assum e that the toxic endpoint is constant, even though the duration of release is only 10 m i nutes.
Q UA NTI T Y R ELEA SED A ND R ELEA SE R A T E IN THE W OR S T -C A SE R ELEA SE S CENA RI O Quantity Released : Take the largest quantity (lb) of am m onia that is liquefied under pressure in any vessel in the am m onia refri geration sy stem

. For m a ny sy stem s, this vessel will be the high pressure receiver with ty pical pressures in the range 100 to 200 psig. Other candidate vessels include: a) an outside vessel in which am m onia is stored as a liquid at ambient tem p erature (som e, but not all, facilities have such a vessel); b) an interm ediate receiver with ty pical pressures in the range 20 to 60 psig (ty p ical of two-stage am m onia refrigeration sy stem s); or c) a low-pressure receiver with pressures in the range 10-60 psig (ty p ical of single-stage refrigeration sy stem s). In the case of a vessel, the quantity does not include any liquid am m onia in pipework connected to the vessel and in any other vessel that can discharge directly into pipework connected to the vessel. In addition, the m a xim u m am ount of am m onia that could be in the vessel at any one tim e, not just during norm a l operation, should be considered. For exam ple, if the vessel is used to store som e or all of the am m onia while the rest of the sy stem is being serviced, then the quantity released should include the additional quantity of am m onia that is in the vessel at such a tim e. However, if there are adm i nistrative controls that lim it the am ount of am m onia that is allowed in the vessel at any one tim e, this lim it can also be taken into account whenNH3 -5- A ppendix E
estim ating the quantity released. Sim ilarly , if the largest quantity resides in a pipeline, y ou do not need to consider th e quantity of am m onia in connected vessels. Release Rate - Unmitigated Releases : For the worst-case scenario for a substance that is a gas under ambient conditions, th e largest vessel is assum e d to fail in a catastrophic m a nner, and the release occurs over a period of 10 m i nutes. The worstcase release rate is: QR = Q /10 (1)
where: QR = Release rate (lbs/m in) Q = Quantity released (lbs) The rapid release of am m onia initially liquefied under pressure leads to an airborne
m i xture of vapor and droplets. If the vessel is outdoors, all of the vapor and droplets
rem a in airborne, and the release rate (QR) is the total inventory uniform ly distributed over 10 m i nutes, as required by the rule. Release Rate - Mitigated Releases: The rule allows y ou to consider passive
m itigation in estim ating the worst-case release rate. Figure E-1 display s the procedure to be followed to determ ine the release ra te for the worst-case scenario. If the release takes place in a building, the building can be considered to provide passive
m itigation, unless:



### — The building m a y fail as a result of the re lease. This is unlikely except in the case of a large vessel in a very sm all room . As a rough rule of thumb, if the
room volum e (V) divided by the quantity of am m onia (Q) in the vessel is less than 0.1 ft 3 /lb, y ou should look at the possibility that the release of am m onia will cause failures such as windows blowing out or doors blowing open.



### — The release takes place facing an opening in the building (door or window). In this case, y ou should assum e that the door or window will be open, and the am m onia will be released through these openings. If the building m a y fail as a result of the release, estim ate the release rate as for an
unm itigated release (Equation 1, QR = Q/10 lb/m in). Sim ilarly , if the release would take place facing doors or windows, the release rate is again the entire inventory uniform ly distributed over 10 m i nutes (Equation 1). If the above conditions do not apply , y ou can assum e that rain-out of liquid droplets is facilitated by im pingem e nt on surfaces (in a com p ressor room , for exam ple), and only a portion of the released m a terial will becom e airborne. The rem a inder collects in relatively slowly evaporating pools and m a kes only a sm all contribution to the rate of release from the building. To estim at e the m itigated release rate, assum e the following:Appendix E

- 6- NH3



### — The am ount of m a terial airborne in the building is four-tenths of the total inventory , or 0.4 Q.



### — The airborne m a terial includes 0.2 Q vapor and 0.2 Q liquid droplets.



### — Exhibit E-1 provides factors for estim ating the m itigated release rate from a building.
To estim ate the release rate using these factors, do the following:



### — Estim ate 1 as follows:

- Determ ine room volum e, V, in ft 3

- Calculate 1 from room volum e divided by the quantity of am m onia initially released as vapor, or 1 (ft 3 /lb) = V/(0.2 Q)



### — Determ ine the active ventilation rate, N v , in room volum es exchanged per hour (hr -1 ), for the building.



### — From Exhibit E-1, find the 10-m i nute building attenuation factor, FR 10 , corresponding to y our estim ated 1 and the ventilation rate, N v .



### — Estim ate the release rate in lbs/m i n from the building attenuation factor and the airborne quantity (0.4 Q) as follows, assum i ng the release takes place over 10 m i nutes: QR B = (FR 10 × 0.4 Q)/10 (2) Example 1 A high-pressure receiver containing 5,000 lb of am m onia is in a room of dim e nsions 20 feet x 50 feet x 30 feet = 30,000 ft 3 . Hence, 1 = 30,000/(5,000 x 0.2) = 30 ft 3 /lb. The nearest value of 1 on Exhibit E-1 is 1 = 25. The ventilation rate for the building is 5 hr -1 . For 1 = 25 and N v = 5, FR 10 = 0.35, and the release rate to the atm o sphere is QR B = (0.35)(0.4)(5,000)/10 = 70 lb/m in, using Equation 2 above.Figure E-1Guidance on Effectiveness of Building Mitigation for Worst-Case ScenariosIdentifyQuantity(Q)in LargestVesselIndoorsorOutside?IndoorsOutsideReleaseRate=0.1Qlb/minReleaseRate=0.1Q lb/minAdjacentto Door orWindow?YesAirborneMass0.4QCalculateθ=V/(0.2Q)ChooseNV(hr-1)IdentifyFR10(Exhibit E-1)ReleaseRate=0.04QFR10lb/minNoAppendix E

- 8- NH3


### Exhibit E-1 Ten-Minute Building Release Attenuation Factors for Prolonged Releases

1 

### (ft 3 

### /lb) N v 

### (hr -1 

### ) FR 10 

### (dim) 1 

### (ft 3 

### /lb) N v 

### (hr -1 

### ) FR 10 

### (dim) 150.0 0 0.07 10.0 0 0.61 1 0 .08 1 0.61 5 0 .32 5 0.61 10 0.51 10 0.61 20 0.71 20 0.71 30 0.80 30 0.80 40 0.85 40 0.85

100.0 0 0.11 5.0 0 0.79 1 0 .11 1 0.79 5 0 .32 5 0.79 10 0.51 10 0.79 20 0.71 20 0.79 30 0.80 30 0.80 40 0.85 40 0.85

50.0 0 0.20 1.0 0 0.96 1 0 .20 1 0.96 5 0 .32 5 0.96 10 0.51 10 0.96 20 0.71 20 0.96 30 0.80 30 0.96 40 0.85 40 0.96
25.0 0 0.35 0.5 0 0.98 1 0 .35 1 0.98 5 0 .35 5 0.98 10 0.51 10 0.98 20 0.71 20 0.98 30 0.80 30 0.98 40 0.85 40 0.98NH3 -9- A ppendix E Example 2
The 5,000 lb vessel in Exam ple 1 is outside. The release rate is, therefore, 5,000/10 = 500 lb/m in. It can be seen that the building provides extensive attenuation. However, to take advantage of this potentia l attenuation, y ou m u st be certain that the worst-case scenario cannot occur outside or adjacent to a door or window that m a y be open.
O THER P OTE N TIA L W OR S T -C A SE S CENA RI O S The rule requires that y ou look for other potential scenarios that could affect offsite populations further away from the site or in different areas than does the release from the largest vessel. Thus, even if an outside storage vessel is sm aller than y our highpressure receiver, y ou should consider th e release of its contents over a 10-m i nute period as a possible worst-case scenario. Sim ilarly , if a pipe containing am m onia liquefied under pressure is outside for part of its length, y ou should consider the release of the contents of that pipe as a possible worst-case scenario.
D ISTA NCE TO THE T OX IC E NDPO I NT
Take the estim ated worst-case rate of release QR (unm itigated) or QR B (in a building) and go to Exhibit E-2. Find the entry in th e “Rate of Release” colum n that is closest to y our estim ated release rate. Read off the corresponding distance from the urban or the rural colum n . This is the “distance to the endpoint” that m u st be subm itted (in
m iles) in the RMP inform ation.
To decide whether the site is rural or ur ban, the rule gives the following guidance in § 68.22(e): “Urban m eans that there are m a ny obstacles in the im m e diate area; obstacles include buildings or trees. Rural m eans that there are no buildings in the im m e diate area and the terrain is generally flat and unobstructed.” Figure E-2 represents Exhibit E-2 in graphical form . Both apply to releases of 10
m i nutes duration. Example 3
Take the 500 lb/m in release rate from Exam ple 2. From Exhibit E-2, the predicted distance to the toxic endpoint is ~ 1.3 m iles at a rural site and ~ 0.9 m iles at an urban site. For the 70 lb/m in release of Exam pl e 1, these distances becom e 0.5 m iles and 0.3 m iles, respectively

.Appendix E

- 10- NH3


### Exhibit E-2 Distances to Toxic Endpoint for Anhydrous Ammonia Liquefied Under Pressure F Stability, Wind Speed 1.5 Meters per Second

Release Rate Distance to Endpoint (m iles)

(lbs/m in) Rural U rban
1 0 .1 <0 .1 *

2 0

. 1 0. 1

5 0

. 1 0. 1

10 0. 2 0

. 1

15 0. 2 0

. 2

20 0. 3 0

. 2

30 0. 3 0

. 2

40 0. 4 0

. 3

50 0. 4 0. 3

60 0. 5 0

. 3

70 0. 5 0

. 3

80 0. 5 0

. 4
90 0. 6 0

. 4

100 0. 6 0

. 4

150 0. 7 0. 5

200 0. 8 0

. 6
250 0. 9 0. 6

300 1. 0 0

. 7

400 1. 2 0

. 8

500 1. 3 0

. 9

600 1. 4 0

. 9

700 1. 5 1

. 0

750 1. 6 1

. 0

800 1. 6 1

. 1
900 1. 7 1

. 2 Release Rate Distance to Endpoint (m iles) (lbs/m in) Rural U rban

1 ,0 0 0 1

. 8 1 .2

1 , 500 2. 2 1

. 5

2 , 000 2. 6 1

. 7
2, 500 2. 9 1

. 9
3, 000 3. 1 2

. 0
4, 000 3. 6 2

. 3
5, 000 4. 0 2

. 6
6, 000 4. 4 2

. 8

7 , 000 4. 7 3

. 1
7, 500 4. 9 3

. 2
8, 000 5. 1 3

. 3
9, 000 5. 4 3

. 4
10, 000 5. 6 3

. 6
15, 000 6. 9 4

. 4
20, 000 8. 0 5

. 0
25, 000 8. 9 5

. 6
30, 000 9. 7 6

. 1
40, 000 11 7. 0
50, 000 12 7. 8
75, 000 15 9. 5
100, 000 18 10
150, 000 22 13
200, 000 ** 15
250, 000 ** 17
750, 000 ** ** *Report distance as 0.1 m ile ** More than 25 m iles (report distance as 25 m iles)Figure E-2Worst-Case Scenario - Predicted Distances to Toxic EndpointAnhydrous Ammonia @ Atmospheric Stability Class F with Wind speed 1.5 m/sAppendix E

- 12- NH3


### E.3.2 A lternative Release Scenario Analy s is
The owner or operator m u st identify and analy ze at least one “alternative” release scenario.
C HO ICE O F THE A LTERNA TIVE S CENA RI O Your alternative scenario for a covered process m u st be one that is m o re likely to occur than the worst-case scenario and th at reaches an endpoint offsite, unless no such scenario exists. Note that this requi rem e nt m eans that the release rate for the alternative scenario for am m onia m u st be fairly large, or it generally will not reach the am m onia endpoint offsite.
A LTERNA TIVE S CENA RI O S FO R A M M O N I A AT R EFRI G E RA TI O N F A C ILITIES For the alternative scenario analy s is, y ou need to estim ate the release rate of
am m onia and the distance to the toxic endpoint. Exhibit E-3 and Figure E-3 provide distances to the endpoint for a range of release rates under the weather conditions discussed above. Note that Exhibit E-3 and Figure E-3 (and Equations 6 and 7 in Section E.3.4) are intended to apply to releases of any duration. For the purposes of this guidance, a sim p le alternative scenario has been chosen: an outdoor release through a hole in a tank or pipe containing am m onia liquefied under pressure, leading to an airborne release. For the release of liquid, y ou can estim ate the release rate from the Bernoulli Equation; for am m onia liquefied under pressure, y o u can assum e the liquid vaporizes im m e diately , and the release rate of the liquid is the
sam e as the release rate to air. The following is a sim p lified version of the Bernoulli Equation, incorporating chem ical-specific factors for am m onia: QR = HA × (203)( Pg ) 1⁄2 (3)
where: QR = Release rate (pounds per m i nute)

HA = Hole area (square inches) Pg = Gauge pressure (psig) See Section E.3.4 for a discussion of the Bernoulli Equation and the derivation of the sim p lified equation above.NH3 -13- Appendix E


### Exhibit E-3 Distances to Toxic Endpoint for Anhydrous Ammonia Liquefied Under Pressure D Stability, Wind Speed 3 Meters per Second

Release Rate Distance to Endpoint (m iles)

(lbs/m in) Rural U rban

<10 < 0. 1*

<0.1* 10 0. 1

15 0. 1

20 0. 1

30 0. 1

40 0. 1

50 0. 1

60 0. 2 0

. 1

70 0. 2 0

. 1

80 0. 2 0

. 1

90 0. 2 0

. 1

100 0. 2 0

. 1

150 0. 2 0

. 1

200 0. 3 0

. 1

250 0. 3 0

. 1

300 0. 3 0

. 1

400 0. 4 0

. 2

500 0. 4 0

. 2

600 0. 5 0

. 2

700 0. 5 0

. 2

750 0. 5 0

. 2

800 0. 5 0

. 2 Release Rate Distance to Endpoint (m iles) (lbs/m in) Rural U rban

900 0. 6 0

. 2

1 , 000 0. 6 0

. 2

1 , 500 0. 7 0

. 3

2 , 000 0. 8 0

. 3

2 , 500 0. 9 0

. 3

3 , 000 1. 0 0

. 4

4 , 000 1. 2 0

. 4
5, 000 1. 3 0

. 5
7, 500 1. 6 0

. 5
10, 000 1. 8 0

. 6
15, 000 2. 2 0

. 7
20, 000 2. 5 0

. 8
25, 000 2. 8 0

. 9
30, 000 3. 1 1

. 0
40, 000 3. 5 1

. 1
50, 000 3. 9 1

. 2
75, 000 4. 8 1

. 4
100, 000 5. 4 1

. 6
150, 000 6. 6 1

. 9
200, 000 7. 6 2

. 1
250, 000 8. 4 2

. 3
300, 000 9. 2 2

. 5



### * Report distance as 0.1 m ileFigure E-3Alternative Release Scenario - Estimated Distances to Toxic Endpoint for Anhydrous AmmoniaStability Class D,Wind Speed 3 Meters per SecondNH3 -15- Appendix E Exhibit E-4 provides release rates and distances for pressures of 100 to 180 psig and hole diam eters of 1/4 inch to 12 inches. (The distances are based on Exhibit E-3). You m a y use this exhibit to estim ate the distance to the endpoint if this ty pe of scenario is reasonable for y our site.


### Exhibit E-4 Release Rates and Distances to Toxic Endpoint for Leaks of Anhydrous Ammonia (Alternative Release Scenario)

A LTERNA TIVE R ELEA SE S CENA RI O S I NSI D E A B UI LDI N G
The alternative release scenario inside a bu ilding is handled in m u ch the sam e way as is the worst-case scenario. See Figure E-4 fo r a flow chart describing the procedure. To use the factors provided in Exhibit E-1 for estim ating the release rate in a building, y ou m u st assum e the release takes place over a ten-m i nute period. The total quantity released will be y our estim ated release rate m u ltiplied by 10. If a ten m i nute release is not a reasonable alternative scenario for y our site, y ou will need to do additional calculations or use a different m e thod for releases in buildings.Figure E-4Guidance on Effectiveness of Building Mitigation for Alternative Release ScenariosCalculateReleaseRateQR(lb/min)IndoorsorOutside?IndoorsOutsideReleaseRate=QRlb/minReleaseRate=QRlb/minAdjacenttoDoororWindow?YesAirborneMassM = 0.4QCalculateθ= V/(0.2Q)Choose NV(hr-1)IdentifyFR10(Exhibit E-1)ReleaseRate=0.1FR10Mlb/minNoReleaseEntirelyVapor?YesNoCalculateθ= V/QAirborneMassM = QNH3 -17- Appendix E Example 4 Suppose the release from a 1⁄2-inch hole in a tank with pressure 180 psig, cited in Exhibit E-4, resulting in a release rate of 550 lb/m in of flashing liquid am m onia, takes place inside a building with a ventilation rate N v = 5 hr -1 . The release is
assum e d to take place over ten m i nutes, and the total quantity released is 550 × 10 = 5,500 lb, of which 0.4 × 5,500 = 2,200 lb becom es airborne. Of the airborne quantity , 1,100 lb is vapor and 1,100 lb is liquid th at rem a ins entrained in the vapor. The
rem a ining 3,300 lb of liquid form s an evaporating pool on the floor. The building volum e is 50 feet x 20 feet x 20 feet = 20,000 ft 3 , so that 1 = 20,000/1,100 = 18 ft 3 /lb.

From Exhibit E-1, FR 10 = 0.35 for 1 = 25 ft 3 /lb (the number closest to 18) and N v = 5. Assum i ng a ten-m i nute release, the rate of release from the building is 77 lb/m in [QR B = (0.35)(0.4)(5,500)/10 from Equation 2 in section E.3.1] . Using Exhibit E-3, the predicted distance to the toxic endpoint is 0.2 m ile for a rural site and 0.1 m ile for an urban site, com p ared to 0.4 m ile (rura l) and 0.2 m ile (urban) for the sam e release outdoors.
As noted above, the attenuation factors in Exhibit E-1 apply to ten-m i nute releases. If y ou want to use the sam e m e thod to perform a calculation for a different duration of release in a building, consult the Technical Background Docum e nt cited at the beginning of this appendix for additiona l inform ation on how to carry out such calculations.Appendix E

- 18- NH3


### E.3.3 Brief Summary of the Various States in Which Ammonia Exists in a Ty pical Refrigeration Facility
A ty pical block diagram of a two-stage am m onia refrigeration facility is shown on the next page; a sim ilar diagram of a single-stage facility is shown on the following page.
A MMON I A L IQU E FIED U NDER P RESSURE

In m a ny parts of a ty pical refrigeration sy stem , there is am m onia liquefied under pressure. If the pressure and tem p erature are sufficiently high, and if there is a sudden release of liquid am m onia, it will all becom e and rem a in airborne as a m i xture of
am m onia vapor and very fine liquid droplet s that do not fall to the ground, provided that no obstacles are encountered in the im m e diate vicinity of the release. Experim e ntal results clearly show that th is is a real phy sical phenom enon (Goldwire et al., 1985; Kaiser, 1989). The droplets evaporate quickly as air is entrained. The evaporation process cools the air so that a cold m i xture of air and am m onia vapor is form ed. The m i xture is denser than air, and a heavy vapor dispersion m odel is required to adequately predict airborne concentrations downwind of the point of release.

In m a ny refrigeration facilities, the am m onia travels from the discharge of the
com p ressors through the evaporative conden sers to the high-pressure receiver. The next page shows a range of ty pical pressures in the high-pressure receiver from 100­ 200 psig (approxim a tely 8-15 atm o sphe res). The figure shows am m onia vapor pressure as a function of tem p erature. Pressures of 8-15 atm o spheres correspond to
am m onia tem p eratures of approxim a tely 10-40 degrees C, or superheats (number of degrees above the atm o spheric boiling point) of about 40-70 degrees C. These conditions are definitely such as to ensure that all of any liquid am m onia release will becom e and rem a in airborne.

Som e (but by no m eans all) refrigeration facilities have an am m onia storage vessel in addition to the high-pressure receiver. This vessel will, in all likelihood, be outside, and its pressure will fluctuate with the extern al tem p erature. However, at an ambient tem p erature of 25 degrees C, the superheat would be about 60 degrees C so that the characteristics of any release fro m such a vessel are expected to be sim ilar to those of a release from the high-pressure receiver. A release from such a vessel should be considered as a candidate for the worst case.

Som e refrigeration facilities m a y not have a high-pressure receiver. In such facilities,
am m onia at pressures as high as 180 psig is confined to pipework, and there m a y be a low-pressure receiver with a ty pical pressure in the range 10-60 psig (~ 2-5 atm o spheres), also containing am m onia liquefied under pressure. From Figure E-5, the corresponding tem p eratures are -20-0 degrees C, or superheats of 10-30 degrees C. It is only slightly conservative to assu m e that all of the am m onia released from such a vessel becom es airborne. Two-stage sy stem s have an interm ediate receiver,NH3 -19- Appendix E which has a range of operating pressures sim ilar to those for low-pressure receivers in a single-stage sy stem

. 

### Exhibit E-5 Tw o-Stage Ammonia Refrigeration SystemAppendix E

- 20- NH3


### Exhibit E-6 Single-Stage Ammonia Refrigeration System w i th High-Side Float Regulator and Pump CirculationNH3 -21- Appendix E 

### Figure E-5. Vapor Pressure of Ammonia as a Function of TemperatureAppendix E

- 22- NH3
A M M O N I A AT S UBA TM O SPHERIC P RESSURES
In som e facilities (e.g., food processing plants ), even colder am m onia m a y be needed (when, for exam ple, very rapid freezing of food is necessary ) . The first figure shows a low-pressure receiver with subatm ospheric pressures as low as 15 inches of water, which corresponds to a tem p erature well below the atm o spheric boiling point. If released, the am m onia will spill onto the ground and, over an average period of 10
m i nutes or m o re, will evaporate at a m u ch lower rate than a release from a worst-case rupture in such a vessel as the high-pr essure receiver. In addition, these low tem p erature vessels are generally inside buildings, and it is likely that this would further reduce the effective rate of rel ease to the atm o sphere external to the refrigeration plant.
A MMON I A G AS Finally , in am m onia refrigeration sy stem s there is am m onia gas (vapor) in the sy stem under a range of tem p eratures and pressures. If there is a rupture in the vapor space of the high-pressure receiver, there will be a buoy ant am m onia jet (i.e., the am m onia vapor is less dense than air). However, for a given hole size and a given pressure, the rate of release of am m onia gas is very m u ch less than that of liquid am m onia, so that it is unlikely that a vapor release would be the worst-case.NH3 -23- Appendix E


### E.3.4 Equations for Log-log Graphs and Calculations

L OG - LOG E QU A T ION S The guidance on Figure E-2 is essentially in the form of a straight line on a log-log plot: D = 0.0607(QR) 0.4923 (4)
for a rural site and D = 0.0443(QR) 0.4782 (5)
for an urban site, where: D = Distance to the endpoint (m iles) and, QR = Release rate (lb/m i n) If y ou wish, y ou can use Equation 4 or 5 instead of Exhibit E-2 or Figure E-2. The curves on Figure E-3 are approxim a tely straight lines on a log-log plot: D = 0.0222(QR) 0.4780 (6)
at a rural site, and D = 0.0130(QR) 0.4164 (7)
at an urban site. If y ou wish, y ou can use Equation 6 or 7 instead of Exhibit E-3 or Figure E-3.
A LTERNA TIVE R ELEA SE S CENA RI O S
There are m a ny possible alternative scenar ios. Som e of those identified from a review of past incidents in refrigeration facilities include:



### — Plant upsets leading to the lifting of relief valves



### — Pipeline failures



### — A blocked-in, liquid-full pipeline rupturing as it heats up



### — Failures during am m onia delivery , such as a hose leakAppendix E

- 24- NH3 The rule states that other scenarios, (discu ssed in Section 4.3 of the m a in docum ent), should be considered In addition, activ e and passive m itigation sy stem s m a y be considered, provided that they can be show n to withstand the cause of the release. It is apparent that there is a great variety of alternative scenarios. However, EPA requires that only one such scenario be identified and m odeled. Many scenarios are effectively equivalent to a sm all hole of diam eter 1⁄4 inch to 1⁄2 inch (e.g., a gasket rupture or a pum p seal leak). Rem e mb er, how ever, that the alternative scenario m u st result in offsite consequences, unless y ou can show that no such scenario exists. The rate of release QR for a liquid release through a hole m a y be calculated using Bernoulli' s form ula: QR = c D LA(2Pg/ D L+2gh) 0.5

where: c = a constant (ty p ical value 0.8)
D

L = the density of the liquid in the vessel (639 kg/m 3 for am m onia) A = the area of the hole (m 2 ) Pg = the gauge pressure in the vessel (Pa) g = the acceleration due to gravity (9.82 m / s 2 ) h = the static head (m ) The static head is likely to be negligible when the tank pressure is high, as is likely for liquefied am m onia; therefore, the 2gh term in the equation can be ignored. The following equation drops the 2gh term and includes conversion factors: QR = 132.2×6.4516 x 10-4×0.8×639× HA× (2×( Pg /639)×6895) 1⁄2

where: QR = Release rate (pounds per m i nute)

HA = Hole area (square inches)

132.2 = Conversion factor for kil ogram s per second to pounds per m i nute
6.4516 x 10 -4 = Conversion factor for square inches to square m e ters ( HA )
0.8 = Discharge coefficient (0.8) 639 = Liquid density of am m onia (kg/m 3 ) Pg = Gauge pressure in tank (psi)NH3 -25- Appendix E 6,895 = Conversion factor for psi to Pascals ( Pg )
Comb ining the conversion factors and incor porating the density of am m onia, leads to the equation presented in the text as Equation 3 for the release rate through a hole of
am m onia liquefied under pressure: QR = 203× HA× ( Pg ) 1⁄2

Note that this is the form ula for the release of a pure liquid and would apply to a breach in the wall of a vessel or to the rupture of a very short pipe. For long pipes, there is a pressure drop between the vessel a nd the hole that leads to flashing in the pipe and a reduced rate of release.
The scenario needs to be m odeled in ty pical weather conditions. For m a ny sites, Atm o spheric Stability Category D with a m oderate wind speed (e.g., 3 m / s) is close to average. The distance to the toxic endpoi nt can then be estim ated from Figure E-3 or from Exhibit E-3, which is a tabulati on of Figure E-3. These results could sim p ly be quoted in the Risk Managem e nt Plan.
You also m a y identify y our own alternative scenario(s). Consult y our trade association (e.g., the International Institute of Am m onia Refrigeration) for guidance on other scenarios. Your Process Hazards Analy s is is another potential source of pertinent inform ation. However, rem e mb er that the regulation requires that releases large enough to have the potential to exceed the toxic endpoint offsite be considered.


### E.3.5 Additional Guidance on Modeling
If the owner or operator decides to perform his/her own m odeling, there are two
m a jor item s that are not trivial. These are: a) Correct characterization of the source term (e.g., rate of release, tem p erature, density , m o m e ntum , aerosol content, etc.) b) Choice of a suitable dispersion m odel It is not possible to cover in detail all of the issues that need to be addressed, although there are sources of useful advice. The quadrennial conferences on vapor cloud dispersion m odeling that are organized by the Center for Chem ical Process Safety (CCPS) are a good source of inform ation on the latest developm ents in source term and dispersion m odeling (CCPS, 1987, 1991, 1995). There are also CCPS Guidebooks, such as "Guidelines for Use of Vapor Cloud Dispersion Models ­ Second Edition". EPA has also published additional guidan ce. There is one docum ent that looks carefully at the definition of source term s (USEPA, 1993). There is another that describes EPA's own screening m odel for accidental releases of accidental chem icals TSCREEN (USEPA, 1992). EPA has also perform ed an evaluation of dense gasAppendix E

- 26- NH3 dispersion m odels (USEPA, 1991). Another re view of available m odels has been given by Hanna, et. al. (1991).


### E.4 References and Additional Sources of Information

Am erican National Standards Institute (1999), American National Standard for Equipment, Design, and Installation of Ammonia Mechanical Refrigeration Systems , ANSI/IIAR Standard 2.

Am erican National Standards Institute (2001), American National Standard: Safety Code for Mechanical Refrigeration , ANSI/ASHRAE Standard 15. Brighton, P.W.M. (1989). "Pressures Produced by Instantaneous Releases of Chlorine Inside Buildings," United Ki ngdom Health and Safety Executive Report SRD/HSE/R467, Her Majesty ' s Stationery Office, London.
Center for Chem ical Process Safety (CCPS, 1987). "Proceedings of the International Symposium on Vapor Cloud Modeling ," Boston, MA; Am erican Institute of Chem ical Engineers, New York, NY.
Center for Chem ical Process Safety (CCPS, 1991). " International Conference and Workshop on Modeling and Mitigating the Con sequences of Accidental Releases of Hazardous Materials ," New Orleans, LA; Am erican Institute of Chem ical Engineers, New York, NY.
Center for Chem ical Process Safety (CCPS, 1995). " International Conference and Workshop on Modeling and Mitigating the C onsequences of Accidental releases of Hazardous Materials ," New Orleans, LA; Am erican Institute of Chem ical Engineers, New York, NY. Goldwire, Jr., H.C., T.G. McRae, G.W. Johnson, D.L. Hipple, R.P. Koopm an, J.W. McLure, L.K. Morris and R.T. Cederwall (1985). "Desert Tortoise Series Data Report - 1983 Pressurized Am m onia Spills," Lawrence Liverm ore National Laboratories Report UCID-20562, Liverm ore, CA.
Hanna, S.R., D.G. Strim a tis and Joseph C. Chang (1991). "Uncertainties in Hazardous Model Gas Predictions," in CCPS (1991), pp. 345-368.
International Institute of Am m onia Refrigeration (IIAR), Ammonia Data Book

. International Institute of Am m onia Refrigeration (1997). Guidelines for Suggested Safety and Operating Procedures When Making Refrigeration Plant Tie-ins , IIAR B107.
International Institute of Am m onia Refrigeration (1986). Guidelines for Water Contamination in Ammonia Refrigeration Systems , IIAR B-108NH3 -27- Appendix E
International Institute of Am m onia Refrigeration (1998). Guidelines for: IIAR Minimum Safety Criteria for a Safe Ammonia Refrigeration System , IIAR B-109.
International Institute of Am m onia Refrigeration (1993). Guidelines for Start-Up, Inspection, and Maintenance of Ammonia Refrigeration Systems , IIAR B-110.
International Institute of Am m onia Refrigeration (1991). Guidelines for Ammonia Machinery Room Ventilation , IIAR Bulletin 111.
International Institute of Am m onia Refrigeration (1991). Guidelines for Identification of Ammonia Refrigera tion Piping and System Components , IIAR B114.
International Institute of Am m onia Refrigeration (1992). Guidelines for Avoiding Component Failure in Industrial Refrig eration Systems Caused by Abnormal Pressure or Shock , IIAR B-116.
United States Environm ental Protection Agency (USEPA, 1991). "Evaluation of Dense Gas Simulation Models ," EPA-450/R-89-018, Research Triangle Park, NC.
United States Environm ental Protection Agency (USEPA, 1993). "Contingency Analysis for Superfund Sites and Other Industrial Sources ," EPA-454/R-93-001, Research Triangle Park, NC.
United States Environm ental Protection Agency (USEPA, 1999). “ Technical Background Document for Offsite Conse quence Analysis for Anhydrous Ammonia, Aqueous Ammonia, Chlorine, and Sulfur Dioxide ,” EPA-550-B99-017, Washington, DC.
United States Environm ental Protection Agency (USEPA, 2001). Chem ical Safety Alert: “ Hazards of Ammonia Releases at Ammonia Refrigeration Facilities (Update) ,” EPA 550-F-01-009. Availa ble through EPA website at: www.epa.gov/em ergencies.

## APPENDIX F: Supplemental Risk Management Program Guidance for Wastewater Treatment PlantsAppendix F

- 2- W W T P


## Appendix F: Supplemental Risk Management Program Guidance for Wastewater Treatment Plants

This appendix supplem ents the m a in body of the General Guidance to provide additional inform ation for wastewater treatm e nt plants (WWTPs), including publicly owned treatm e nt works (POTWs) and other industrial treatm e nt sy stem s. It provides guidance on how to comp ly with part 68 with respect to chlorine, am m onia (anhy drous and aqueous), su lfur dioxide, and digester gas, the substances WWTPs usually use for treatm e nt or produce as a result of treatm e nt. We expect that any regulated substances present in y our waste stream s will be in concentrations too low to require comp liance. If y ou have other processes that use regulated substances other than these, refer to the m a in body of the General Guidance (and any other applicable industry

- specific appendix) for inform ation on comp liance with the rule for those processes. The appendix covers Risk Managem e nt Program elem ents in the
sam e general order as those elem ents are a ddressed in the m a in docum ent. However, note that the appendix does not address som e generic RMP elem ents (e.g., Managem e nt Sy stem ). For elem ents not addressed in this appendix, simp ly refer to the applicable guidance in the m a in docum ent.



### F.1 G eneral Applicability
The following list includes the chem icals regulated under part 68 and OSHA PSM that are com m only used at WWTPs, along with their associated threshold quantity :
Chem ical EPA Threshold Quantity OSHA Threshold Quantity
Chlorine Anhy drous Am m onia Aqueous Am m onia (concentration 20% or greater) Anhy drous Sulfur Dioxide
Methane 2,500 pounds 10,000 pounds 20,000 pounds 5,000 pounds 10,000 pounds 1,500 pounds 10,000 pounds 15,000 pounds ( >44% ) 1,000 pounds (Liquid) 10,000 pounds

For m e thane, the 10,000-pound threshold applies to the total weight of the flam m a ble
m i xture of digester gases, not just the weight of m e thane or flam m a bles in the
m i xture. However, if y our WWTP uses m e thane (or a m e thane m i xture) as fuel or sells it as fuel (as a retail facility ), the am ount of m e thane that y ou use or sell as fuel is not covered under part 68. For aqueous am m onia, the threshold applies only to the weight of am m onia in the m i xture. In general, regulated chem icals in a waste stream at a POTW will not exceed one percent of a m i xture and thus will not be covered by part 68. If an industrial WWTP has m o re than 1 percent of a regulated s ubstance in the waste stream , the quantity ofW W T P

- 3- Appendix F
the substance in the waste stream will have to be determ ined and comp ared to the threshold quantity . Oxy g en is not subject to either part 68 or OSHA PSM. Ozone is also not subject to part 68, although it is covered by OSHA PSM.


### F.2 P rogram Levels
Program levels for private WWTPs and industrial wastewater treatm e nt processes are determ ined in the sam e m a nner as other covered processes (See Chapter 2 of the
m a in docum ent for m o re inform ation). However, a POTW will determ ine its Program levels based, in part, on the state or territory in which it is located. If OSHA has delegated its program s to the state or territory in which y our POTW is located, y ou are covered by OSHA standards under st ate law (it is a condition of gaining delegation that the state apply OSHA rules to state and local governm e nts). If y ou are in one of the states or territories with a delegated OSHA program(listed in Exhibit F2), y our processes will be in Program 1, if eligible; otherwise, processes involving regulated toxics substances or digester gas production not used for fuel will be in Program 3 because they are subject to OSHA PSM. Several states have not been granted delega tion by federal OSHA (listed in Exhibit F1). However, som e of these states have enacted legislation or prom ulgated regulations that adopt the federal OSHA PSM standard and applied them to state and local governm e nts. If y ou are in one of these states, y our POTW process will be in either Program 1 or Program 3. If y ou are in one of the states without a delegated OSHA program and the state has not incorporated the federal OSHA PSM standa rd by reference into state law or code, y our processes will generally be in either Program 1 or Program 2. An exception to this would be in cases where a POTW in a Federal OSHA state is operated by contractor employ ees. Since the private contractors employ ees are subject to Federal OSHA regulations, these POTW processes will be subject to Program 1 or Program 3.Appendix F

- 4- W W T P
Exhibit F-1: Federal OSHA States

Alabam a K ansas North Dakota
Arkansas Louisiana O hio
Colorado Maine O klahom a Delaware Massachusetts Pennsy l vania
DC Missouri R hode Island
Florida M ississippi South Dakota Georgia M ontana T exas Idaho N ebraska W est Virginia
Illinois N ew Hamp shire W isconsin New Jersey

Exhibit F-2: States with Delegated OSHA Program s

Alaska M ary l and S outh Carolina
Arizona Michigan Tennessee
California M innesota Utah
Connecticut Nevada Verm ont Hawaii New Mexico Virginia
Indiana N ew York Virgin Islands
Iowa North Carolina W ashington Kentucky Oregon Wy om ing
Puerto RicoW W T P

- 5- Appendix F


### F.2.1 Q UICK RULES FOR DETERMINING PROGRAM 1 ELIGIBILITY

TOXIC GASES If y ou have a process containing m o re than a threshold quantity of chlorine,
am m onia, or sulfur dioxide or any other regulated toxic gas that is not liquefied by refrigeration alone (i.e., y ou hold it as a gas or liquefied under pressure), the distance to the endpoint estim ated for a worst-case release of the toxic gas will generally be several m iles. As a result, the distance to endpoint is unlikely to be less than the distance to public receptors, unless the process is very rem o te. In som e cases, however, toxic gases in processes in enclosed areas m a y be eligible for Program 1.
REFRIGERATED TOXIC GASES If y ou have a process containing anhy drous am m onia liquefied by refrigeration alone, and y our worst-case release would take place into a diked area, the chances are good that the process m a y be eligible for Progr am 1, unless there are public receptors very close to the process. Even if y ou have m a ny tim es the threshold quantity of am m onia, the process m a y still be eligible for Program 1. The worst-case analy s is for a process containing chlorine liquefied by refrigera tion is unlikely to show eligibility for Program 1, unless y our site is extrem ely rem o te from the public or the release would occur within an enclosure.
TOXIC LIQUIDS The distance to an endpoint for a worst-case release involving toxic liquids kept under am bient conditions m a y be sm aller than the distance to public receptors in a
num ber of cases. If public receptors are not found very close to the process (within 1⁄2
m ile), the process m a y be eligible for Program 1. However, facilities on sm all acreage sites are highly unlikely to m eet to be eligible for Program 1 if they are in a developed area. Rem o tely located facilities or processes found near the center of large (acreage) sites are m o re likely to be eligible.
WATER SOLUTIONS OF TOXIC SUBSTANCES Processes containing water solutions of toxi c substances (e.g., aqueous am m onia) at
am bient temp eratures m a y be eligible for Program 1 (depending in som e cases on the concentration of the solution), if spills would be contained in diked areas and public receptors are not located close to the process (within 1⁄2 m ile). As noted above, facilities on sm all acreage sites in developed areas are highly unlikely to be eligible for Program 1; rem o tely located facilities or processes found near the center of large acreage sites are m o re likely to be eligible.Appendix F

- 6- W W T P
FLAMMABLE SUBSTANCES Many processes containing regulated flam m a ble substances are likely to be eligible for Program 1, unless there are public receptors within a very short distance. If y o u have a process containing up to about 20,000 pounds (twice the threshold quantity ) of m e thane, y our process is likely to be eligible for Program 1 if y ou have no public receptors within about 400 y a rds (1,200 feet) of the process. If y ou have up to 100,000 pounds in a process (ten tim es the threshold quantity ), the process m a y be eligible for Program 1 if there are no public receptors within about 700 y a rds (2,000 feet). In general, it would be worthwh ile to conduct a worst-case analy s is for any processes containing only flam m a bles to determ ine Program 1 eligibility , unless y o u have public receptors very close to th e process. Consequently , y ou m a y have to conduct m o re worst-case analy ses if y ou want to qualify processes for Program 1; for Program 2 and 3 processes, y ou need analy ze only one worst-case release scenario to cover all flam m a bles. For Program 1, y ou m u st be able to dem onstrate, through y our worst-case analy s is, that every process y ou claim is Program 1 m eets the criteria.

Rem e m b er that the Program level designation for a process is based on the regulated substance that has the greatest distance to an endpoint. If y our digesters are considered part of a process that includes chlorine, am m onia, or sulfur dioxide, the toxics will determ ine whether the process is eligible for Program 1 because the distances to an endpoint will be greater for the toxics.


### F.2.2 P ROGRAM 3
Any covered process that is not eligible for Program 1 and is subject to OSHA PSM under federal or state law is subject to Program 3 requirem e nts, which include risk
m a nagem e nt m easures and requirem e nts virtually identical to the OSHA PSM Standard. (The other criterion for Program 3 applicability (§ 68.10(d)(1)) does not apply to WWTPs.) Private WWTPs are likely to be subject to OSHA PSM for processes containing m o re than a threshold quantity of chlorine, anhy drous am m onia, or sulfur dioxide. POTWs in states with delegated OSHA program s or in non-state-plan states that have adopted the PSM standard to cover state and local governm e nts are subject to the PSM standard if they have m o re than a th reshold quantity of these substances. OSHA’ s thresholds are generally lower than EPA’s so it is possible that y ou m a y have a process that is subject to OSHA PSM and is not covered by part 68. For example, if y ou store a single, one-ton cy linder of chlorine, OSHA PSM will cover it because it has a 1,500 pound threshold for chlorine, but EPA’ s part 68 will not because its threshold quantity for chlorine is 2,500 pounds. OSHA PSM covers aqueous am m onia at a c oncentration of greater than 44 percent (as opposed to EPA’s 20 percent or greate r); therefore, y our aqueous am m onia process m a y not be subject to OSHA PSM.W W T P

- 7- Appendix F


### F.2.3 P ROGRAM 2
Program 2 is considered a default program level because any covered process that is not eligible for Program 1 or assigned to Pr ogram 3 is, by default, subject to Program 2 requirem e nts, including a stream lined accident prevention program . One or m o re processes at y our facility are likely to be in Program 2 if:



### — You are a publicly owned and operated fac ility in a state that does not have a delegated OSHA program , and the state has not incorporated the OSHA PSM standard by reference into state law or code.



### — You use aqueous am m onia in solutions with greater than 20 percent concentration but less than 44 percent concentration.



### — You use regulated acids in solution in activities.



### — You store regulated liquid flam m a ble substances in atm o spheric storage tanks. The last two of these conditions are unlikely to apply to WWTPs.


### F.3 O ffsite Consequence Analy s is
This section gives guidance on how to perform the OCA for the five regulated substances that are ty pically used or produced at WWTPs:



### — Chlorine (toxic)



### — Sulfur dioxide (toxic)



### — Anhy drous am m onia (toxic)



### — Aqueous am m onia (20 percent or greater, toxic)



### — Methane (digester gas, flam m a ble) This chapter presents discussions and tabl es for the worst-case scenario for all five substances listed above, followed by discussi ons and tables for alternative scenarios for the six substances. Because m a ny WWTPs store chlorine and sulfur dioxide in buildings, we have included m e thods fo r estim ating the m itigating effects of buildings. The rem a ining sections provide guidance on defining offsite impacts, docum entation, and the sy m bols used in th e chapter. The guidance presented in this chapter is intended for users - that is, it do es not contain any explanations of how the guidance was derived. Those readers who ar e interested in obtaining an explanation can obtain from EPA a docum ent entitled Technical Background Document for Offsite Consequence Analysis for Anhydrous Ammonia, Aqueous Ammonia, Chlorine and Sulfur Dioxide

.Appendix F

- 8- W W T P


### F.3.1 W orst-Case Release Scenarios
This subsection provides guidance on how to analy ze worst-case scenarios for chlorine, sulfur dioxide, anhy drous am m oni a, aqueous am m onia, and m e thane. For inform ation on the general requirem e nts of the regulations pertaining to worst-case scenarios, refer to chapter 4 of the m a in docum ent.
The toxic endpoint s are:
Am m onia: 0.14 m g /L (200 ppm ) Chlorine: 0.0087 m g /L (3 ppm ) Sulfur Dioxide: 0.0078 m g /L (3 ppm )

The regulations require y ou to use tables or m odels for atm o spheric dispersion analy s is that appropriately account for gas density . For the specific case of WWTPs, chlorine and sulfur dioxide are alway s dense gases (that is, denser than air). Anhy drous am m onia, if released from the liquid space of a container in which it is liquefied under pressure, form s a denser-tha n-air vapor cloud. Am m onia evaporating from a pool of aqueous am m onia is treated as neutrally buoy ant (that is, it has about the sam e density as air).
CHLORINE
At WWTPs, chlorine is m o st likely to be present in 150-lb cy linders, in one-ton (2,000-lb) cy linders, in 17-ton tank trucks , or in 90-ton railcars. The worst-case scenario assum es that these quantities are co mp letely released over a period of 10
m i nutes (e.g., a 150-lb worst case corresponds to a 15-lb/m in rate of release). The predicted distances to the toxic endpoint for each of these scenarios is given in Exhibit F-3. These distances are for rel eases that are assum e d to take place outdoors. See Section F.3.3 for a discussion on buildings.W W T P

- 9- Appendix F
Exhibit F-3 Distances to Toxic Endpoints - Chlorine F Stability, Wind Speed 1.5 Meters per Second

Scenario Release Rate (lbs/min) D istance to Toxic Endpoint (miles)
Rural U rban 150-lb cylinder 1 5 0 .8 0.4 1-ton cylinder 200 3.0 1 .3
17-ton tank trucks 3,400 12 5.8
90-ton rail car 18,000 >25 1 4

If y our facility does not fit into the sta ndard pattern of 150-lb cy linders, one-ton cy linders, 17-ton tank trucks, or 90-ton rail cars, y ou should use Figure F-1 or Exhibit F-4. Identify the chlorine vessel that cont ains the largest quantity of any in y our facility and divide that m ass by 10 to obtain the release rate in lb/m in. Look for that release rate, or the rate nearest to it, in E xhibit F-4. Then read across to the rural or urban distances. Alternatively , look along the bottom axis of Figure F-1, read up to the curve(s) and then across to the corresponding distances on the vertical axis. As noted above, the results presented in Exhibits F-3 and F-4 are for a release that is outside. Many of y ou will keep y our chlorine vessels inside buildings. Som e will even have specially designed, leak-tight buildings with chlorine or sulfur dioxide scrubbers. However, the intention of this section is to provide inform ation on the worst-case scenario. There are tim es when y ou will be handling the cy linders outside. Nevertheless, in discussions with local agencies and local com m unities y ou m a y well want to explain how y our facility is designed to prevent or m itigate worst-case scenarios.Appendix F

- 10- W W T P
Exhibit F-4 Distances to Toxic Endpoint - Chlorine F Stability, Wind Speed 1.5 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an
1 0 .2 0.1
2 0 .3 0.1
5 0 .5 0.2
10 0.7 0 .3
15 0.8 0 .4
20 1.0 0 .4
30 1.2 0 .5
40 1.4 0 .6
50 1.5 0 .6
60 1.7 0 .7
70 1.8 0 .8
80 1.9 0 .8
90 2.0 0 .9
100 2.2 0 .9
150 2.6 1 .2
200 3.0 1 .3
250 3.4 1 .5
300 3.7 1 .6
400 4.2 1 .9
500 4.7 2 .1
600 5.2 2 .3
700 5.6 2 .5 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an
750 5.8 2 .6
800 5.9 2 .7
900 6.3 2 .9 1,000 6.6 3 .0 1,500 8.1 3 .8 2,000 9.3 4 .4 2,500 10 4.9 3,000 11 5.4 4,000 13 6.2 5,000 14 7.0 6,000 16 7.6 7,000 17 8.3 7,500 18 8.6 8,000 18 8.9 9,000 19 9.4 10,000 20 9.9 15,000 25 12 20,000 * 1 4 25,000 * 1 6 30,000 * 1 8 40,000 * 2 0 50,000 * 0

* More than 25 m iles (report distance as 25 m iles) These are results that y ou can simp ly quote when y ou subm it y our RMP.W W T P

- 11- Appendix F
SULFUR DIOXIDE Sulfur dioxide, if present at a WWTP, is also likely to be in 150-lb cy linders, one-ton cy linders, 17-ton tank cars, or 90-ton railcars. The worst-case scenario assum es that these quantities are comp letely released over a period of 10 m i nutes. The predicted distances to the toxic endpoint for each of these scenarios is given in Exhibit F-5.
EXHIBIT F-5 Distances to Toxic Endpoint - Sulfur Dioxide F Stability, Wind Speed 1.5 Meters per Second

Scenario Release Rate (lbs/min) D istance to Toxic Endpoint (miles)
Rural U rban 150-lb cylinder 1 5 0 .7 0.3 1-ton cylinder 200 3.1 1 .3
17-ton tank truck s 3,400 15 6.0
90-ton rail car 18,000 >25 1 5

These are results that y ou can simp ly quote when y ou subm it y our RMP. If y our facility does not fit into the standard patte rn of 150-lb cy linders, one-ton cy linders, or 90-ton railcars, y ou should use Figure F-2 or Exhibit F-6. Identify the sulfur dioxide vessel that contains the largest quantity of any in y our facility . Divide that quantity by 10 to obtain the release rate in lb/m in and look for that rate, or the rate nearest to it, on Exhibit F-6. Then read across to the rural or urban distances. Alternatively , use Figure F-2.Appendix F

- 12- W W T P
EXHIBIT F-6 DISTANCES TO TOX I C ENDPOINT FOR SULFUR DIOX IDE F Stability, Wind Speed 1.5 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an
1 0 .2 0.1
2 0 .2 0.1
5 0 .4 0.2
10 0.6 0 .2
15 0.7 0 .3
20 0.9 0 .4
30 1.1 0 .5
40 1.3 0 .5
50 1.4 0 .6
60 1.6 0 .7
70 1.8 0 .7
80 1.9 0 .8
90 2.0 0 .8
100 2.1 0 .9
150 2.7 1 .1
200 3.1 1 .3
250 3.6 1 .4
300 3.9 1 .6
400 4.6 1 .9
500 5.2 2 .1
600 5.8 2 .3
700 6.3 2 .5 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an
750 6.6 2 .6
800 6.8 2 .7
900 7.2 2 .9 1,000 7.7 3 .1 1,500 9.6 3 .8 2,000 11 4.5 2,500 13 5.0 3,000 14 5.6 4,000 17 6.5 5,000 19 7.3 6,000 21 8.1 7,000 23 8.8 7,500 24 9.1 8,000 25 9.5 9,000 * 1 0 10,000 * 1 1 15,000 * 1 3 20,000 * 1 6 25,000 * 1 8 30,000 * 1 9 40,000 * 2 3 50,000 * *

* More than 25 m iles (report distance as 25 m iles)W W T P

- 13- Appendix F
ANHYDROUS AMMONIA In WWTPs, anhy drous am m onia is genera lly stored as a liquid under pressure in vessels that are kept outdoors. These vessels are relatively large (e.g., 10,000 gallons or ~56,000 lb). Identify the quantity of am m onia in y our storage vessel and divide by 10 to obtain the release rate in lb/m in. Look for that release rate, or the release rate nearest to it, on Exhibit F-7. Then read across to the rural or urban distances. Alternatively , use Figure F-3. The 10,000-gallon vessel m e ntioned above c ontains 56,000 lb when full. (You m a y take into account any adm i nistrative controls that lim it the quantity of the am m onia in the vessel. For example, y ou will generally require that the vessel never be filled above 85 percent of its total volum e to allow for the high coefficient of volum etric expansion of am m onia.) Assum i ng for the sake of the present example that 56,000 lb is the greatest quantity of am m onia that will ever be in the vessel, the release rate is 5,600 lb/m in. The closest release rate on Exhibit F-7 is 6,000 lb/m in. The corresponding rural distance is approxim a te ly 4.4 m iles and the corresponding urban distance is approxim a tely 2.8 m iles.Appendix F

- 14- W W T P
EXHIBIT F-7 DISTANCES TO TOX I C ENDPOINT FOR ANHYDROUS AMMONIA LIQUEFIED UNDER PRESSURE F Stability, Wind Speed 1.5 Meters per Second

Release Rate Distance to Endpoint (m iles)

(lbs/m in) Rural U rban
1 0 .1 <0 .1 *

2 0

. 1 0. 1

5 0

. 1 0. 1

10 0. 2 0

. 1

15 0. 2 0

. 2

20 0. 3 0

. 2

30 0. 3 0

. 2

40 0. 4 0

. 3

50 0. 4 0. 3

60 0. 5 0

. 3

70 0. 5 0

. 3

80 0. 5 0

. 4
90 0. 6 0

. 4

100 0. 6 0

. 4

150 0. 7 0. 5

200 0. 8 0

. 6
250 0. 9 0. 6

300 1. 0 0

. 7

400 1. 2 0

. 8

500 1. 3 0

. 9

600 1. 4 0

. 9

700 1. 5 1

. 0

750 1. 6 1

. 0

800 1. 6 1

. 1
900 1. 7 1

. 2 Release Rate Distance to Endpoint (m iles) (lbs/m in) Rural U rban

1 ,0 0 0 1

. 8 1 .2

1 , 500 2. 2 1

. 5

2 , 000 2. 6 1

. 7
2, 500 2. 9 1

. 9
3, 000 3. 1 2

. 0
4, 000 3. 6 2

. 3
5, 000 4. 0 2

. 6
6, 000 4. 4 2

. 8

7 , 000 4. 7 3

. 1
7, 500 4. 9 3

. 2
8, 000 5. 1 3

. 3
9, 000 5. 4 3

. 4
10, 000 5. 6 3

. 6
15, 000 6. 9 4

. 4
20, 000 8. 0 5

. 0
25, 000 8. 9 5

. 6
30, 000 9. 7 6

. 1
40, 000 11 7. 0
50, 000 12 7. 8
75, 000 15 9. 5
100, 000 18 10
150, 000 22 13
200, 000 ** 15
250, 000 ** 17
750, 000 ** **

* M o r e than 25 miles ( r e por t distance as 25 miles)W W T P

- 15- Appendix F
AQUEOUS AMMONIA

Som e WWTPs keep aqueous am m onia in outside storage tanks at atm o spheric pressure. The tanks usually stand in a diked area. Com m e rcial grades of aqueous
am m onia vary from less than 20 weight percent to about 30 weight percent. For ease of presentation, the am m onia is assum e d to be in a 30 weight percent solution. Because this has the highest vapor pressure of any of the com m e rcial grades used in wastewater treatm e nt facilities, its use is conservative if y ou have aqueous am m onia in a less than 30 weight percent solution. If there is a catastrophic failure, the aqueous am m onia will spill into the diked area.
You are allowed to consider the dike, whic h is a passive m itigation feature. However, if y ou have any reason to believe that the dike will not withstand the event that leads to the spill, or if y our tank does not stand in a diked area, then y ou should assum e , as required by the rule, that the spill spreads out until its depth is only 1 cm (0.39 inch). The first step is to calculate the rate of evaporation from the pool.

U

NDIKED A REA For an undiked area, the rate of release of am m onia from the pool (QR) (lb/m i n) is given by : QR = 0.020QS (1) where QS is the total quantity (lb) of the spill of aqueous am m onia. For example, if there is a spillage of 80,000 lb, the rate of evaporation is 0.02 x 80,000 = 1,600 lb/m in. The present guidance assum es that this is the average rate of release over 10
m i nutes, after which the pool will be m o re dilute than it was initially and will be evaporating m u ch less rapidly

. D IKED A REA For a diked area, the rate of evaporation is: QR = 0.036A p (2)
where A p is the diked area in square feet. For example, if the vessel stands in a diked area that is 40 feet x 40 feet = 1,600 ft 2 , the predicted rate of evaporation is 0.036 x 1,600 = 58 lb/m in.
The m a xim u m area of the pool that would be form ed by the spilled liquid can be estim ated as 0.55QS. If y ou have a diked area that is larger than the m a xim u m area, use Equation 1 for an undiked area to estim ate the release rate to air.

R

ATES OF R ELEASE AT T EMPERATURES O TH ER T HA N 25 O CAppendix F

- 16- W W T P

The actual temp erature of stored aqueous am m onia varies with the am bient temp erature. The rule requires y ou to consider the release temp erature to be the highest daily temp erature observed during the last three y ears, or the operating temp erature, whichever is highest. The ratio R vp (T) represents the ratio of the partial pressure of am m onia at temp erature T o C to the partial pressure at 25 o C. Exhibit F-8 gives values of R vp (T) for 30 percent aqueous am m onia in 1 o C increm ents from 15 o C to 40 o C (59 o F to 104 o F). The rates of evaporation in Equations 1 and 2 are proportional to the vapor pressure, so to obtain a rate of evaporation for a temp erature T o C other than 25 o C, simp ly m u ltiply the right-hand side of Equation 1 or 2 by the corresponding value of R vp (T). For example, for an undiked release of 80,000 lbs of am m onia at 35 o C, the calculation is (0.020)(80,000)(1.45) = 2,300 lbs/m i n. The vapor pressure of am m onia at other temp eratures can be obtained from the Handbook of Chemistry and Physics , CRC Press, 1998.
DISTANCES TO TOXIC ENDPOINT Take the evaporation rate and look for that ra te, or the rate nearest to it, on Exhibit F9. Then read across to the rural or urba n distances. For example, for the 58 lb/m in release rate derived above, the closest rel ease rate on Exhibit F-9 is 60 lb/m in. The predicted rural distance is approxim a tely 0. 4 m ile and the predicted urban distance is approxim a tely 0.2 m ile. Alternatively , use Figure F-4.W W T P

- 17- Appendix F

Exhibit F-8 Ratio of Vapor Pressure of Ammonia in 30% Aqueous Ammonia (Ratio is Unity at 25 o C)

Tem p erature ( o C) Ratio R vp (T) T emperature ( o C) Ratio R vp (T)
15 0.67 28 1.12
16 0.70 29 1.16
17 0.73 30 1.21
18 0.76 31 1.25
19 0.79 32 1.30
20 0.82 33 1.35
21 0.86 34 1.40
22 0.89 35 1.45
23 0.93 36 1.50
24 0.96 37 1.55
25 1.00 38 1.61
26 1.04 39 1.66
27 1.08 40 1.72Appendix F

- 18- W W T P
EXHIBIT F-9 Distances to Toxic Endpoint for Aqueous Ammonia F Stability, Wind Speed 1.5 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an 1 0

. 1

<0.1* 2 0 .1
5 0 .1
10 0.2 0 .1
15 0.2 0 .1
20 0.3 0 .1
30 0.3 0 .1
40 0.4 0 .1
50 0.4 0 .1
60 0.4 0 .2
70 0.5 0 .2
80 0.5 0 .2
90 0.5 0 .2
100 0.6 0 .2
150 0.7 0 .2
200 0.8 0 .3
250 0.8 0 .3
300 0.9 0 .3
400 1.1 0 .4
500 1.2 0 .4
600 1.3 0 .4
700 1.4 0 .5
750 1.4 0 .5
800 1.5 0 .5
900 1.5 0 .6 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an

1,000 1.6 0 .6 1,500 2.0 0 .7 2,000 2.2 0 .8 2,500 2.5 0 .9 3,000 2.7 1 .0 4,000 3.1 1 .1 5,000 3.4 1 .2 6,000 3.7 1 .3 7,000 4.0 1 .4 7,500 4.1 1 .5 8,000 4.2 1 .5 9,000 4.5 1 .6 10,000 4.7 1 .7 15,000 5.6 2 .0 20,000 6.5 2 .4 25,000 7.2 2 .6 30,000 7.8 2 .8 40,000 8.9 3 .3 50,000 9.8 3 .6 75,000 12 4.4 100,000 14 5.0 150,000 16 6.1 200,000 19 7.0 250,000 21 7.8 750,000 ** 13 *Report distance as 0.1 m ile ** More than 25 m iles (report distance as 25 m iles)W W T P

- 19- Appendix F
METHANE Methane is present at som e wastewater treatm e nt facilities as a component of digester gas. Ty pical constituents of digester gas are 55 to 70 percent m e thane by volum e, 25 to 30 percent carbon dioxide by volum e, and sm all am ounts of nitrogen and hy drogen. Modern facilities m a y well have processes containing m o re than 10,000 lb of digester gas at any one tim e (the entire quantity of the flam m a ble m i xture in a process m u st be comp ared with the threshold quantity (TQ) of 10,000 lb to determ ine whether the facility is covered; note that digester gas that is used as fuel is not covered). Proceed as follows:

1. Determ ine the density Dm of the m e thane in the digester at operating temp erature T ( o F), assum i ng that there is X volum e percent of m e thane and 100 - X volum e percent of carbon dioxide and other m a terial s. You should determ ine X by analy s is of y our digester gas; if y ou do not know the percentage of m e thane, y ou m a y use 70 percent as a conservative assump tion. If X varies over tim e, y ou should use the largest value of X that is seen in y our facility

. D

m

= 0.22 X/(460+T) (3)

As an example, if X = 65, and the operating temp erature is 95 o F, D m

= 0.026 lb/ft3.

2. Calculate the total volum e V (ft 3 ) occupied by digester gas in one digester (the largest). Associated pipework can be neglected.

V = B r 2 H (4) Here, r is the digester radius and H is the m a xim u m digester head space. As an
example, if H = 8 ft and r = 40 ft, then V = B r 2 H = (3.14)(40) 2 (8) • 40,200 ft 3

. 3. Calculate the quantity Q of m e thane contained in V: Q = D m V (5)

In the current example, Q = (0.026)(40,200) = 1,045 lb Note that this quantity of m e thane itself, as well as the total quantity of digester gas, is less than the 10,000-lb TQ for flam m a bl e m a terials. This is because the total
am ount of digester gas (i.e., not just m e th ane) in a process is used to determ ine whether that process is covered by the regulation (assum i ng the digester gas is not being used as fuel). It m a y be the case that no single digester contains m o re than the TQ of digester gas, but y ou still will be covered if there are several digesters in y our process and the total quantity of digester g as in all of the digesters together exceeds the threshold. However, y ou are required to consider only the quantity of m e thane in a single vessel when calculating the results of a worst-case vapor cloud explosion.Appendix F

- 20- W W T P
4. Use the TNT-equivalency m odel to calculate the distance D (m iles) to the 1 psi overpressure endpoint: D = 0.0082 (Q) 1/3 (6) Equation 6 has been custom ized for m e thane. In the present example, D = 0.0082(1,045) 1/3 = 0.08 m ile. Alternatively , y ou can use Exhibit F-10 to estim ate the distance to the endpoint for a range of quantities of m e thane.
EXHIBIT F-10 Distance to Overpressure Endpoint of 1.0 PSI for Vapor Cloud Explosions of Methane Based on TNT Equivalent Method, 10 Percent Yield Factor

Quantity in Cloud (pounds) Distance to Endpoint

(miles)
500 0.07 2,000 0.1 5,000 0.1 10,000 0.2 20,000 0.2 Quantity in Cloud (pounds) Distance to Endpoint

(miles) 50,000 0.3 100,000 0.4 200,000 0.5 500,000 0.7
1 ,000,000 0.8

Som e facilities have an interm ediate storage vessel for digester gas, at a pressure that
m a y be ty pically 45-50 psig. You should use the quantity of m e thane in such a vessel in Equation 6 or Exhibit F-10 if it contains the largest quantity of digester gas on site.



### F.3.2 Alternative Release Scenarios
This subsection provides guidance on how to choose and m odel alternative scenarios for chlorine, sulfur dioxide, anhy drous am m onia, aqueous am m onia, and m e thane. For inform ation on the general requirem e nts of the regulations pertaining to alternative release scenarios, refer to chapter 4 of the m a in docum ent.
A num ber of scenarios other than those liste d in the rule m a y be worth considering for WTTPs. Many WWTPs have single-stage, pass-through chem ical scrubbers to neutralize compounds such as sulfur dioxide . Failure of the neutralizing solution’s recirculation pump and conti nued operation of the blower fan could not only allow aW W T P

- 21- Appendix F release, but also exacerbate it by m echan ically evacuating the substance from the
room
. Accidents reported to EPA involving chlorine sy stem s have been caused by “rust holes,” failure of a diaphragm , leak during hookup to a tank, a packing nut leak, faulty cy linders, rem oval of a valve in erro r, faulty valves, leaking gaskets, and a blown pressure gauge. Sim ilar accidents involving sulfur dioxide sy stem s have been reported. In addition, natural events, such as floods, tornados, earthquakes, and hurricanes could cause several releases to occur sim u ltaneously . You m a y want to consider these ty pes of scenarios when y ou select y our alternative release scenarios.
CHLORINE

FLASHING LIQUID RELEASES Many of the potential alternative scenarios could involve the release of liquid chlorine from a sm all hole. The liquid chlorine flashes im m e diately to vapor and fine liquid droplets and is carried downwind. The rate of release of a liquid through an hole is given by Bernoulli’ s form ula for liquid releases (see section F.3.4). Using chem ical-specific data for chlorine, the form ula becom es: QR = 3,140 × A h (8)
where:

A h = the area of the hole (in 2 - for example, the area of a hole of diam eter 1 inch is 0.785 in 2 )
3,140 = factor applicable to chlorine liquefied under a pressure of 98.5 psig (see Section F.3.4)
Note that this is the form ula for the release of a pure liquid and would apply to a breach in the wall of a vessel or to the rupture of a very short pipe. For long pipes, there is a pressure drop between the vessel and the hole, and there will be flashing in the pipe and a reduced rate of release. Th erefore, Equation 8 m a y be conservative.
If there is a sm all leak from the liquid sp ace of a large storage vessel, the reservoir can essentially be considered as infinite, and the chlorine will be steadily em itted at a constant rate for a relatively long period. Such leaks m a y occu r because of a gasket failure, a pump seal leak, or a corrosion hole, for example. You can use Equation 8 and the estim ated area of the hole to calculate the release rate (QR). To predict the distance to the toxic endpoi nt, take the calculated value of QR and identify the closest value on Exhibit F-11 (150 lb/m in). Read off the corresponding distance, in this case, 0.6 m ile for a rura l site and 0.2 m ile for an urban site. Alternatively , use Figure F-5.Appendix F

- 22- W W T P Exhibit F-12 provides release rate estim ates for releases of liquid chlorine through holes of diam eter 1/16 inch to 5 inches and the distances to the endpoint corresponding to these release rates. You can u se this table instead of Equation 8 and Exhibit F-11 to estim ate the distance to the endpoint.W W T P

- 23- Appendix F
EXHIBIT F-11 Distances to Toxic Endpoint for Chlorine D Stability, Wind Speed 3 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an
1 < 0.1*

<0.1* 2 0 .1

5 0 .1

10 0.2 0 .1

15 0.2 0 .1

20 0.2 0 .1

30 0.3 0 .1

40 0.3 0 .1

50 0.3 0 .1

60 0.4 0 .2

70 0.4 0 .2

80 0.4 0 .2

90 0.4 0 .2

100 0.5 0 .2

150 0.6 0 .2

200 0.6 0 .3

250 0.7 0 .3

300 0.8 0 .3

400 0.8 0 .4

500 1.0 0 .4

600 1.0 0 .4

700 1.1 0 .4 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an
750 1.2 0 .4

800 1.2 0 .5

900 1.2 0 .5
1,000 1.3 0 .5
1,500 1.6 0 .6
2,000 1.8 0 .6
2,500 2.0 0 .7
3,000 2.2 0 .8
4,000 2.5 0 .8
5,000 2.8 0 .9
7,500 3.4 1 .2
10,000 3.9 1 .3
15,000 4.6 1 .6
20,000 5.3 1 .8
25,000 5.9 2 .0
30,000 6.4 2 .1
40,000 7.3 2 .4
50,000 8.1 2 .7
75,000 9.8 3 .2
100,000 11 3.6
150,000 13 4.2
200,000 15 4.8

* Report distance as 0.1 m ileAppendix F

- 24- W W T P
EXHIBIT F-12 Release Rates and Distance to the E ndpoint for Liquid Chlorine Releases D Stability, Wind Speed 3 Meters per Second

Hole Diameter (inc he s) Release Rate (lb/min) Distanc e (mile s)
Ru ral U rb an
1/16 10 0.2 0 .1
3/16 87 0.4 0 .2
1/4 150 0.6 0 .2
5/16 240 0.7 0 .3
1/2 620 1.0 0 .4
1 2 ,500 2.0 0 .7
2 9 ,900 3.9 1 .3
3 22,200 5.3 1 .8
4 39,500 7.3 2 .4
5 61,700 8.1 2 .7

TWO-PHASE RELEASES
In case of a release from a long pipe carry ing liquid chlorine (L/d h >> 1, where L is the length of the pipe between the reservoi r of chlorine and the atm o sphere and d h is the diam eter of the pipe), there can be fl ashing in the discharge pipe, resulting in a two-phase m i xture em erging to the atm o sphere. In this case, the rate of release in lb/m in for chlorine is given by : QR = 1,100 × A h × F (9)
where: 1,100 = chem ical-specific factor applicable to chlorine at 25 o C (see

A h = Section F.3.4) hole area (in 2 ) = area of pipe opening F = frictional loss factor (dim ensionless) with values as follows: F L/d h 1 10 0.85 50 0.75 100 0.65 200 0.55 400W W T P

- 25- Appendix F Exhibit F-13 presents release rates for a range of pipe diam eters and length-diam eter ratios for two-phase releases of chlorine fro m a pipe. You can read the release rate from the exhibit or calculate the release ra te from Equation 9, then find the distance to the endpoint corresponding to the release rate by referring to Exhibit F-11.
EXHIBIT F-13 Release Rates for Two-Phase Releases from Pipes Carrying Liquid Chlorine

Pipe Diameter (inches) Pipe Length/Diameter (L/d h ) 10 (F=1) 50 (F=0.85) 100 (F=0.75) 200 (F=0.65) 400 (F=0.55) Chlorine Release Rate (lbs/min)

1 / 4 5 4 4 6 4 0 3 5 3 0
5/16 84 72 63 55 46

1/2 220 180 160 140 120
3/4 490 410 360 320 270

1 860 730 650 560 480
2 3 ,500 2,900 2,600 2,200 1,900
3 7 ,800 6,600 5,800 5,100 4,300

VAPOR RELEASES For a choked release of vapor (i.e., em erging at the speed of sound from the hole, which will invariably be the case for chlorine at atm o spheric temp eratures), the release rate for chlorine is given by : QR = 190 × A h (10)
where:
190 = chem ical-specific factor for chlorine at a tank pressure of 113 psia and temp erature 25 o C (see Section F.3.4)

A h = hole area (in 2 ) You can use Equation 10 to estim ate the release rate of chlorine from a hole in the vapor space of a tank. For example, such a hole could result from shearing off a valve at the top of a tank. The distance to th e endpoint can be estim ated from the release rate, using Exhibit F-11 or Figure F-5.Appendix F

- 26- W W T P As an alternative to Equation 10, for releases from holes ranging from 1/16-inch to 5 inches in diam eter, y ou can read the re lease rate and the corresponding distance from Exhibit F-14.

EXHIBIT F-14 Release Rates and Distance to the E ndpoint for Chlorine Vapor Releases D Stability, Wind Speed 3 Meters per Second

Hole Diameter (inches) Release Rate (lbs/min) Distance (miles)
Rural U rban

1/16 0.6 0 .1 0.1
3/16 5 0 .1 0.1

1/4 9 0.2 0 .1
5/16 15 0.2 0 .1

1/2 3 7 0 .3 0.1

1 150 0.6 0 .2
2 600 1.0 0 .4
3 1 ,300 1.6 0 .6
4 2 ,400 2.0 0 .7
5 3 ,700 2.5 0 .8

Note that the release rate estim ated by the m e thod above is conservative. As the release proceeds, chlorine continuously evaporates from the liquid surface in the cy linder. This causes the liquid to cool, the vapor pressure to decrease, and the rate of release to decline. However, the equations for calculating this effect are rather
comp lex and not included in this guidance.
OTHER CHLORINE SCENARIOS If y ou wish to do so, y ou can simp ly quote any of the results above, if they are applicable to y our site, when y ou subm it y our Risk Managem e nt Plan. However, y o u m a y also choose to develop other scenarios, using Equations 8, 9, or 10, and Exhibit F-11 or Figure F-5.W W T P

- 27- Appendix F
DURATION OF RELEASE

You m a y calculate the m a xim u m duration by dividing the quantity in the tank or the quantity that would be released from a pipe by the release rate. You m a y use 60
m i nutes as a default value for m a xim u m release duration. If y ou know, and can substantiate, how long it is likely to take to stop the release, y ou m a y use that tim e as the release duration.


### SULFUR DIOXIDE

FLASHING LIQUID RELEASES
Sulfur dioxide is sim ilar to chlorine in the way that it would be released, so Bernoulli’s form ula is applicable. Using Be rnoulli’s form ula, incorporating chem icalspecific data for sulfur dioxide, y ou can estim ate the release rate from a hole in the liquid space of a tank from the following equation: QR = 2,020 × A h (11)
where:

A h = the area of the hole (in 2 )
2,020 = factor applicable to sulfur dioxide liquefied under a pressure of 43 psig (see Section F.3.4) After y ou have estim ated the release rate, y ou can find the predicted distance to the toxic endpoint for sulfur dioxide from Exhibit F-16 or Figure F-6. Alternatively , y o u can use Exhibit F-15. This exhibit giv es release rates and distances to the endpoint for flashing liquid releases through holes of diam eter 1/16 inch to 5 inches.Appendix F

- 28- W W T P

EXHIBIT F-15 Release Rates and Distance to the Endpo int for Liquid Sulfur Dioxide Releases D Stability, Wind Speed 3 Meters per Second

Hole Diameter (inc he s) Release Rate (lb/min) Distanc e (mile s)
Ru ral U rb an
1/16 6 0 .1 0.1
3/16 56 0.4 0 .2

1/4 9 9 0 .5 0.2
5/16 160 0.6 0 .2

1/2 400 0.9 0 .4

1 1 ,600 1.9 0 .6
2 6 ,300 3.3 1 .1
3 14,300 5.6 1 .7
4 25,300 7.3 2 .1
5 39,600 9.2 2.6

TWO PHASE RELEASES A break in a long pipe (whose length is m u ch greater than its diam eter) carry ing liquid sulfur dioxide can result in the release of a two-phase m i xture, as discussed above for chlorine. The release rate can be estim ated from the following equation: QR = 252 × A h × F (12)
where: 252 = chem ical-specific factor applicable to sulfur dioxide at 25 o C (see Section F.3.4) A h = hole area (in 2 ) = area of pipe opening F = frictional loss factor (dim ensionless) with values as shown in the section on chlorine

You can estim ate the release rate from Equa tion 12, then find the distance to the endpoint corresponding to the release rate by referring to Exhibit F-11. You also can find the release rate for a range of pipe diam eters and L/d h values in Exhibit F-17.W W T P

- 29- Appendix F
Exhibit F-16 Distances to Toxic Endpoint for Sulfur Dioxide D Stability, Wind Speed 3.0 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an
1 < 0.1*

<0.1* 2 0 .1

5 0 .1

10 0.2 0 .1

15 0.2 0 .1

20 0.2 0 .1

30 0.2 0 .1

40 0.3 0 .1

50 0.3 0 .1

60 0.4 0 .2

70 0.4 0 .2

80 0.4 0 .2

90 0.4 0 .2

100 0.5 0 .2

150 0.6 0 .2

200 0.6 0 .2

250 0.7 0 .3

300 0.8 0 .3

400 0.9 0 .4

500 1.0 0 .4

600 1.1 0 .4

700 1.2 0 .4 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an
750 1.3 0 .5

800 1.3 0 .5

900 1.4 0 .5
1,000 1.5 0 .5
1,500 1.9 0 .6
2,000 2.2 0 .7
2,500 2.3 0 .8
3,000 2.7 0 .8
4,000 3.1 1 .0
5,000 3.3 1 .1
7,500 4.0 1 .3
10,000 4.6 1 .4
15,000 5.6 1 .7
20,000 6.5 1 .9
25,000 7.3 2 .1
30,000 8.0 2 .3
40,000 9.2 2 .6
50,000 10 2.9
75,000 13 3.5
100,000 14 4.0
150,000 18 4.7
200,000 20 5.4

* Report distance as 0.1 m ileAppendix F

- 30- W W T P
EXHIBIT F-17 Release Rates for Two-Phase Releases fr om Pipes Carrying Liquid Sulfur Dioxide

Pipe Diameter (inches) Pipe Length/Diameter (L/d h ) 10 (F=1) 50 (F=0.85) 100 (F=0.75) 200 (F=0.65) 400 (F=0.55) Sulfur Dioxide Release Rate (lb/min)

1 / 4 1 2 1 1 9 8 7
5/16 19 16 14 13 11

1 / 2 4 9 4 2 3 7 3 2 2 7
3/4 110 95 83 72 61

1 200 170 150 130 110
2 800 670 600 520 440
3 1 ,800 1,500 1,300 1,200 980

VAPOR RELEASES
For a choked release of sulfur dioxide vapor, the release rate is given: QR = 91 × A h (13)
where:
91 = chem ical-specific factor for sulfur dioxide at a tank pressure of 58 psia and temp erature 25 o C (see Section F.3.4)

A h = hole area (in 2 ) The distance to the endpoint can be estim at ed fromthe release rate, using Exhibit F16 or Figure F-6. As an alternative to Equation 13 and Exhibit F-16, for releases from holes ranging from 1/4 inch to 5 inches in diam eter, y ou can read the release rate and the corresponding distance from Exhibit F-18.W W T P

- 31- Appendix F
EXHIBIT F-18 Release Rates and Distance to Endpoin t for Sulfur Dioxide Vapor Releases D Stability, Wind Speed 3 Meters per Second

Hole Diameter (inc he s) Release Rate (lb/min) Distanc e (mile s)
Ru ral U rb an

1/4 4 0.1 0 .1
5/16 7 0 .1 0.1

1/2 1 8 0 .2 0.1

1 7 1 0 .4 0.2
2 280 0.8 0 .3
3 640 1.1 0 .4
4 1 ,100 1.5 0 .5
5 1 ,800 2.2 0.7

OTHER SULFUR DIOXIDE SCENARIOS If y ou wish to do so, y ou can simp ly quote any of the results above, if they are applicable to y our site, when y ou subm it y our Risk Managem e nt Plan. However, y o u m a y also choose to develop other scenario s, using Equations 11, 12, or 13, and Exhibit F-16 or Figure F-6.
ANHYDROUS AMMONIA
FLASHING LIQUID RELEASES
Like chlorine and sulfur dioxide, am m onia will be liquefied under pressure in its own storage vessel. Bernoulli’ s equation is applicable for flashing liquid releases (see Section F.3.4). The equation for am m onia liquefied under a pressure of 130 psig is: QR = 2,380 × A h (14)
where:

A h = hole area (in 2 )Appendix F

- 32- W W T P 2,380 = chem ical-specific factor for am m onia liquefied under pressure. After y ou have estim ated the release rate, y ou can find the predicted distance to the toxic endpoint for am m onia from Exhibit F-20 or Figure F-7. Alternatively , y ou can use Exhibit F-19. Th is exhibit gives release rates and distances to the endpoint for flashing liquid releases through holes of diam eter 1/16 inch to 5 inches.
EXHIBIT F-19 Release Rates and Distance to the Endpoint for Liquid Ammonia Releases D Stability, Wind Speed 3 Meters per Second

Hole Diameter (inc he s) Release Rate (lb/min) Distanc e (mile s)
Ru ral U rb an
1/16 7 0 .1 0.1
3/16 66 0.2 0 .1

1/4 120 0.2 0 .1
5/16 180 0.4 0 .2

1/2 470 0.4 0 .2

1 1 ,900 0.8 0 .3
2 7 ,500 1.6 0 .5
3 16,800 2.2 0 .7
4 30,000 3.1 1 .0
5 46,800 3.9 1.2W W T P

- 33- Appendix F
EXHIBIT F-20 DISTANCES TO TOX I C ENDPOINT FOR ANHYDROUS AMMONIA D Stability, Wind Speed 3 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an
<10 < 0.1*

<0.1* 10 0.1

15 0.1

20 0.1

30 0.1

40 0.1

50 0.1

60 0.2 0 .1

70 0.2 0 .1

80 0.2 0 .1

90 0.2 0 .1

100 0.2 0 .1

150 0.2 0 .1

200 0.3 0 .1

250 0.3 0 .1

300 0.3 0 .1

400 0.4 0 .2

500 0.4 0 .2

600 0.5 0 .2

700 0.5 0 .2

750 0.5 0 .2

800 0.5 0 .2 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an
900 0.6 0 .2

1 ,000 0.6 0 .2

1 ,500 0.7 0 .3

2 ,000 0.8 0 .3

2 ,500 0.9 0 .3

3 ,000 1.0 0 .4

4 ,000 1.2 0 .4
5,000 1.3 0 .5
7,500 1.6 0 .5
10,000 1.8 0 .6
15,000 2.2 0 .7
20,000 2.5 0 .8
25,000 2.8 0 .9
30,000 3.1 1 .0
40,000 3.5 1 .1
50,000 3.9 1 .2
75,000 4.8 1 .4
100,000 5.4 1 .6
150,000 6.6 1 .9
200,000 7.6 2 .1
250,000 8.4 2 .3

* Report distance as 0.1 m ileAppendix F

- 34- W W T P
AQUEOUS AMMONIA Alternative scenario spills of aqueous am m onia are going to be sim ilar to worst-case scenario spills in that there will be a leak of som e kind and the liquid will either spread across a diked area or spread out until its depth is only 1 cm (0.39 inch). The principal difference will be in the am ount spilled. The calculation of the rate of spillage is again perform ed using Bernoulli’s form ula see Section F.3.4). The density of 30 percen t aqueous am m onia is 57.33 lb/ft3, so the equation becom es: QR L = 153 × A h × (h) 0.5 (15)
where: QR L = rate of spillage of am m onia solution onto the ground (lbs/m in), not the rate of evaporation

A h = hole area (in 2 )

h = static head

For example, for a 1⁄2-inch diam eter opening with a static head h of 10 ft: QR L = 153 × B × (1⁄2×1⁄2) 2 × (10) 1⁄2 = 153 × 3.142 × 1/16 × 3.16 = 95 lb/m in This is the rate of spillage of the total solution of water plus am m onia as a liquid onto the ground. If y ou know, and can docum ent, how long it w ill take to stop the release, y ou should estim ate the total quantity of solution spilled to the ground (QS) by m u ltiply ing the estim ated rate of liquid spillage by the estim ated duration of the release (in m i nutes). Then y ou can estim ate the release rate to air (QR) as the evaporation rate of am m onia from the pool. For an undiked area (pool depth 1 cm ): QR = 0.025QS (16) For a diked pool (pool depth greater than 1 cm ) of area A p square feet: QR = 0.046A p (17)
The m a xim u m area of the pool that would be form ed by the spilled liquid is 0.55QS. If y ou have a diked area that is larger than the m a xim u m area, use the equation for an undiked area to estim ate the release rate to air.W W T P

- 35- Appendix F It is possible that y ou m a y estim ate a rate of evaporation of am m onia from the pool that exceeds the spill rate of the liquid soluti on, particularly if the liquid spill rate is
sm all and the spill of the liquid m a y last for a fairly long tim e. In such a case, under the assump tions used in this estim ation m e thod, no pool would be form ed. Instead of the evaporation rate, in this case, y ou should use the liquid spill rate (QR L ) as the release rate to air.
You also can determ ine how far the pool will spread until the rate of spillage is
m a tched by the rate of evaporation of am m onia. For aqueous am m onia at 77 o F (25

o C), the rate of evaporation is 0.046 A p (from Equation 17). The area that will cause the rate of evapora tion to exactly balance the rate of spillage is given by :
A p = QR/0.046 = 22QR L (18)
In the example given above, QR L = 95 lb/m in, so A p = 2,100 ft 2 . This value should be
comp ared with the available diked area and the sm aller of the two values chosen. Thus, if the diked area happens to be 50 ft x 50 ft = 2,500 ft 2 , the area chosen for subsequent calculation is A p = 2,100 ft 2 and QR = 95 lb/m in. (If the diked area happened to be sm aller — say 20 ft x 20 ft = 400 ft 2 — then the spilled am m onia would cover the diked area, and, using Equation 17, the rate of evaporation QR would be (0.046)(400) = 18 lb/m in.) To predict the distance to the toxic endpoint in ty pical weather conditions, take the value of QR calculated above and identify the closest value on Exhibit F-21. Read off the corresponding distance. For the 95 lb/m in case, the result is 0.2 m ile for a rural site and 0.1 m ile for an urban s ite. Alternatively , use Figure F-8.Appendix F

- 36- W W T P
EXHIBIT F-21 Distance to Toxic Endpoint for Aqueous Ammonia D Stability, Wind Speed 3 Meters per Second

Release Rate Distanc e to Endpoint (mile s)

(lbs/min) Ru ral U rb an
<8 <0.1*

<0.1* 8 0 .1
10 0.1
15 0.1
20 0.1
30 0.1
40 0.1
50 0.2 0 .1
60 0.2 0 .1
70 0.2 0 .1
80 0.2 0 .1
90 0.2 0 .1
100 0.2 0 .1
150 0.3 0 .1
200 0.3 0 .1
250 0.4 0 .2
300 0.4 0 .2
400 0.4 0 .2
500 0.5 0 .2
600 0.6 0 .2
700 0.6 0 .2
750 0.6 0 .2 Re le ase Rate Distanc e to Endpoint (mile s) (lbs/min) Ru ral U rb an
800 0.7 0 .2
900 0.7 0 .3
1 ,000 0.8 0 .3
1 ,500 1.0 0 .4
2 ,000 1.2 0 .4
2 ,500 1.2 0 .4
3 ,000 1.5 0 .5 4,000 1.8 0 .6 5,000 2.0 0 .7 7,500 2.2 0 .7 10,000 2.5 0 .8 15,000 3.1 1 .0 20,000 3.6 1 .2 25,000 4.1 1 .3 30,000 4.4 1 .4 40,000 5.1 1 .6 50,000 5.8 1 .8 75,000 7.1 2 .2 100,000 8.2 2 .5 150,000 10 3.1 200,000 12 3.5

* Report distance as 0.1 m ileW W T P

- 37- Appendix F
METHANE

Consider the case of m e thane released fro m a digester. Assum i ng that the full contents of a digester were released over a few m i nutes (say 10 m i nutes), in the
example given in Section 4.1, the release rate would be 105 lb/m in (total quantity of
m e thane in the digester, 1,053 lb). The LFL for m e thane is 33 m g /L. Conservatively taking digester gas/m e thane as a neutrally buoy ant gas (it will actually rise from the ground), y ou need to use Exhibit F-22 (for a rural site) or Exhibit F-23 (for an urban site) to estim ate the distance to the LFL. From Exhibit F-22, the predicted distance for a release rate of 105 lb/m in is 0.1 m ile at a rural site and, from Exhibit F-23, it is 0.1 m ile at an urban site. It is unlikely that a BLEVE would occur. They are not known to take place in low pressure containm ent such as that of a digester. A pool fire does not need to be considered, because the m e thane is not liquefied.

EXHIBIT F-22 Neutrally Buoyant Plume Distances to Lower Flammability Limit (LFL) Rural Conditions, D Stability, Wind Speed 3.0 Meters per Second

Release Rate Distance to

(lbs/min) Endpoint (miles) 0 - 1,980 0.1 1,980 - 7,260 0.2 7,260 - 17,490 0.3 17,490 - 28,380 0.4 28,380 - 42,900 0.5 42,900 - 56,100 0.6 56,100 - 72,600 0.7 72,600 - 89,100 0.8 89,100 - 108,900 0.9 Release Rate Distance to (lbs/min) Endpoint (miles) 108,900 - 128,700 1.0 128,700 - 148,500 1.1 148,500 - 171,600 1.2 171,600 - 191,400 1.3 191,400 - 224,400 1.4 224,400 - 270,600 1.6 270,600 - 320,100 1.8 320,100 - 363,000 2.0 363,000 - 429,000 2.2Appendix F

- 38- W W T P
EXHIBIT F-23 Neutrally Buoyant Plume Distances to Lower Flammability Limit (LFL) Urban Conditions, D Stability, Wind Speed 3.0 Meters per Second

Release Rate Distance to

(lbs/min) Endpoint (miles) 0 - 4,950 0.1 4,950 - 23,430 0.2 23,430 - 49,500 0.3 49,500 - 85,800 0.4 85,800 - 132,000 0.5 132,000 - 181,500 0.6 181,500 - 240,900 0.7 Release Rate (lbs/min) Distance to Endpoint

(miles) 240,900 - 303,600 0.8 303,600 - 363,000 0.9 363,000 - 462,000 1.0 462,000 - 594,000 1.2 594,000 - 858,000 1.4 858,000 - 1,023,000 1.6
1 ,023,000 - 1,254,000 1.8



### F.3.3 BUILDINGS

In m a ny WWTPs, chlorine and sulfur dioxide cy linders or other vessels are kept indoors. Unless y our cy linders are delivered directly into the building (i.e., they are not unloaded outdoors and m oved inside late r), y ou should not consider buildings in y our worst-case scenario, even though they are passive m itigation sy stem s, because there will be som e tim e when the vessels are outdoors. If y our cy linders are delivered indoors or if y our largest vessel is indoors, y ou m a y want to analy ze the m itigating effects of the building when y ou do y our worst-case analy s is. You m a y also want to consider alternative scenarios that consid er buildings as m itigation sy stem s. Som e buildings are strong, leak-tight buildings that are designed to contain the release of the contents of a one-ton cy linder or other vessel. Som e of them contain scrubbers that activate upon release of chlorine or sulfur dioxide; if these scrubbers function as designed, they can ensure that any release to the external atm o sphere would be sm all. (Scrubbers are active m itigation features that cannot be considered to work for a worst-case scenario.) At the other end of th e spectrum , som e buildings are intended to do no m o re than keep the rain off.
M ITIGA TION OF R ELEA SES O F A NHYDRO US A MMON I A , C H L OR IN E , OR S ULFUR D IOX ID E IN TO B U I LD IN GS
EPA’s RMP Offsite Consequence Analysis Guidance provides a simp le building release-rate- m u ltiplicative factor of 55 percent for toxic gases in both worst-case andW W T P

- 39- Appendix F alternative scenarios (i.e., the predicted rate of release is 55 percent of that for the
sam e accident if it should occur outdoors).

Example: Assum e that there is a liquid chlorine release through a 5/16-inch opening as described in the discussion of chlorine alternative scenarios (see Exhibit F-12). This release takes place indoors and, per the discussion above, is reduced to 55 percent of the release rate of 240 lb/m in, i.e., to 130 lb/m in. From Exhibit F-11, the predicted distance to the toxic endpoint is 0.6 m ile for a rural site and 0.2 m ile for an urban site, comp ared to 0.7 m ile (rural) and 0.3 m ile (urban) for an outdoor release.
The RMP Offsite Consequence Analysis Guidance also provides factors for toxic liquids of 10 percent for worst-case scenario s and 5 percent for alternative scenarios. These factors m a y be used for releases of aqueous am m onia that take place inside buildings. The following discussion provides a m o re sophisticated approach for considering effects of building m itigation for worst-case (if appropriate) and alternative scenarios involving release of gases and m i xtures of gases and entrained liquid. Analy s is of release scenarios inside buildings involves consideration of the structure of the building, liquid rain-out, and release containm ent issues. The procedure addressing these issues which is recom m e nded for developing release rate estim ates for both worst-case (if appropriate) and alternative scenarios is presented in Figure F-9. The release into the building is assum e d to occur over a 10-m i nute period. For the worst-case scenario, the quantity released into the building equals the total quantity in the largest vessel or pipeline. For altern ative scenarios, y ou m u st estim ate the total quantity of am m onia, chlorine, or sulfur dioxide released from the equipm ent over a 10-m i nute period. This 10-m i nute assump tion is m a de to keep this guidance simp le. Calculations of the likely rise in pressure show that, for a release distributed over 10
m i nutes, building failure is unlikely to occu r unless y ou have a very large vessel in a very sm all room . However, if the ratio of room volum e to quantity in the vessel is < 0.1 ft 3 /lb for am m onia and < 0.05 ft 3 /lb for chlorine or sulfur dioxide, y ou should look at the possibility that the room will fail by windows blowing out or doors blowing open. If the release is indoors directed towards a door or window that is potentially open, the release rate to the outside is the total quantity , uniform ly distributed over 10
m i nutes. If the release is indoors and not directed towards a door or window,
m itigation of the release by scrubbing, rain-out, or ventilation dilution m a y occur. If there is a scrubber, the release of m a terial to the environm ent m a y be low. If there is no scrubber, the ventilation rate N v , expressed as room volum es exchanged per hour, is identified, and the room volum e per unit quantity of either am m onia, chlorine, or sulfur dioxide vapor released to the room ( 1 ) and the quantity airborne in the room (Q a ) are calculated for either a vapor or a vapor/liquid release.Appendix F

- 40- W W T P For vapor releases, the am ount of vapor released into the room is clearly Q, so 1 = V/Q. For a flashing liquid release, 20 percent of the release ty pically flashes to vapor,
so 1 = V/(0.2Q). The quantity airborne in the room is the total quantity released from the equipm ent to the room in 10 m i nutes for vapor releases and fourteenths of the total quantity released from the equipm ent to the room in 10 m i nutes for vapor/liquid releases. The basis for this fou r-tenths assump tion is that, in a room , a flashing liquid jet will encounter obstacles that will cause 60 percent of the release to collect as a relatively slowly evaporating pool on the ground. The release over the initial ten m i nutes leads to predictions of higher concentrations downwind than does the slowly evaporating pool; therefore, y ou can consider only the release rate of the airborne m a terial (0.4Q/10) and ignore the evaporating pool in estim ating the distance to the toxic endpoint.
Given the values of N v and 1 , the building m itigation factor (FR 10 ) is identified for 10-m i nute releases of am m onia in Exhibit F-24, and for 10-m i nute releases of either chlorine or sulfur dioxide in Exhibit F-25, respectively

. The release rate to the environm ent is the total quantity airborne in the room , reduced by the building
m itigation factor, distributed uniform ly over 10 m i nutes.
Example: A 25-ton (50,000 lb) chlorine storage vessel is in a room of dim e nsions 40 feet x 40 feet x 30 feet = 48,000 ft 3 . There is a worst-case release, so that the 50,000 lb is released into the building over a period of 10 m i nutes. The release is not adjacent to a potentially open door or window. Because it is a worst-case scenario, the scrubber (if there is one) is notoperating. The ventilation rate N v = 4. The release is a m i xture of vapor and liquid droplets, so that 1 = V/(0.2Q) = 48,000/10,000 = 4.8 ft 3 /lb, and the airborne quantity Q a = 0.4Q = 20,000 lb. From Exhibit F-24, with N v = 4 and 1 = 4.8 (the closest entries on Exhibit F-25 are N v = 5 and 1 = 4.0), FR 10 = 0.46. Therefore, the predicted worst-case scenar io release rate from the building is: 0.46×((0.4×50,000)/10) = 920 lb/m in

Comp are this value with 5,000 lb/m in from an open-air release. From Exhibit F-4, the predicted distance for a 920 lb/m in release at a rural site is 6.3 m iles and, at an urban site, is 2.9 m iles. By comp arison, the 5,000 lb/m in release would lead to corresponding distances of 15 m iles and 7 m iles, respectively

. Example: Take a chlorine alternative scen ario for a flashing liquid release through a 1/4-inch hole (see Section F.3.2). Exhibit F-13 shows a release rate of 150 lbs/m i n for this release. Assum e this release tak es place in a building with no scrubber for 10
m i nutes at a release rate of 150 lb/m in for a total release of 1,500 lb. Assum e that the building has dim e nsions of 50 feet x 25 feet x 20 feet = 25,000 ft 3 . The release is a flashing liquid and, therefore, consists of a m i xture of vapor and liquid. Q a , the quantity that becom es airborne, is (0.4)(1,500) = 600 lb. The quantity of vapor is (0.2)(1,500) = 300 lb. Then 1 = 25,000/300 = 83

. 80. You will have to determ ine N v from the characteristics of y our buildi ng. For this example, assum e that theW W T P

- 41- Appendix F building is being ventilated with N v = 5. From Exhibit F-25, FR 10 = 0.32, so that the rate of release to the external atm o sphere is (0.1)(0.32)(600) = 19 lb/m in. From Exhibit F-11, the predicted distance to the e ndpoint is 0.2 m ile for a rural site and 0.1
m ile for an urban site. For the original re lease rate of 150 lb/m in, the distances to the endpoint are 0.6 m ile for a rural site and 0.2 m ile for an urban site.Appendix F

- 42- W W T P
EXHIBIT F-24 TEN-MINUTE BUILDING RELEASE ATTENUATION FACTORS FOR PROLONGED RELEASES OF ANHYDROUS AMMONIA

1 (ft 3 /lb) N v (hr -1 ) FR 10 (dim) 150.0 0 0.07 1 0 .08 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85
100.0 0 0.11 1 0 .11 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85
50.0 0 0.20 1 0 .20 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85
25.0 0 0.35 1 0 .35 5 0 .35 10 0.51 20 0.71 30 0.80 40 0.85 1 (ft 3 /lb) N v (hr -1 ) FR 10 (dim) 10.0 0 0.61 1 0.61 5 0.61 10 0.61 20 0.71 30 0.80 40 0.85
5.0 0 0.79 1 0.79 5 0.79 10 0.79 20 0.79 30 0.80 40 0.85
1.0 0 0.96 1 0.96 5 0.96 10 0.96 20 0.96 30 0.96 40 0.96
0.5 0 0.98 1 0.98 5 0.98 10 0.98 20 0.98 30 0.98 40 0.98W W T P

- 43- Appendix F
EXHIBIT F-25 TEN-MINUTE BUILDING RELEASE ATTENUATION FACTORS FOR PROLONGED RELEASES OF CHLORINE AND SULFUR DIOX IDE

1 (ft 3 /lb) N v (hr -1 ) FR 10 (dim) 160.0 0 0.02 1 0 .08 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85
80.0 0 0.03 1 0 .08 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85
32.0 0 0.08 1 0 .08 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85
16.0 0 0.15 1 0 .15 5 0 .32 10 0.51 20 0.71 30 0.80 40 0.85 1 (ft 3 /lb) N v (hr -1 ) FR 10 (dim) 8.0 0 0.28 1 0.28 5 0.32 10 0.51 20 0.71 30 0.80 40 0.85
4.0 0 0.46 1 0.46 5 0.46 10 0.51 20 0.71 30 0.80 40 0.85
0.8 0 0.85 1 0.86 5 0.86 10 0.86 20 0.86 30 0.86 40 0.86
0.32 0 0 .94 1 0.94 5 0.94 10 0.94 20 0.94 30 0.94 40 0.94Figure F-1Worst-Case Scenario – Estimated Distances to Toxic Endpoint for ChlorineAtmospheric Stability Class F with Wind Speed 1.5 m/sFigure F-2Worst-Case Scenario – Estimated Distances to Toxic Endpoint for Sulfur DioxideAtmospheric Stability Class F with Wind Speed 1.5 m/sFigure F-3Worst-Case Scenario – Estimated Distancesto Toxic Endpoint for Anhydrous AmmoniaAtmospheric Stability Class F with Wind Speed 1.5 m/sFigure F-4Worst-Case Scenario – Estimated Distancesto Toxic Endpoint for Aqueous AmmoniaAtmospheric Stability Class F with Wind Speed 1.5 m/sFigure F-5Alternative Release Scenario – Estimated Distances to Toxic Endpoint for ChlorineAtmospheric Stability Class D with Wind Speed 3 m/sFigure F-6Alternative Release Scenario – EstimatedDistances to Toxic Endpoint for Sulfur DioxideAtmospheric Stability Class D with Wind Speed 3 m/sFigure F-7Alternative Release Scenario – Estimated Distances to Toxic Endpoint for Anhydrous AmmoniaAtmospheric Stability Class D with Wind Speed 3 m/sFigure F-8Alternative Release Scenario – Estimated Distances to Toxic Endpoint for Aqueous AmmoniaAtmospheric Stability Class D with Wind Speed 3 m/sFigure F-9Guidance on Effectiveness of Building Enclosures for Alternative Release ScenariosIndoorsorOutside?CalculateReleaseRateQR(lb/min)AdjacenttoDoororWindow?IndoorsOutsideYesAirborneMassM= 0.4QCalculateθ=V/(0.2Q)Choose NV(hr-1)IdentifyFR10(ExhibitF-24orF-25)Release Rate =0.1FR10Mlb/minNoReleaseEntirelyVapor?YesNoCalculateθ= V/QAirborneMassM= QScrubber?YesNoReleaseRate=QRlb/minReleaseRate =QRlb/minMinimalReleasetoEnvironmentW W T P

- 53- Appendix F


### F.3.4 Equations

AMMONIA PARTIAL PRESSURE

The ratio R vp (T) of the partial pressure of am m onia at temp erature T o C to the partial pressure at 25 o C is given by the empirical form ula:

R vp (T) = exp[ 10.438 - 717.4/(T + 273.4) - 2132.5/(T + 240.25)]
DENSITY OF METHANE IN DIGESTER


### D

m

= (X/100)(0.0409)(537/(460+T)) = 0.22 X/(460+T)

where 0.0409 lb/ft 3 is the density of pure m e thane at 77 o F (25 o C) and the factor 537/(460+T) represents how the density changes with temp erature, assum i ng that
m e thane obey s the perfect gas law. The effect of the sm all operating pressure in
comp ressing the gas has been ignored.
ALTERNATIVE RELEASE EQUATIONS
B ERNO ULLI ’ S F OR MU LA The rate of release of a liquid through an hole is given by Bernoulli’ s form ula for predicting the rate of release QR (lb/m i n) of liquid from a vessel:

m = A h C d ( 

### D L [ 2g 

### D L (H L - H h ) + 2(P 0 - P a )] ) 2

where:

m = Discharge rate (kilogram s per second)

A h = Opening area (square m e ters)
C d = Discharge coefficient (unitless) g = Gravitational constant (9 .8 m e ters per second squared)


### D

L = Liquid density (kilogram s per cubic m e ter)

P 0 = Storage pressure (Pascals)

P a = Am bient pressure (Pascals)

H L = Liquid height above bottom of container (m eters)

H h = Height of opening (m eters)Appendix F

- 54- W W T P To create the equations in the text, this equation was converted to English units.
G

ASES L IQUEFIED UNDER P RESSURE For gases liquefied under high pressure, the term containing the liquid height in Bernoulli’ s form ula can be neglected. Th e equation for the release rate for gases liquefied under pressure becom es: QR = 32.07×Ah× 

### D L ×(P g / 

### D L ) 0.5

To derive the chem ical specific factors pr esented in the text for gases liquefied under their vapor pressure at 25 o C, the following data were substituted into the equation: Liquefied Gas Liquid Density ( 

### D L ), lbs/ft 3 Tank Vapor Pressure (P g ), psig

Chlorine 97.5 98.5
Sulfur dioxide 91.3 43.3

Am m onia 42.5 130

L

IQUID AT A MBIENT P RESSURE For liquids stored at am bient pressure, th e difference between storage pressure and
am bient pressure is zero, and the pressure term drops out of the equation above. The equation can be rewritten and convert ed to English units as follows: QR = 132.2×A h ×6.4516×10 -4 ×(h) 0.5 ×0.5521×0.8×(2×9.8) 0.5 × 

### D L ×16.018

where: QR = Release rate (pounds per m i nute)
132.2 = Conversion factor for kilogram s per second to pounds per m i nute
A h = Hole area (square inches)
6.4516 x 10 -4 = Conversion factor for square inches to square m e ters (HA) 0.5521= Conversion factor for square root of feet to square root of m e ters (h)

0.8 = Discharge coefficient (0.8)
9.8 = Gravitational constant (m eters per second squared)


### D

L = Liquid density (pounds per cubic foot)W W T P

- 55- Appendix F
16.018 = Conversion factor for pounds per cubi c foot to kilogram s per cubic m e ter
For am m onia solutions, the factor presented in the text was derived assum i ng a density of 57.33 lb/ft 3

. T WO -P HA SE R ELEA SE For long pipes (L/d h >> 1, where L is the length of the pipe between the reservoir of chlorine and the atm o sphere and d h is the pipe diam eter), there can be flashing in the discharge pipe, and a two-phase m i xture em er ges to the atm o sphere. In this case, the rate of release in lb/m in is given by : QR = 9,490(A h )(F)(h L )/[ v lg ([ T + 460] C pl ) 1⁄2 ] where those sy m bols not already defined are:
F a frictional loss factor, which is dim e nsionless and takes on a value of 1 for L/d h = 10, 0.85 for L/d h = 50, 0.75 for L/d h = 100, 0.65 for L/d h = 200, and 0.55 for L/d h = 400

h L the latent heat of vaporization (Btu/lb)

v lg the difference in specific volum e between the gas and liquid (lb/ft 3 )
T the reservoir temp erature ( o F), and

C pl the liquid heat capacity (Btu/lb/ o F)
For chlorine, h L is 124 Btu/lb, v lg = 0.68 lb/ft 3 , T = 77 o F (25 o C), and C pl = 0.222 Btu/lb/ o F
For sulfur dioxide, v lg = 1.55 ft 3 /lb, h L = 80 Btu/lb, C pl = 0.34 Btu/lb/ o F
V AP O R R ELEA SES For a gas release under choked flow conditions (i.e., em erging at the speed of sound from the hole, the m a xim u m flow rate), the following equation can be used to estim ate the release rate:

m = C d A h ( ( p 0 D 0 [2 / ( ( +1)] ( ( +1)/( ( -1) ) 0.5

where:

m = Discharge rate (kg/s)

C d = Discharge coefficientAppendix F

- 56- W W T P
A h = Opening area (m 2) ( = Ratio of specific heats

p 0 = Tank pressure (Pascals)
D

0 = Density (kg/m 3 ) Density ( D 0 ) can be rewritten as a function of pressure and m o lecular weight, based on the ideal gas law:
D

0 = (p 0 ×MW)/R T t where: MW = Molecular weight (kilogram s per kilom o le) R = Gas constant (8,314 Joules per degree-kilom o le)

T t = Tank temp erature (K) The choked flow equation can be rewritten a nd converted to English units as follows: QR = 132.2×A h ×6.4516×10 -4 ×P a ×6895 × 0.8( ( [2 / ( ( +1)] ( ( +1)/( ( -1) ) 0.5 ×(MW/8314×T t ) 0.5

where:

0.8 = Discharge coefficient

132.2 = Conversion factor for lbs/m i n to kg/s 6,895 = Conversion factor for psi to Pascals (p0)
6.4516 x 10 -4 = Conversion factor for square inches to square m e ters (A h )

P a = Absolute pressure in the reservoir/tank (psia)

A h = Hole area (inches)
To derive the chem ical-specific factors for gas releases presented in the text, the temp erature (T t ) was assum e d to be 298 K, and the following chem ical-specific data were substituted into th e choked flow equation:W W T P

- 57­ Appendix F
Gas Molecular Wt (MW) Tank Press. (P a ) (psia) Ratio of Specific Heats ( ( )

Chlorine 70.91 113 1.32
Sulfur dioxide 64.07 58 1.26
LOG-LOG TABLE EQUATIONS This section presents form ulas for estim ating the distance to the endpoint from the rate of release for each of the toxic substances addressed in this appendix. The form ulas are given in the form : D = a (QR) b

where: D = distance to the endpoint (m iles)
a and b = chem ical-specific factors QR = release rate (lbs/m in)
The form ulas for each chem ical were develope d based on the best straight-line fits to the log-log graphs of release rate versus distance (Figures F-1 to F-8). The form ulas are easy to use with a scientific calculator and m a y be used instead of the distance tables or figures. Since the equations are best fits to the curves on Figures F-1 to F-8, they m a y not give exactly the sam e predictions as appear in the corresponding exhibits.
C H L OR IN E
W ORST C ASE The guidance on Figure F-1 is essentially in the form of a straight line on a log-log plot: D = 0.2273(QR) 0.4879 for a rural site, and D = 0.0878(QR) 0.5134 for an urban site

A LTERNATIV E Figure F-5 is roughly a straight line on a log-log plot: D = 0.053(QR) 0.4647 for a rural site, and D = 0.026(QR) 0.4263 for an urban site.Appendix F

- 58- W W T P
S ULFUR D IOX ID E
W

ORST C ASE The guidance on Figure F-2 is essentially in the form of a straight line on a log-log plot: D = 0.165(QR) 0.5562 for a rural site, and D = 0.0726(QR) 0.5419 for an urban site.

A LTERNATIV E The curves on Figure F-6 are approxim a tely straight lines on a log-log plot: D = 0.047(QR) 0.4961 for a rural site, and D = 0.025(QR) 0.4407 for an urban site.
A NHYDRO US A MMON I A
W

ORST C ASE The guidance on Figure F-3 is essentially in the form of a straight line on a log-log plot: D = 0.0607(QR) 0.4923 for a rural site, and D = 0.0443(QR) 0.4782 for an urban site.

A LTERNATIV E The curves on Figure F-7 are approxim a tely straight lines on a log-log plot: D = 0.0222(QR) 0.4780 at a rural site, and D = 0.0130(QR) 0.4164 at an urban site.
A QU E O U S A MMON I A
W

ORST C ASE The guidance on Figure F-4 is essentially in the form of a straight line on a log-log plot: D = 0.0667(QR) 0.4617 for a rural site, and D = 0.0221(QR) 0.4712 for an urban site.W W T P

- 59- Appendix F
A LTERNATIV E The curves on Figure F-8 are roughly straight lines on a log-log plot: D = 0.02(QR) 0.5174 for a rural site, and D = 0.0107(QR) 0.4748 for an urban site.


### F.3.5 Limitations of Results
The guidance in this appendix is sum m a rized in the form of various tables and plots giving the predicted distance to the toxic endpoint as a function of the rate of release. There are upper and lower lim its on the validity of these tables and plots—the m odels used are not valid bey ond 25 m iles, nor at less than 0.06 m ile (100 m ~ 300 feet). It should be noted that the guidance presented in this chapter in the form of plots and tables y i eld estim ates that are am ong m a ny possible. There is, in fact, a wide range of uncertainty , partly due to the still inco mp lete theoretical understanding of the atm o spheric dispersion of large-scale accidental releases of hazardous vapors in the industrial environm ent, partly due to the need to specify the values of a num ber of param e ters, the values of which m a y not be well known, and partly because there are relatively few large-scale experim e ntal data sets with which to “tune” the m odels, especially for the conditions applicable to the worst-case scenario. Therefore, for any given rate of release of a specific m a terial, such as chlorine, there m a y be a wide variety of predictions by analy s ts using different m odels, or using the sam e m odel with different input param e ters. The potentia l range of uncertainty is addressed in the Technical Background Document for Offs ite Consequence Analysis for Anhydrous Ammonia, Aqueous Ammonia, Chlorine and Sulfur Dioxide

. An attemp t has been m a de to develop guida nce in the m i d-range of possibilities, with the hope that the m o st extrem e conservatism s have been rem oved, but which is still
m odestly conservative. As a general (and m u ch simp lified) rule, y ou should not be surprised if, for worst-case scenarios, othe r analy s ts and m odels produce estim ates that m a y be up to a factor of three higher or a factor of three lower than those presented here.
The estim ates in the distance tables in the exhibits and all other estim ates in this appendix for regulated toxic chem icals ar e based upon the m e thods described in the Technical Background Docum e nt. That m e t hod consisted of perform ing a range of sensitivity studies and then choosing guidance that lies within that range.
There are a num ber of caveats of which y ou should be aware. The results given in the exhibits and figur es are not in any absolute sense the “right” or “correct” ones. On the contrary , the Technical Background Docum e nt contains estim ates from m a ny sources. The intention there is to establish a range of uncertainties that m i ght be regarded as reasonable by practitioners in the field of atm o spheric dispersion m odeling, and then to locate a reasonable guidance curveAppendix F

- 60- W W T P (such as Figure F-1) within that range of un certainty . In this way , it is hoped that the following objectives will be achieved:



### — The facts that the results are uncertain and that there is no uniquely “right” result are not disguised.



### — Nevertheless, there is a reasonable solution that is easy to use, and users of this guidance do not have to understand its derivation.
As noted above, the further downwind, the m o re likely it is that y ou are bey ond the range of applicability of any atm o spheric dispersion m odel. That is why , for the 90­ ton railcar release of chlorine, the result is stated as “> 25 m iles.” For such a large release of chlorine, few m odels will estim at e less than this distance, and som e will estim ate considerably m o re. There is no way to avoid the conclusion that the distance to the toxic endpoint for a worst-case release from a 90-ton chlorine railcar is very large, even though the current state of th e m odels does not allow us to say exactly how far “large” is. Note that the discussion in this paragraph applies to railcars that are in the open air. For the 150-lb and one-ton cy linder cases, the r esults are uncertain to within perhaps a factor of 5-10. The Technical Background Docum e nt shows that, under certain
m odeling assump tions, the distances could be perhaps a factor of three larger than those stated above or a factor of three sm aller. You will also alm o st certainly be able to find a computer m odel that can be run to produce even sm aller estim ated distances. If y ou opt to do that, y ou will have to produce justification that the m odeling is reasonable if y ou are audited by an implem enting agency . [Note, however, that y o u are not obliged to use the guidance presente d here; y ou can use whatever m odel y o u want provided that y ou have a solid scientific basis for doing so]

. The fact that these large uncertainties exist explains why it is so difficult to develop a single guidance curve that every one accepts. Many different choices for the guidance could fit
com f ortably within the range of uncertainties.W W T P

- 61- Appendix F


### F.4 Supplemental Accident Prevention Program Information
This section provides additional inform ation specific to WWTPs on implem entation of selected prevention program elem ents, to supplem ent the inform ation provided in the m a in docum ent.


### F.4.1 Safety Information

M AX I M U M I NVENTO RY
You m u st docum ent the m a xim u m intended inventory of any vessel in which y o u store or process a regulated substance above its threshold quantity . The U1A certificates on all vessels constructed under the ASME Boiler and Pressure Vessel Code are kept on file by the National Board. The nom inal nam e plate capacity can also be found on the perm anently attached nam e plate for y our storage tank. The
nam e plate will also have the National Board Num b er for y our vessel, which is the key to retrieving y our U1A form from the Board. These nam e plates m a y be located on one of the hem i spherical heads, the m a nway , or the m a nway cover. The nom inal capacity will usually be the water capac ity , and y ou m a y want to convert it to pounds. If y ou use transportation containers (railcars or tank trucks) as storage vessels, y o u can obtain the capacity from the required DOT nam e plate, identification plate, or specification plate or from the owner of th e containers. Sm aller shipping containers are also m a rked. If y ou are not sure of the capacity of the vessel, y ou can obtain this inform ation from the m a nufacturer of the vessel or tank.
The Chlorine Institute recom m e nds that chlorine tanks not be filled bey ond 95 percent at a m a xim u m temp erature of 122 degrees F. OSHA regulations lim it liquid volum es of unrefrigerated anhy drous am m onia to the following:
Ty pe of Container P ercent by Weight Percent by Volum e Aboveground - Uninsulated 56% 82% Aboveground - Uninsulated* 87.5%

Aboveground - Insulated 57% 83.5% Underground - Uninsulated 58% 85%
*Aboveground uninsulated containers m a y be charged to 87.5 percent by volum e if the temp erature of the anhy drous am m onia being charged is determ ined to be not lower than 30 degrees F or if the charging container is stopped at the first indication of frost or ice form ation on its outside surface and is not resum e d until such frost or ice has disappeared. (29 CFR 1910.111(b)(11))Appendix F

- 62- W W T P Aqueous am m onia m a y be held in various concentrations; y our supplier can provide the density and weight. You can use this inform ation, with y our tank capacity , to estim ate the quantity of am m onia being stored.
The Comp ressed Gas Association provides the following recom m e ndations for filling sulfur dioxide tanks at vary ing temp eratures (CGA pamphlet G-3):

Temp erature of Liquid SO 2 in Tank o F M axim um Safe Volum e Liquid SO 2 in % of Full Volum e at 125% Filling Density
30 86
40 87
50 88
60 89
70 90
80 91
90 92
100 93



### F.4.2 Hazard Review

Som e sample checklists for chem icals at wastewater treatm e nt facilities are provided in section F.5 of this appendix, including:



### — Exhibit F-26 General Conditions , Operation and Maintenance



### — Exhibit F-27 Hum a n Factors



### — Exhibit F-28 Checklists for Chlorine and Sulfur Dioxide



### — Exhibit F-29 Checklist for Anhy drous Am m onia Sy stem s



### — Exhibit F-30 Checklist for Aqueous Am m onia Sy stem s
The examples of What-If questions in Exhibits F-31 through F-35 are derived from a variety of sources, including:



### — “Guidelines for Hazard Evaluation Procedures - Second Edition with Worked Examples,” published by the Center for Chem ical Process Safety (CCPS), New York, 1992WWTP

- 63- Appendix F



### — Information collected from various wastewater treatment facilities during the development of this guidance.



### — Information from industry associations such as the Chlorine Institute, the International Institute of Ammonia Refrigeration (IIAR), and the American Water Works Association (AWWA).


### F.4.3 Additional References
The Chlorine Institute ( http://www.cl2.co m ) publishes information on safe use and handling of chlorine, including:



### — Chlorine Vaporizing Systems (Pamphlet # 9).



### — Cylinder and Ton Container Procedures for Chlorine Packaging (Pamphlet # 17).



### — Maintenance Instructions for Chlorine Institute Standard Safety Valves, Type 1-1/2 JQ (# 39).



### — Maintenance Instructions for Chlorine Institute Standard Angle Valve (#40).



### — Maintenance Instructions for Chlorine Institute Standard Safety Valve, Type 4JQ (#41).



### — Maintenance Instructions for Chlorine Institute Standard Excess Flow Valves (#42).



### — Water and Wastewater Operators Chlorine Handbook (# 155). The Compressed Gas Association publishes information on safe use and handling of compressed gases, including:



### — Anhydrous Ammonia on properties, storage, handling, and use of anhydrous ammonia (Publication ID # G-2).



### — ANSI K61.1, American National Standard Safety Requirements for the Storage and Handling of Anhydrous Ammonia (Publication ID # G-2.1).



### — Sulfur Dioxide on properties, storage, handling, and use of sulfur dioxide (Publication ID # G-3). The Water Environment Federation provides several training programs on wastewater treatment operation and maintena nce (the programs also include general procedures) including the following:Appendix F

- 64- W W T P



### — Basic Course for Wastewater Treatment Plant Operators , Instructor Set Order No. E0100GB, Student Workbook Order No. E0110GB.



### — Intermediate Course for Wastew ater Treatment Plant Operators , Instructor Set Order No. E0295GB, Student Workbook Order No. E0296GB.



### — Chlorination Skill Training Course , Order No. E0312GB. Self Instruction Course.
The Water Environm ent Federation also publishes:



### — Operation and M a intenance of M unicipal W a stewater Treatment Plants (MOP-11).
The Water Environm ent Federation is located at 601 Wy the Street, Alexandria, VA 22134, and can be contacted at (800) 666-0206 or (703) 684-2452. In addition, the following m a y be useful:



### — NFPA-820, Standard for Fire Protection in Wastewater Treatm e nt and Collection Facilities.W W T P

- 65- Appendix F


### F.5 Hazard Review Checklists, What If Questions, and HAZOP Procedures

Exhibit F-26 General Conditions, Operation and Maintenance (For any WWTP)

General Conditions, Operation a nd Maintenance Y es/No/NA C omments Are work areas clean? Are adequate warning signs posted?
Is am bient temp erature norm a lly com f ortable Is lighting sufficient for all operations? Are the right tools provided and used? Is personal protective equipm en t (PPE) provided and adequate? Are containers and tanks protected from vehicular traffic?
Are all flam m a ble and com bustible m a terials kept away from containers, tanks, and feed lines? Are containers, tanks, and feed line areas kept free of any objects that can fall on them (e.g., ladders, shelves? )
Are leak detectors with local and rem o te audible and visible alarm s present, operable, and tested? Are windsocks provided in a visible location?
Are em ergency repair kits available for each ty pe of supply present? Are appropriate em ergency supplies and equipm ent present, including PPE and self-contained breathing apparatus (SCBA)?
Are em ergency num bers posted in an appropriate spot? Are equipm ent, containers, and railcars inspected daily ? Are written operating procedures available to the operators? Are preventative m a intenance, inspections, and testing perform ed
as recom m e nded by the m a nufacturer and industry groups and docum ented?Appendix F

- 66- W W T P
Exhibit F-27 Human Factors (General)

Human Factors Y es/No/NA C omments Have operators been trained on the written operating procedures and the use of PPE in norm a l operations (or for operators on the job before June 21, 1999, have y ou certified that they have the required knowledge, skills, and ability to do their duties safely ) ? Do the operators follow the written operating procedures? Do the operators understand the applicable operating lim its on temp erature, pressure, flow, and level? Do the operators understand th e consequences of deviations above or below applicable operating lim its? Have operators been trained on the correct response to alarm s and conditions that exceed the operating lim its of the sy stem ? Are operators provided with enough inform ation to diagnose alarm s ? Are controls accessible and easily understood? Are labels adequate on instrum e nts and controls?
Are all m a jor components, valves, and piping clearly and
unam b iguously labeled?
Are all components m e ntioned in the procedures adequately labeled? Are safe work practices, such as lockout/tagout, hot work, and line opening procedures followed? Are personnel trained in the em ergency response plan and the use of em ergency kits, PPE, and SCBAs? Are contractors used at the facility ? Are contractors trained to work as safely as y our own employ ees? Do y ou have program s to m onitor that contractors are working safely ?W W T P

- 67- Appendix F
Exhibit F-28 Checklists for Chlorine and Sulfur Dioxide

Chlorine and Sulfur Dioxide - Siting Yes/No/NA C omments Are storage, use, and transfer areas not located uphill from adjacent operations? Are storage, use, and transfer areas located away from sewer openings and other underground structures? Do storage, use, and transfer areas have easy access for
em ergency response? Are storage, use, and transfer areas free of com bustible or incomp atible m a terials and isolated from hy drocarbons in accordance with NFPA Standard No. 49, Hazardous Chem icals Data? Are storage, use and transfer areas downwind of or separated from
m o st operations and support areas and ventilation intakes based on prevailing wind direction? Are storage, use, and transfer areas isolated from sources of corrosion, fire, and explosion and protected from vehicle impact? Are storage, use, and transfer areas located away from residences and facility boundaries? If cy linders are stored outside, are they protected from impact by vehicular traffic?
Chlorine and Sulfur Dioxide - Haz a rd Recognition Y es/No/NA C omments
Are m a terial safety data sheets (MSDSs) readily available to those operating and m a intaining the sy stem ?
Do employ ees understand that there are certain m a terials with which Cl 2 (SO 2 ) m u st not be m i xed?
Do employ ees understand the toxicity , m obility , and ability of Cl 2 (SO 2 ) to sustain com bustion?
Do employ ees understand the consequences of confining liquid Cl 2 (SO 2 ) without a therm a l expansion device?
Do employ ees understand the effect of m o isture on the corrosive potential of Cl 2 (SO 2 )?Appendix F

- 68- W W T P

Do employ ees understand the effects of fire and elevated temp erature on the pressure of confined chlorine (SO 2 ) and the potential for release? Chlorine and Sulfur Dioxide - Container Shipment Unloading Y es/No/NA C omments Is the truck inspected for wheel chocks, proper position, and condition of crane? Are adequate warning signs posted? Are there “stops”? Is the shipm e nt inspected for l eakage, general condition, currency of hy drostatic test, and valve protective housing before accepting? Are containers placed in the 6 o’ clock/12 o’ clock position for storage to reduce the chance of a liquid leak through the valve? Chlorine and Sulfur Dioxide - Bulk Shipment Unloading Y es/No/NA C omments Do procedures call for hand brakes to be set and wheels chocked before unloading? Do procedures call for safety sy stem s to be inspected prior to
m a king connections for unloading or between storage tanks and transfer or distribution sy stem s? For railcars, are derails to protect the open end located at least 50 feet from the car being protected? Are railcars staged at dead-end tracks and guarded against dam a ge from other railcars and m o tor vehicles? Are caution signs placed at each derail and as appropriate in the vicinity of Cl 2 (SO 2 ) storage, use, and transfer areas? Does the transfer operation incorporate an em ergency shutoff sy stem ? Is a suitable operating platform provided at the transfer station for easy access and rapid escape? Is padding air for railcars from a dedicated, flow-lim ited, dry (to ­ 40 E F or below), and oil-free source? Is tank car attended as long as the car is connected, in accordance with DOT regulations? Building and Housing Cl 2 (SO 2 ) Systems Y es/No/NA C omments Does the building conform with local building and fire codes and NFPA-820?W W T P

- 69- Appendix F
Is the building constructed of non-com bustible m a terials? Is continuous leak detection, using area Cl 2 (SO 2 ) m onitors, provided in storage and process areas?
If flam m a ble m a terials are stored or used in the sam e building, are they separated from the Cl 2 (SO 2 ) areas by a fire wall?
Are two or m o re exits provided from each Cl 2 (SO 2 ) storage and process area and building? Is the ventilation sy stem appropriately designed for indoor operations (and scrubbing, if required) by local codes in effect at the tim e of construction or m a jor m odification?
Are the exhaust ducts near floor level and the intake elevated?
Can the exhaust fan be re m o tely started and stopped?
If Cl 2 and SO2 are stored in the sam e building, are storage room s separated as required? Chlorine and Sulfur Dioxide - Piping and Appurtenances Yes/No/NA C omments Do piping specifications m eet Cl 2 (SO 2 ) requirem e nts for the service? Do y ou require suppliers to provi de docum entation that all piping and appurtenances are certified “for chlorine service” or “for sulfur dioxide service” by the m a nufacturer? Are piping sy stem s properly supported, adequately sloped to allow drainage, and with a m i nim u m of low spots? Is all piping protected from all risks of excessive fire or heat? Is an appropriate liquid expansi on device or vapor pressure relief provided on every line segm e nt or device that can be isolated? Chlorine and Sulfur Dioxide - Design Stage Review of New/Modified Process Yes/No/NA C omments

Is the sy stem designed to operate at lowest practical temp eratures and pressures?
If Cl 2 (SO 2 ) dem a nd is low enough, is the sy stem designed to feed gaseous chlorine (SO 2 ) from the storage container, rather than liquid? Have the lengths of liquid Cl 2 (SO 2 ) lines been m i nim i zed (reduces quantity of chlorine in lines available for release)?Appendix F

- 70- W W T P
Are low-pressure alarm s and autom a tic shutoff valves provided on Cl 2 (SO 2 ) feed lines? Are vent-controlled spill collection sump s provided and floors sloped toward sump s for stationary tanks and railcars? Are vaporizers provided with autom a tic gas line shutoff valve, downstream pressure reducing valve, gas flow control valve, temp erature control sy stem and interlocks to shut down gas flow on low vaporizer temp erature, and appropriate alarm s in a continuously m a nned control room ? Do vaporizers have a lim ited heat input capacity ? Are curbs, sump s, and diking that m i nim i ze the surface of potential spills provided for stationary tanks and railcars?W W T P

- 71- Appendix F
Exhibit F-29 Checklist for Anhydrous Ammonia Systems

Anhydrous Ammonia - Basic Rules Y es/No/NA C omments Does the storage tank have a perm anently attached nam e plate? Are container(s) at least 50 feet from wells or other sources of potable water supply ? Are container(s) painted white or other light reflecting colors and
m a intained in good condition? Is the area free of readily ignitable m a terials?
Are all m a in operating valves on ta nks identified to show liquid or vapor service? Anhydrous Ammonia - Appurtenances Yes/No/NA C omments Are all appurtenances designed for m a xim u m working pressure and suitable for am m onia service?
Do all connections to containers have shut-off valves as close to container as practicable (except safety relief devices and gauging devices)?
Are the excess flow and/or backpressure check valves located inside of the container or at a point outside as close as practicable to where line enters container? Are excess flow valves plainly and perm anently m a rked with
nam e of m a nufacturer, catalog num ber, and rated capacity ? Anhydrous Ammonia - Piping Yes/No/NA C omments Are piping and tubing suitable for am m onia service? Are provisions m a de for expansion, contraction, jarring, vibration and settling? Is all exposed piping protected from phy sical dam a ge from vehicles and other undue strain (2,000 lb. pull)? Anhydrous Ammonia - Hoses Yes/No/NA C omments Does the hose conform to TFI-RMA specifications for anhy drous
am m onia? Is it 350 psig working, 1750 psig - burst?Appendix F

- 72- W W T P

Is it m a rked every 5 feet with “Anhy drous Am m onia, xxx psig (m axim um working pressure), m a nufacturer’ s nam e or tradem ark, y ear of m a nufacture? Anhydrous Ammonia - Safety Relief Devices Yes/No/NA C omments Are safety relief valves installed? Are they vented upward and unobs tructed to the atm o sphere? Do they have a Rain/Dust Cap? Are shut-off valves not installed between safety relief valve and container? Are safety relief valves m a rked with “NH3" or “AA”, psig valve is set to start-to-discharge, CFM flow at full open, m a nufacturer’ s nam e , and catalog num ber? Is flow capacity restricted on upstream or downstream side? Are hy drostatic relief valve insta lled between each pair of valves in liquid piping or hose? Anhydrous Ammonia - Safety Yes/No/NA C omments Are there two suitable full face m asks with am m onia canisters as approved by the Bureau of Mines? Are self-contained breathing air apparatus required in concentrated atm o spheres? Is an easily accessible shower or a 50 gallon drum of water available? Anhydrous Ammonia - Transfer of Liquid Y es/No/NA C omments Are pump(s) designed for am m onia service and at least 250 psig working pressure? Does P.D. pump have relief valve installed? Is a 0-400 psi pressure gauge installed on pump discharge? Are loading/unloading lines fitted with back flow check or excess flow valves? Are caution sign(s) posted when rail car(s) are loading/unloading? Are containers equipped with an approved liquid level gauging device (except those filed by weight)?
Are containers fitted with a fixe d tube liquid level gauge at 85% of water capacity ?W W T P

- 73- Appendix F
Anhydrous Ammonia - Stationary Tank Yes/No/NA C omments Are non-refrigerated container(s) designed for a m i nim u m 250 (265 in CA) psig pressure? Are all liquid and vapor connections to container(s) except safety relief valves, liquid gauging and pr essure gauge connections fitted with orifices not larger than No. 54 drill size equipped with excess-flow valves? Are storage containers fitted with a 0-400 psi am m onia gauge? Are they equipped with vapor return valves(s)?
Are containers m a rked on at least two sides with “Anhy drous Am m onia” or “Caution - Am m onia” in contrasting colors and
m i nim u m 4 inch high letters? Is a sign display e d stating nam e , address and phone num ber of nearest representative, agent or owner?
Are containers installed on s ubstantial concrete, m asonry or structural steel supports?
Are am m onia sy stem s protected from possible dam a ge by m oving vehicles?Appendix F

- 74- W W T P
Exhibit F-30 Checklist for Aqueous Ammonia Systems

Anhydrous Ammonia - Basic Rules Y es/No/NA C omments Are storage tank(s) painted white or other light reflecting colors and m a intained in good order? Is storage area free of readily ignitable m a terials? Are storage tank(s) kept away from wells or other sources of potable water supply ? Are storage tank(s) located with ample working space all around? Are storage tank(s) properly vented and away from areas where operators are likely to be? Does receiving sy stem include a vapor return? Is storage capacity adequate to receive full volum e of delivery vehicle? Are storage tank(s) secured against overturn by wind, earthquake and/or floatation?
Are tank bottom ( s) protected from external corrosion? Is aqua am m onia sy stem protected from possible dam a ge from
m oving vehicles? Are storage tank(s) labeled as to content? Are all appurtenances suitable for aqua am m onia service? Are all storage tank(s) fitted with liquid level gauges? Are liquid level gauge(s) adequately protected from phy sical dam a ge? If tubing is used, is it fitted with a fail closed valve? Are all storage tank(s) fitted with overfill fittings or high level alarm s ? Are tank(s) fitted with pressure/vacuum valves?
Is an am m onia gas scrubber sy stem used? Are piping and hose m a terials suitable for aqua am m onia service?W W T P

- 75- Appendix F
Is piping free of strain and provision m a de for expansion, contraction, jarring, vibration and settling? Is all exposed piping protected from phy sical dam a ge from
m oving vehicles and other undue strain? Are hoses securely clamped to hose barbs? Are hoses inspected and renewed periodically to avoid breakage? Are pump(s) designed for aqua am m onia service? Are pump(s) fitted with splash guard around seals? Are pump(s) fitted with coupling guard(s)? Do pump(s) have local start/stop stations? Are two (2) suitable full face m asks with am m onia canisters as approved by the Bureau of Mines available? Is a self-contained breathing air apparatus required in concentrated atm o spheres? Is an easily accessible quick acting shower with bubble fountain or 250-gallon drum of clean water available? Is an extra pair of chem ical splash proof goggles and/or full face shields available?
Is an extra set of am m onia resistant gloves, boots, coat and apron available? Are fire extinguishers and a first aid kit available? Are handlers/operators wearing their goggles and gloves when working with aqua am m onia? Are safety and first aid inform ation posted?
Are em ergency phone num bers and individuals to contact posted?Appendix F

- 76- W W T P
Exhibit F-31 Sample What-If Analysis Procedure

Analysis Procedure . The steps in a What-If/Check list analy s is are as follows:

1. Select the team (personnel experienced in the process)

2. Assem ble inform ation (piping and instrum e ntation drawings (P&IDs), process flow diagram s (PFDs), operating procedures, equipm ent drawings, etc.)

3. Develop a list of What-If questions (use the on es in Exhibits F-32 through F-35 if y ou want)

4. Assem ble y our team in a room where each team m e m b er can view the inform ation
5. Ask each What-If question in turn and determ ine: 

### g What can cause the deviation from design intent that is expressed by the question? 

### g What adverse consequences m i ght follow ? 

### g What are the existing design and procedural safeguards? 

### g Are these safeguards adequate? 

### g If these safeguards are not adequate, wh at additional safeguards does the team
recom m e nd?

6. As the discussion proceeds, record the answers to these questions in tabular form at. Exhibit F-36 provides an example.

7. Do not restrict y ourself to the list of questions that y ou developed before the project started. The team is free to ask additional questions at any tim e.
8. When y ou have finished the What-If questions, proceed to exam ine the checklist. The purpose of this checklist is to ensure that the team has not forgotten any t hing. While y ou are reviewing the checklist, other What-If questions m a y occur to y ou.
9. Make sure that y ou follow up all recom m e ndati ons and action item s that arise from the hazards evaluation.W W T P

- 77- Appendix F
Exhibit F-32 What-If Questions for Chlorine and Sulfur Dioxide Systems
M O VEM ENT O F 1-T ON C L 2 (SO2) C YLI NDERS What if the cy linder is dropped from the lifting apparatus?
What if the truck rolls forward or backward? What if a cy linder rolls and drops from the truck? What if the cy linder swings while being lifted? What if the Cl2 (SO2) container is not empty when rem oved from service?
What if the autom a tic container switchover sy stem fails? What if a Cl2 (SO2) cy linder is delivered instead of SO2 (Cl2 ) What if the cy linder is not in good condition?
T ON C YLI NDERS O N T RUNNI O N , I NCL
. P IGTA I LS , ( SUBHEA D ER LI NES ) TO M AI N H EA DER L IN E S What if pigtails rupture while connected on-line? What if pigtail connections open or leak when pressure is applied?
What if som e thing is dropped onto cy linder or connection? What if cracks develop in the ton cy linder flexible connection? What if liquid Cl2 (SO2) is withdrawn through the vapor lines from the ton cy linder? What if the cy linder valve cannot be closed during an em ergency ? What if there are pinholes or sm all leaks at the fusible plugs? What if ton cy linder ends change shape from concave to convex? What if liquid is trapped between two closed valves and the temp erature rises? What if there is a fire near the cy linders? What if the operator leaves the valve open and disconnects the pigtail? What if water enters the sy stem ?Appendix F

- 78- W W T P
C L 2 (SO2) H EA DERS I N THE C H L OR IN A T ION (S ULFO NA TI O N ) R OOM What if the pressure relief valve sticks open?
What if a valve leaks? What if there is inadequate flow in the gas line (e.g., filter clogged)?
E VA PO RA TO RS

What if there is overpressure in the evaporator? What if there is high temp erature in the evaporator?
What if there is low temp erature in the evaporator? What if rupture disks leak?
What if the vacuum regulator valve fails? What if there is a gas pressure gauge leak?
What if the vacuum regulator check unit fails? What if there is liquid Cl2 (SO2) carry over to the vacuum regulating valve downstream of the evaporator?
C H L OR IN A T ION (S ULFONA TION ) A ND P I PES TO I NJECTO RS
What if there are leaks in th e chlorinator (sulfinator) unit? What if there is rupture of the pipe from the chlorinator to the injector? What if there is backflow of water into the Cl2 (SO2) line? What if the water pump is not working?
G ENERA L What if there is a power failure? What if Cl2 (SO2) is released during m a intenance? What if a Cl2 (SO2) leak is not detected?
What if there is m o isture in the Cl2 (SO2) sy stem ?W W T P

- 79- Appendix F
S CRUBBERS What if the sy stem loses scrubber draft? What if the sy stem loses scrubber solution?
What if the m a nual vent to th e scrubber is opened during operation? What if the leak tightness of the building is comp rom i sed during em ergency operation of the scrubbers?
T A NK T RUCKS What if the liquid hose leaks or ruptures? What if the vapor return hose leaks or ruptures?
What if the truck m oves?
What if the m ass of Cl2 (SO2) in th e truck exceeds the capacity of the tank?
What if the Cl2 tank truck is connected to an SO2 vessel (or vice versa)?
What if there is som e thing other than Cl2 (or SO2) in the truck?
What if there is a fire under or near the truck? What if the truck collides with pipework or a building housing Cl2 (SO2) storage vessels?
R AI L C AR S What if the liquid hose leaks or ruptures? What if the padding air is m o ist? What if the padding air hose ruptures?
What if the railcar m oves? What if the relief valve lifts below the set pressure?
What if there is a fire under or near the truck?
What if there is a fire on or near the railcar?Appendix F

- 80- W W T P
Exhibit F-33 What-If Questions for Ammonia Systems

S TORA GE V ESSEL
What if the vessel is overfilled?
What if there is fire under or near the vessel?
What if the relief valve fails to lift on dem a nd? What if the relief valve opens below its set pressure? What if the deluge sy stem fails to work on dem a nd?
T A NK T RUCK U NLO A DI NG What if the liquid unloading hose partially ruptures? What if the liquid unloading hose comp letely ruptures?
What if the tank truck m oves? What if the tank truck drives away before the hose is disconnected? What if the vapor return hose partially or comp letely ruptures?
What if valves are not comp letely closed before disconnecting the hoses?
What if the tank truck contains som e thing other than am m onia?
What if the am m onia in the tank truck contains excess oxy gen?W W T P

- 81- Appendix F
Exhibit F-34 What-If Questions for Digester Systems

What if som e thing falls onto a digester cover? What if relief valves on a digester open?
What if an interm ediate dig ester gas storage vessel fails? What if air is introduced into the gas collection sy stem ? What if the flare fails to operate? What if the gas collection header leaks or ruptures or becom es blocked? What if a digester gas comp ressor fails catastrophically ? What if there is a digester gas leak in to a building (digester building, comp ressor room , boiler room )? What if the digester gas pressure exceeds the cover pressure rating? What if the floating digester gas cover jam s or tilts?Appendix F

- 82- W W T P
Exhibit F-35 General What-If Questions

What if the am bient temp erature is abnorm a lly high?
What if the am bient temp erature is abnorm a lly low?
What if there is a hurricane?
What if there is a tornado? What if there is flooding? What if there is a heavy snowfall? What if there is an earthquake?
What if there is a tidal wave? What if there is a failure of electric power?Exhibit F-36Example What-If Checklist Log SheetCompany/ Facility:Process Unit:PHA Date:Leader / Secretary:TeamMembers:Description:Drawing Number:ItemEquipment/ActivityQuestionsCausesConsequence/HazardsSafeguardsSafeguardsAdequate?Recommendations4.1Generic Pressure VesselWhatif the set pressure of theequipment SRV is more than thedesign pressureof theequipment?Incorrectly set valve purchasedor returned after maintenance atcontractor’sshopPotential for rupture andrelease ofvessel contentsManufacturerorrepairshop’s QAYNone4.2Generic Pressure VesselWhat is the SRV is incorrectlysized?Design basis for SRVincorrectly chosen or SRV sizedforvaporflow when two-phaseorliquid flow is possibleSRV cannot relievepressure,potentialruptureValvespurchased forspecificserviceYNone4.3Generic PressureVesselWhat if the SRV opens belowVibration,incorrect design,Release of vaporatPMprogramNDevelop PMits set pressure?weakened SRV spring, failurerelatively low pressureprogramforSRVsdue to inadequate PMprogram4.4Generic Pressure VesselWhat ifthere is a fire near orunderthe vessel?Spillage of flammable liquidfromnearbyvesselHigh pressurein vessel,potential ruptureSRVsDelugesystemYNoneSeparationDistancesKeepflammablesaway fromvesselAppendix F

- 84- W W T P
Exhibit F-37 HAZ O P Analysis Guide Words, Meanings, and Process Parameters

In this approach, each guide word is com b ined with relevant process param e ters and applied at each point (study node, process section, or operating step) in the process that is being exam ined.

Guide Words M eaning
No Negation of the Design Intent
Less Quantitative Decrease
More Quantitative Increase
Part Of Other Material Present by Intent
As Well As Other Materials Present Unintentionally
Reverse L ogical Opposite of the Intent
Other Than Comp lete Substitution

Common HAZ O P Analysis Process Parameters

Flow Tim e Frequency M ixing
Pressure Composition V iscosity Addition
Temp erature p H V oltage Separation
Level S peed Inform ation R eaction
The following is an example of creating deviations using guide words and process param e ters:
Guide Words Param e ter Deviation NO + FLOW = NO FLOW MORE + P RESSURE = H IGH PRESSURE AS WELL AS + ONE PHASE = TWO PHASE OTHER THAN + O PERATION = MAINTENANCE MORE + LEVEL = H IGH LEVELW W T P

- 85- Appendix F
Guide words are applied to both the m o re ge neral param e ters (e.g., react, m i x) and the
m o re specific param e ters (e.g., pressure, temp erature). With the general param e ters, it is not unusual to have m o re than one devia tion from the application of one guide word. For example, “m ore reaction” could m ean either that a re a c t i o n takes place at a faster rate, or that a greater quantity of product r esults. On the other hand, som e com b inations of guide words and param e ters will y i eld no sensible deviation (e.g., “as well as” with “pressure”).
How to Perform a Haz a rd and Operability (HAZ OP) Review

1. Select the team

. 2

. Assem ble inform ation (P&IDs, PFDs, operating procedures, equipm ent drawings , etc.).
3. Assem ble y our team in a room where each team m e m b er can view P&IDs.

4. Divide the sy stem y ou are reviewing in to nodes (y ou can preset the nodes, or the team can choose them as y ou go along).
5. Apply appropriate deviations to each node. For each deviation, address the following questions:



### — What can cause the deviation from design intent?



### — What adverse consequences m i ght follow ?



### — What are the existing design and procedural safeguards?



### — Are these safeguards adequate?



### — If these safeguards are not adequate, what does the team recom m e nd?

6. As the d i s c ussion proceeds, record the answers to these questions in tabular form at as shown below.Node No:From:To:Drawing No:Line ID:Date:Node Description:1Tanker TruckAmmonia Storage VesselLiquid loading line fromtanker trucktoammonia storage vesselKeywordDeviationCausesConsequencesSafeguardsAdequate?RecommendationsFlowHighNone IdentifiedNoneN/ANFlowLowMalfunction of truck equipment,blockage in line,excess pressure in tankor check valve failureOperational ProblemsN/ANFlowNoMalfunction of truck equipment,orvaporlineexcess flow valve snaps shutHose RuptureOperational ProblemsAmmonia LeakN/AEmergencyshutdownfeaturesNNY1FlowReverseCheck valve and excess flow valve failurewithhose ruptureBlock valves not closed when hose disconnectedVaporrelease fromvesselVaporrelease fromvesselCheck valve, excessflow valve,and hoseinspectionsOperator TrainingYYNNFlowWrong TypeDeliveryof wrong materialUnknownOperational safeguardsYNFlowIn AdditionWater, oxygen, oilContamination, corrosionManufacturer’s qualitycontrolYNPressureHighValve closed, blockage, overfill vesselAmmonia overflow or ruptureRelief valves, levelgaugesYN1Arbitraryexample of recommendation: Currently, the truck must parksofar awayfromthe tank that it isnecessaryto connect two lengths of hose.Investigate thewaysin which truck unloading can be accomplished using onlyone length of hose.