System Safety Engineering Project - Team 15

!
System!Safety!Engineering!
SENG!312/674!
Spring!2015!
Professor!Alim!Dewan!Ph.D.!
!
Rubber Replication Inc.

System Safety Program Plan
for production of
Triallyl Cyanurate
Due!April!19,!2015!
!
!
Submitted!by!Team!#15!
Kate!Godfrey!
Emily!Sturgell!
Andrew!Bohuslav!
Hana!Warren!
!
!
1!
Table&of&Contents&
Executive!Summary!.................................................................................................................!4!
PART!I:!SAFETY!PROGRAM!&!POLICY!ADMINISTRATION!...........................................!5!
I.1!INTRODUCTION!R!POLICY!&!PURPOSE!..................................................................................!5!
I.1.1!Purpose!......................................................................................................................................................!5!
I.1.2!Scope!...........................................................................................................................................................!5!
I.1.3!Policy!&!Objectives!...............................................................................................................................!7!
I.1.4!References!................................................................................................................................................!7!
I.2!SYSTEM!SAFETY!ADMINISTRATION!&!ORGANIZATION!..................................................!7!
I.2.1!Functions!and!Responsibilities!...........................................................................................!7!
I.2.2!Safety,!Health,!and!Environmental!Committees!......................................................................!7!
I.2.3!Safety!Engineering!Staff!......................................................................................................................!8!
I.2.4!Acquisition!Responsibilities!.............................................................................................................!8!
I.2.5!Safety!Engineering!Standards!..........................................................................................................!8!
I.2.6!Waivers!......................................................................................................................................................!8!
I.3!SYSTEM!SAFETY!METHODOLOGY!..........................................................................................!8!
I.3.1!Hazard!Reduction!Precedence!.........................................................................................................!8!
I.3.2!Hazard!Inspection!and!Abatement!................................................................................................!9!
I.3.3!Hazard!Resolution!Process!...............................................................................................................!9!
I.3.4!Hazard!Tracking!.....................................................................................................................................!9!
I.4!SAFETY!ASSESSMENT!.................................................................................................................!9!
I.4.1!System!Life!Cycle!Safety!Activities!.................................................................................................!9!
I.4.2!System!Safety!Analyses!.......................................................................................................................!9!
I.4.3!Trend!Analyses!....................................................................................................................................!20!
I.5!SAFETY!VERIFICATION!TASKS!.............................................................................................!20!
I.5.1!System!Safety!in!the!Design!Review!...........................................................................................!20!
I.5.2!Change!Order!Review!and!Signatory!Authority!....................................................................!20!
I.5.3!Inputs!to!Specifications!....................................................................................................................!20!
I.5.4!Acquisition!Tests!................................................................................................................................!20!
I.5.5!Operational!Tests!...............................................................................................................................!20!
I.5.6!Safety!Tests!...........................................................................................................................................!20!
I.6!SAFETY!TRAINING!AND!AWARENESS!................................................................................!21!
I.6.1!Employees!RightYtoYknow!.............................................................................................................!21!
I.6.2!Safety!Awareness!and!Training!....................................................................................................!21!
I.6.3!Personnel!Certification!for!Hazardous!Operations!..............................................................!21!
I.7!RISK!MANAGEMENT!.................................................................................................................!21!
I.7.1!Risk!Assessment!.................................................................................................................................!21!
I.7.2!Risk!Acceptance!Criteria!.................................................................................................................!22!
I.8!ACCIDENT!REPORTING,!INVESTIGATION,!AND!RECORD!KEEPING!..........................!22!
I.8.1!Reporting!the!Accident!....................................................................................................................!22!
I.8.2!Forming!an!Investigation!Board!..................................................................................................!22!
I.8.3!Documenting!the!Accident!.............................................................................................................!22!
I.8.4!Corrective!Action!&!Verification!of!Corrective!Action!........................................................!24!
I.8.5!OSHA!and!EPA!Mishap!Notification!Reporting!and!Record!Keeping!...........................!24!
I.8.7!Informing!the!Public!.........................................................................................................................!24!
I.9!EMERGENCY!PREPAREDNESS!PLAN!...................................................................................!24!
I.9.1!Emergency!Preparedness!and!Response!Analysis!...............................................................!24!
I.9.2!Emergency!Response!and!Community!Services!...................................................................!25!
2!
I.9.3!Emergency!Preparedness!Training!............................................................................................!25!
I.10!ENVIRONMENTAL!PROTECTION!AND!OCCUPATIONAL!HEALTH!...........................!25!
I.10.1!Hazardous!Materials!and!Chemicals!Control!.......................................................................!25!
I.10.2!Environmental!Compliance!Control!........................................................................................!25!
I.10.3!Occupational!Health!.......................................................................................................................!25!
I.11!SUBCONTRACTOR!SAFETY!PROGRAMS!REVIEW!AND!EVALUATION!....................!25!
I.11.1!Oversight!and!Methods!.................................................................................................................!25!
I.11.2!SelfYEvaluations!................................................................................................................................!26!
I.11.3!Evaluation!of!Transient!Contractors!.......................................................................................!26!
I.12!SAFETY!COMPLIANCE!...........................................................................................................!26!
I.12.1!Documentation!and!Configuration!Control!..........................................................................!26!
I.12.2!Preparing!for!Internal!Safety!Audits!.......................................................................................!26!
I.12.3!OSHA!Audits!.......................................................................................................................................!26!
PART!II:!OPERATIONAL!SAFETY!REQUIREMENTS!.....................................................!26!
II.1!OPERATIONAL!SYSTEM!SAFETY!PLANS!&!PROCEDURES!...........................................!26!
II.1.1!Hazardous!Operations!Procedures!...........................................................................................!26!
II.1.2!Construction!Safety!..........................................................................................................................!27!
II.1.3!Safety!Design!Requirements!........................................................................................................!27!
3!
Executive&Summary&
This%paper%outlines%Rubber%Replication%Inc.s%system%safety%program%plan%to%produce%a%Triallyl%
Cyanurate%plant%near%College%Station,%TX.%%This%plant%will%be%built%to%the%highest%standards%and%
will%meet%the%OSHA%and%EPA%standards%prescribed%for%a%production%process%of%this%type.%%In%this%
SSPP%we%use%the%MFG%Chemical%Company%incident%on%April%12,%2004%as%a%case%study%to%learn%
from.%%In%this%plan%we%create%a%PHL,%PHA,%SHA,%SSHA,%Swiss%Cheese%model,%and%a%Fault%Tree%
Analysis%using%the%MFG%Chemical%case%study%to%showcase%various%hazard%analysis%techniques%
that%our%SSPP%calls%for.%
%
4!
PART&I:&SAFETY&PROGRAM&&&POLICY&ADMINISTRATION&
I.1&INTRODUCTION&H&POLICY&&&PURPOSE&
I.1.1&Purpose&
Rubber%Replication%Inc.%plans%to%build%a%new%triallyl%cyanurate%(TAC)%production%plant%near%
College%Station,%TX.%The%production%of%TAC%is%one%that%involves%extreme%care%considering%the%
formation%reaction%is%extremely%exothermic%and%involves%a%high%reaction%rate.%With%extremely%
exothermic%reactions%and%high%reaction%rates,%the%probability%for%risk%and%hazards%is%high.%With%
that%said,%Rubber%Replication%Inc.%finds%it%vital%to%have%a%strong%System%Safety%Program%Plan%
(SSPP)%in%place.%
I.1.2&Scope&
The% scope% of% this% document% will% include% the% planned% tasks% and% activities% to% be% used% by% a%
contractor% to% implement% a% system% safety% program% (SSP).% It% shall% include% the% organizational%
responsibilities,% resources,% methods% of% accomplishment,% milestones,% depth% of% effort,% and%
integration%with%other%program%engineering%and%management%activities%and%related%systems.%
[1]%
In% order% to% help% with% the% understanding% and% implementation% of% this% SSPP,% a% case% study% for%
another%TAC%production%plant%will%be%referenced.%This%plant,%owned%by%MFG%Chemical%Inc.,%had%
an% incident% on% April% 12,% 2004% that% was% investigated% by% the% CSB.% This% investigation% provided% a%
stepping% stone% in% the% creation% of% this% SSPP% by% highlighting% issues% in% the% safe% design% and%
operation%of%a%TAC%production%facility.%
Background% information% regarding% TAC% Process% Chemistry% and% the% MFG% Chemical% case% study%
can%be%found%below%and%is%included%for%the%completeness%of%this%report.%
I.1.2.1&TAC&Process&Chemistry&
Triallyl% cyanurate,% TAC,% is% produced% in% a% reaction% between% allyl% alcohol% and% cyanuric% chloride.%
This%reaction%produces%both%TAC%and%hydrochloride,%HCl.%This%reaction%can%include%the%use%of%a%
catalyst.%The%TAC%production%reaction%is%extremely%exothermic%(e.g.%produces%a%high%amount%of%
heat).%
Allyl%alcohol%is%extremely%flammable;%the%National%Fire%Protection%Agency%considers%it%a%Class%IB%
flammable%liquid.%It%is%also%highly%toxic%and%is%a%severe%inhalation,%skin%absorption,%and%ingestion%
hazard.% When% used% in% quantities% of% 10,000% pounds% or% more,% OSHA% considers% the% chemical% a%
Process% Safety% Management% regulated% flammable% liquid.% In% quantities% of% 15,000% pounds% or%
more,%the%EPA%considers%allyl%alcohol%a%Risk%Management%Plan%regulated%toxic%chemical.%
Cyanuric%chloride%is%a%highly%reactive%crystalline%powder.%It%is%also%a%strong%irritant%to%the%skin,%
eyes,%mucus%membranes,%respiratory%system,%and%gastrointestinal%tract.%
I.1.2.2&MFG&Chemical&Case&Study&
An%attempt%to%manufacture%TAC%at%an%MFG%Chemical%Inc.%plant%in%Georgia%resulted%in%a%
catastrophic%runaway%reaction%and%toxic%chemical%release%to%the%environment.%The%incident%was%
!
5!
investigated%by%the%U.S.%Chemical%Safety%And%Hazard%Investigation%Board.%The%root%causes%of%the%
incident%were%identified%and%analyzed.%The%top]level%decision%makers%of%the%company%did%not%
investigate%the%chemical%reactivity%of%the%reactants%and%did%not%anticipate%the%high%level%of%
exothermic%activity%involved%in%the%reaction%they%were%attempting%to%initiate.%This%led%to%
inadequate%information%exchange%with%those%directly%involved%in%the%manufacturing%process,%
including:%the%contractor%who%supplied%the%reactor%vessel%coolant%system,%the%employees%who%
operated%the%reactor,%the%employees%who%added%the%reactants%to%the%reactor%vessel,%and%the%
employees%who%made%the%initial%report%to%the%local%emergency%response%personnel.%
Since%the%reaction%was%not%listed%to%produce%a%varying%and%intense%amount%of%heat,%the%
contractor%who%installed%the%coolant%system%did%not%include%an%adjustment%mechanism%to%allow%
the%employees%to%control%the%level%of%coolant%entering%the%reactor%vessel.%Again%due%to%the%lack%
of%communication%from%top]level%company%officials,%the%employees%did%not%add%the%reactants%
slowly%to%control%the%rate%and%temperature%of%the%reaction,%and%instead%rapidly%added%the%entire%
amounts%of%both%reactants%and%a%catalyst%to%the%reactor%vessel%and%activated%the%agitator%
immediately.%When%the%initial%mishap%occurred,%the%blowing%of%the%manway%cover%of%the%reactor%
vessel,%the%employee%who%informed%the%local%emergency%authorities%did%not%understand%the%full%
danger%of%the%runaway%reaction%because%some%of%the%chemistry%of%the%process%was%unknown%to%
the%management%and,%by%extension,%the%employees.%
%
Figure:%MFG%TAC%Production%Process%Design%
6!
I.1.3&Policy&&&Objectives&
Rubber%Replication%Inc.%is%committed%to%the%safe%design,%implementation,%and%operation%of%this%
upcoming%TAC%production%plant.%We%value%employee%safety%and%corporate%responsibility%to%the%
environment%and%the%public.%%Our%new%operations%will%be%held%to%the%highest%degree%of%safety%
and%environmental%stewardship.%%We%ensure%our%operations%meet%the%federal%standards%and%
compile%with%OSHA%regulations%and%EPA%regulations.%%
I.1.4&References&
[1].% Ericson,% Clifton% A.% Hazard% Analysis% Techniques% for% System% Safety.% Hoboken,% NJ:% Wiley]
Interscience,%2005.%Print.%
[2]% Bahr,% Nicholas% J.% System% Safety% Engineering% and% Risk% Assessment:% A% Practical% Approach.%
Washington,%DC:%Taylor%&%Francis,%1997.%Print.%
[3]% U.S.% Chemical% Safety% And% Hazard% Investigation% Board,% 2006,% Investigation% Report:% Toxic%
Chemical%Vapor%Cloud%Release%at%MFG%Chemical,%Inc.,%(Report%No.%2004]09]I]GA)%
[4]%Occupational%Safety%and%Health%Administration%(OSHA),%PSM%Program%
[5]%US%Environmental%Protection%Agency%(EPA),%RMP%
%
I.2&SYSTEM&SAFETY&ADMINISTRATION&&&ORGANIZATION&
I.2.1&Functions&and&Responsibilities&
To%show%Rubber%Replications%dedication%to%the%safety%of%this%facility,%a%chief%safety%officer%will%be%
appointed%who%will%oversee%the%Safety,%Health,%and%Environmental%committees%and%direct%the%
general%workings%of%the%safety%engineering%staff.%
I.2.2&Safety,&Health,&and&Environmental&Committees&
Three%committees%will%be%created%to%oversee%the%safety%of%the%facility.%
The% Safety% Committee% will% oversee% the% safe% working% and% operation% of% the% facility% and% will% be%
brought% together% to% discuss% the% main% findings% of% the% Health% and% Environmental% Committees.%
This% committee% will% include% all% facility% managers% in% order% to% spread% safety% awareness% to% all%
facility%functions.%
The%Health%Committee%will%oversee%compliance%with%OSHAs%Process%Safety%Management%plan,%
dealing% with% the% requirements% for% handling% hazardous% substances% and% focusing% on% protecting%
on]site%personnel.%
%The%Environmental%Committee%will%oversee%compliance%with%EPAs%Risk%Management%Plan,%with%
the% aim% to% decrease% the% number% and% magnitude% of% incidents,% focusing% on% protecting% off]site%
people%and%the%environment.%
7!
I.2.3&Safety&Engineering&Staff&
A%safety%engineering%staff%will%be%assembled%and%dedicated%to%ensuring%the%smooth%working%of%
the% Safety,% Health,% and% Environmental% Committees.% They% will% be% in% charge% of% maintaining%
committee% meeting% minutes,% ensuring% follow% through% on% committee% meeting% decisions,% and%
maintaining% documentation% of% all% safety% related% components% and% incidents.% They% will% also%
hands]on%ensure%that%OSHA%recordkeeping%requirements%are%being%met.%
I.2.4&Acquisition&Responsibilities&
During%the%acquisition%of%the%new%plant%the%follow%will%be%performed%during%the%acquisition%
process%as%part%of%their%Responsibility%to%create%a%safe%process.%%
%
Comprehensive%Process%Hazards%Analysis%
This%process%Hazards%analysis%includes%all%possible%hazards%to%the%system.%This%will%
be%performed%before%the%system%is%built%to%ensure%the%system%to%be%built%will%
meet%a%strict%level%of%safety%
Pre]startup%review%
This%review%is%performed%to%include%the%hazards%and%ensure%the%process%is%safe%
before%startup,%and%that%the%proper%precautions%are%taken%to%ensure%the%safety%of%
the%operators.%
Review%of%Emergency%Response%elements%
This%review%should%take%into%account%the%local%first%responders%and%how%they%
would%respond%to%a%potential%emergency.%%During%the%acquisition%of%the%new%
plant%it%is%required%by%OSHA%that%%
I.2.5&Safety&Engineering&Standards&
This%process%meets%the%requirements%for%the%OSHA%PSM%requirements.%%This%outlines%the%
requirements%of%management%of%the%process.%These%requirements%ensure%that%the%systems%on%
going%operation%are%safe.%%In%addition%to%these%requirements%there%are%codes%that%apply%to%the%
sizing%of%relief%valves.%%
I.2.6&Waivers&
Waivers%to%any%of%the%requirements%outlined%in%this%SSPP%must%be%unanimously%approved%by%the%
Safety%Committee.%
%
I.3&SYSTEM&SAFETY&METHODOLOGY&
I.3.1&Hazard&Reduction&Precedence&
In%systems%safety,%the%Hazard%Reduction%precedence%is%set%by%the%hazard%which%has%the%highest%
probability%of%incident%and%will%cause%the%most%damage.%Refer%to%Section%I.7.1%for%determination%
8!
of% risk.% Any% hazard% within% the% orange% or% red% zones% is% to% be% addressed% within% the% Safety%
Committee%and%brought%down%to%the%yellow%zone%as%soon%as%possible.%
I.3.2&Hazard&Inspection&and&Abatement&
All%hazards%will%have%documentation%maintained%by%the%Safety%Engineering%Staff.%Within%these%
documentations,%each%hazard%is%to%have%a%quarterly%inspection%report%to%lower%its%hazard%level.%
Should%the%hazard%level%increase,%the%hazard%is%to%be%brought%to%the%attention%of%the%Safety%
Committee.%
I.3.3&Hazard&Resolution&Process&
All%hazards%within%the%red%and%orange%zones%are%to%have%an%adequate%timeline%with%milestones%
in%order%to%address%the%lowering%of%the%hazard%risk.%This%timeline%is%to%be%maintained%and%
updated%throughout%the%hazard%resolution%process.%
I.3.4&Hazard&Tracking&
All% hazards% will% have% documentation% maintained% by% the% Safety% Engineering% Staff.% All% near]
misses,% incidents,% major% incidents,% and% fatalities% are% to% be% reported% to% the% Safety% Engineering%
staff% and% analyzed% by% the% Safety% Engineering% staff% utilizing% the% pyramid% scheme.% Should% the%
facilitys%pyramid%not%meet%general%good%safety%practices%standards,%it%is%to%be%brought%to%the%
Safety%Committee's%attention.%
The%Safety%Engineering%staff%is%to%maintain%OSHA%PSM%recordkeeping%standards.%
%
I.4&SAFETY&ASSESSMENT&
I.4.1&System&Life&Cycle&Safety&Activities&&&
Each%system%is%to%have%a%comprehensive%safety%evaluation%during%its%design,%implementation,%
and%operating%phases.%These%safety%evaluations%are%to%include%at%least%two%pertinent%safety%
hazard%analyses.%Each%phase%is%to%also%have%a%working%emergency%response%plan%in%case%of%an%
incident.%Refer%to%Section%I.9.%
I.4.2&System&Safety&Analyses&&
System% Safety% Analyses% are% to% be% conducted% every% five% years% to% comply% with% OSHAs% PSM%
regulations.% Internal% system% safety% analyses% are% to% be% done% before% and% after% every% system%
change.%%
Example%system%safety%analyses%utilizing%the%MFG%Chemical%case%study%are%below.%
I.4.2.1&Preliminary&Hazard&List&&
To%be%conducted%every%five%years%to%comply%with%OSHAs%PSM%regulations.%
%
9!
I.4.2.1.1&Preliminary&Hazard&List&
!
Preliminary&Hazard&List&(PHL)&
System'Element'Type:'Chemicals'
No.&
PHL01&
PHL02&
PHL03&
System&Item&
Analyst:'Emily&Sturgell&
Hazard&
Hazard&Effect&
Extremely&flammable&
Could&start&fire&in&storage&
vessel&or&reactor&
&&
Toxic&
Harmful&to&workers&who&inhale,&
contact,&or&ingest&vapors&or&
liquid&
Protection&equipment&must&be&
worn&by&all&who&handle&or&work&
near&liquid&or&vapors&
Highly&reactive&
Could&cause&runaway&reaction&
Control&rate&of&reactant&addition&to&
reactor&vessel&to&control&reaction&
speed&
Strong&irritant&
Harmful&to&workers&who&ingest&
or&touch&crystals&
&&
Spontaneously&decomposes&in&
exothermic&reaction&
Undergoes&spontaneous&
exothermic&decomposition&
reaction&at&high&temperatures&
Cooling&must&be&maintained&to&
avoid&decomposition&reaction&
Highly&flammable&
Could&start&fire&in&reactor&
&&
Strong&irritant&
liquid&
Toxic&
liquid&
Allyl&Alcohol&
Cyanuric&Chloride&
Allyl&Chloride&
Comments&
PHL04&
Triallyl&Cyanurate&
Spontaneously&polymerizes&in&
exothermic&reaction&
Ruin&product&
Must&use&inhibitor&
PHL05&
Hydrogen&Chloride&
Acidic&
May&change&chemical&
conditions&within&reactor&
Must&use&neutralizer&
System'Element'Type:&System&Hardware'
No.&
System&Item&
Hazard&
PHL06&
Comments&
Breakdown&
Catastrophic&runaway&reaction&
&&
Ineffective&coolant&levels&
Catastrophic&runaway&reaction&
Must&be&easily&adjustable&
Reactor&Vessel&Coolant&System&
PHL07&
Reactor&Vessel&
Over&pressurization&
Explosion&and&toxic&chemical&
release&to&environment&
Relief&valve&with&scrubbers&or&
other&safety&equipment&is&
necessary&
PHL08&
Allyl&Alcohol&Storage&Vessel&
Leak&
Toxic&chemical&release&to&
environment&
Scrubbers&and&other&safety&
equipment&are&necessary&
PHL09&
Cyanuric&Chloride&Storage&
Vessel&
Leak&
Chemical&release&to&environment&
PHL010&
Allyl&Alcohol&Pipeline&
Isolation&valve&malfunction&
Inability&to&control&rate&of&
reaction&could&result&in&runaway&
reaction&
&&
Unmixed&reactants&may&build&up&
to&unsafe&levels&
&&
Unmixed&reactants&may&fail&to&
produce&quality&product&
&&
Blow&off&from&over&pressurization&
Toxic&chemical&release&to&
environment&
Must&be&reinforced&and&
surely&secured&against&high&
pressures&
Malfunction&
Failure&to&alarm&operators&to&
unsafe&pressure&levels&within&
reactor&could&lead&to&toxic&
chemical&release&and&equipment&
damage&
Backup&and&automatic&alarm&
may&be&necessary&
PHL011&
PHL012&
PHL013&
Analyst:'Emily&Sturgell'
Hazard&Effect&
Reactor&Agitator&
Reactor&Manway&
Reactor&Mounted&Pressure&
Gauge&
Malfunction&
11!
System'Element'Type:&System&Hardware'
No.&
System&Item&
Hazard&
PHL014&
Comments&
Malfunction&
unsafe&temperature&levels&within&
reactor&could&lead&to&runaway&
reaction&
may&be&necessary&
may&be&necessary&
PHL015&
Remote&Temperature&Display&
Malfunction&
unsafe&temperature&levels&within&
reactor&could&lead&to&runaway&
reaction&
PHL016&
Allyl&Alcohol&Recovery&Tank&
Failure&to&separate&allyl&alcohol&
effectively&
Loss&of&allyl&alcohol&
&&
PHL017&
Condenser&
Failure&to&recondense&all&allyl&
alcohol&
Pressure&buildup&in&condenser&
could&result&in&explosion&and&toxic&
chemical&release&
&&
Premature&rupture&
Equipment&damage&and&toxic&
chemical&release&
Failure&to&rupture&
Over&pressurization&of&reactor&
vessel&could&lead&to&explosion&and&
toxic&chemical&release&
Reactants&and&byproducts&could&
travel&to&TAC&storage&vessel&and&
degrade&product&
&&
Reactants&and&byproducts&could&
travel&to&TAC&storage&vessel&and&
react&further&
&&
PHL018&
PHL019&
Reactor&Mounted&
Temperature&Gauge&
Analyst:'Emily&Sturgell'
Hazard&Effect&
Rupture&Disk&Relief&Valve&
TAC&Wash&Tank&
Inadequate&washing&
PHL020&
TAC&Filter&
Inadequate&filtering&
Allyl&alcohol&in&TAC&storage&tank&
Allyl&alcohol&detectors&may&
be&necessary&
PHL021&
TAC&Storage&Vessel&
Residual&allyl&alcohol&
Pressure&buildup&of&flammable&
toxic&chemical&could&result&in&fires&
or&explosion&
Allyl&alcohol&detectors&may&
be&necessary&
12!
I.4.2.1.2&Preliminary&Hazard&Analysis&&
!
System:&TAC&Production&Plant&
Function:&Chemical&Mishaps&
No.&
PHA01&
Item&
PHA02&
PHA03&
Causes&
Effects&
IMRI&
Recommendations&
Extremely&
flammable&
Inadvertent&release&of&
chemical&coupled&with&
an&ignition&source.&
Could&start&fire&in&
storage&vessel&or&
reactor.&
ID&
Install&a&fire&protection&system&
and&Allyl&Alcohol&vapor&detectors&
throughout&the&facility.&
IE&
Toxic&
low&ventilation.&
Harmful&to&workers&
who&inhale,&contact,&
or&ingest&vapors&or&
liquid.&
ID&
Protection&PPE&must&be&worn&by&
all&who&handle&or&work&near&
liquid&or&vapors.&
Install&Allyl&Alcohol&vapor&
detectors&throughout&the&facility.&
IE&
Highly&reactive&
Inadvertent&mixing&of&
chemical.&
Runaway&reaction.&
ID&
Control&the&rate&of&reactant&
addition&to&reactor&vessel&to&
control&reaction&speed.&Install&
control&valves&to&limit&the&flow.&
IE&
&&
Strong&irritant&
chemical.&
Harmful&to&workers&
who&ingest&or&touch&
crystals.&
ID&
Install&Cyanuric&Chloride&vapor&
IE&
&&
Spontaneously&
decomposes&in&
exothermic&
reaction&
Inadvertent&heating&of&
chemical.&
Undergoes&
spontaneous&
exothermic&
decomposition&
reaction&at&high&
temperatures.&
ID&
Cooling&must&be&maintained&to&
avoid&decomposition&reaction.&
Install&flow&detectors&in&the&
cooling&water&lines&and&
temperature&sensors&in&the&
reactor.&
IE&
&&
Highly&flammable&
an&ignition&source.&
Could&start&fire&in&
reactor.&
ID&
Install&a&fire&protection&system&
and&Allyl&Alcohol&vapor&detectors&
throughout&the&facility.&
IE&
&&
Strong&irritant&
low&ventilation.&
Harmful&to&workers&
liquid.&
ID&
liquid&or&vapors.&
Install&Allyl&Chloride&vapor&
IE&
&&
Allyl&Chloride&
Analyst:&Hana&Warren&
Date:&4/19/2015&
Hazard&
Allyl&Alcohol&
Cyanuric&
Chloride&
Preliminary&Hazard&Analysis&(PHA)&
FMRI& Comments&&&Status&
(ensure&
recommendations&are&
being&followed&through&
on,&to&be&monitored&by&
the&Safety&Engineering&
Staff)&
13!
Function:&Chemical&Mishaps&
No.&
Item&
Hazard&
Causes&
Effects&
Toxic&
low&ventilation.&
PHA04&
Triallyl&
Cyanurate&
Spontaneously&
polymerizes&in&
exothermic&
reaction&
PHA05&
Hydrogen&
Chloride&
Acidic&
Date:&4/19/2015&
IMRI&
Recommendations&
Harmful&to&workers&
liquid.&
ID&
liquid&or&vapors.&
IE&
&&
Failure&to&mix&inhibitor.&
Ruin&product&
ID&
Create&operational&checks&to&
ensure&presence&of&inhibitor.&
IE&
&&
Failure&to&mix&
neutralizer.&
May&change&
chemical&conditions&
within&reactor.&
ID&
Create&operational&checks&to&
ensure&presence&of&neutralizer.&
IE&
&&
&
&
Function:&Hardware&Mishaps&
No.&
PHA06&
PHA07&
Item&
Date:&4/19/2015&
Hazard&
Causes&
Effects&
IMRI&
Recommendations&
Breakdown&
Lack&of&maintenance.&
Catastrophic&
runaway&reaction&
ID&
Ensure&proper&maintenance.&
Install&flow&control&valve&to&
monitor&coolant&flows.&
IE&
Ineffective&coolant&
levels&
Lack&of&operator&
attention.&Leak&in&the&
system.&
ID&
Ensure&proper&operation&controls&
and&attention.&
Install&coolant&level&gauge&and&a&
flow&control&valve&to&monitor&
coolant&flows.&
IE&
(ensure&
recommendations&are&
being&followed&through&
on,&to&be&monitored&by&
the&Safety&Engineering&
Staff)&
Over0
pressurization&
Lack&of&operator&
attention.&
Runaway&reaction.&
Cooling&failure.&
ID&
and&attention.&
Install&a&properly&sized&
overpressure&relief&system&with&
scrubbers&or&other&safety&
equipment&where&necessary.&
IE&
&&
Reactor&Vessel&
Coolant&System&
Reactor&Vessel&
Catastrophic&
runaway&reaction&
Explosion&and&toxic&
chemical&release&to&
environment&
14!
Date:&4/19/2015&
No.&
Item&
Hazard&
Causes&
Effects&
IMRI&
Recommendations&
PHA08&
Allyl&Alcohol&
Storage&Vessel&
Leak&
Lack&of&mechanical&
integrity&checks&
Toxic&chemical&
release&to&
environment&
ID&
IE&
&&
PHA09&
Cyanuric&
Chloride&
Storage&Vessel&
Leak&
Lack&of&mechanical&
integrity&checks&
Chemical&release&to&
environment&
ID&
Install&Cyanuric&Chloride&vapor&
IE&
&&
PHA010&
Allyl&Alcohol&
Pipeline&
Isolation&valve&
malfunction&
Lack&of&mechanical&
integrity&checks&
Inability&to&control&
rate&of&reaction&
could&result&in&
runaway&reaction&
ID&
Perhaps&install&two&valves&in&a&
row&to&lower&total&control&failure&
probability.&
IE&
&&
Unmixed&reactants&
may&build&up&to&
unsafe&levels.&
Unmixed&reactants&
may&fail&to&produce&
quality&product.&
IID&
Perhaps&install&a&spare&agitator&to&
lower&total&mixing&failure&
probability.&
IIE&
&&
ID&
Ensure&manway&reinforcement&
and&that&it&is&surely&secured&
against&high&pressures.&
IE&
&&
ID&
Install&a&backup&and&automatic&
alarm.&
IE&
&&
PHA011&
Reactor&
Agitator&
Malfunction&
Lack&of&mechanical&
integrity&checks&
PHA012&
Reactor&
Manway&
Blow&off&from&over&
pressurization&
Lack&of&proper&
overpressure&testing.&
Improper&installation.&
Toxic&chemical&
release&to&
environment.&
Lack&of&mechanical&
integrity&checks&
Failure&to&alarm&
operators&to&unsafe&
pressure&levels&
within&reactor&could&
lead&to&runaway&
reaction,&toxic&
chemical&release,&
and&equipment&
damage&
PHA013&
Reactor&
Mounted&
Pressure&Gauge&
Malfunction&
15!
No.&
Item&
Hazard&
Causes&
Effects&
IMRI&
Recommendations&
Failure&to&alarm&
operators&to&unsafe&
temperature&levels&
within&reactor&could&
lead&to&runaway&
reaction.&
ID&
Install&a&backup&and&automatic&
alarm.&
Install&automatic&cooling&system&
triggered&by&high&temperatures.&
IE&
&&
IIID&
Ensure&proper&maintenance&and&
operation.&
IIIE&
&&
ID&
Ensure&proper&maintenance&and&
operation.&
IE&
ID&
Ensure&proper&maintenance.&&
Ensure&a&properly&sized&
IE&
IE&
IIIE&
PHA015&
Remote&
Temperature&
Display&
Malfunction&
Lack&of&mechanical&
integrity&checks&
PHA016&
Allyl&Alcohol&
Recovery&Tank&
Failure&to&separate&
allyl&alcohol&
effectively&
Lack&of&proper&operator&
controls&and&
notification.&
Loss&of&allyl&alcohol.&
Failure&to&
recondense&all&allyl&
alcohol&
Failure&of&cooling&side&
flow.&
Pressure&buildup&in&
condenser&could&
result&in&explosion&
and&toxic&chemical&
release.&
Premature&rupture&
Improper&sizing.&
Equipment&damage&
and&toxic&chemical&
release.&
Failure&to&rupture&
Improper&sizing.&
of&reactor&vessel&
could&lead&to&
explosion&and&toxic&
chemical&release.&
ID&
Ensure&proper&maintenance.&&
Ensure&a&properly&sized&
Lack&of&operator&
attention.&&
Reactants&and&
byproducts&could&
travel&to&TAC&
storage&vessel&and&
degrade&product&or&
react&further.&
IIID&
and&attention.&
PHA017&
Condenser&
Rupture&Disk&
Relief&Valve&
PHA018&
PHA019&
TAC&Wash&Tank&
Inadequate&
washing&
Date:&4/19/2015&
&
&
&
&
16!
Date:&4/19/2015&
No.&
Item&
Hazard&
Causes&
Effects&
IMRI&
Recommendations&
PHA020&
TAC&Filter&
Inadequate&
filtering&
Lack&of&operator&
attention.&&
Allyl&alcohol&in&TAC&
storage&tank.&
IID&
and&attention.&
IIE&
Residual&allyl&
alcohol&
Lack&of&operator&
attention.&&
Lack&of&detectors.&
Pressure&buildup&of&
flammable&toxic&
chemical&could&
result&in&fires&or&
explosion.&
ID&
and&attention.&
Install&Allyl&Alcohol&detectors&
within&the&storage&vessel.&
IE&
TAC&Storage&
Vessel&
PHA021&
&
!
&
&
&
17!
I.4.2.3&System&Hazard&Analysis&
!
System:&TCA&Production&System&
No.&
TLM/SCF&
Analyst:&Kate&Godfrey&
Date:&4/16/14&
IMRI& Recommended&Action&
FMRI&
Inability&to&control&
rate&of&reaction&could&
result&in&runaway&
reaction&
Runaway&Reaction&
1D&
Regular&inspection&of&all&
piping&&
1E&
Open&
1C&
1E&
Open&
Toxic&chemical&
release&to&
environment&
1D&
Ensure&coolant&levels&can&
be&easily&adjusted&
Regular&inspection&and&
necessary&maintenance&
Scrubbers&and&other&
safety&equipment&are&
necessary&
Installation&of&pressure&
gage&on&condenser&so&
pressure&can&easily&be&
monitored&
Scrubbers&and&other&
safety&equipment&are&
necessary&
!E&
Open&
1E&
Open&
1E&
Open&
1E&
Installation&of&allyl&alcohol&
detectors&
Open&
System&Hazard&Analysis&(SHA)&
Hazard&
Causes&
Effects&
SHA01&
Allyl&Alcohol&Pipeline&
Isolation&valve&
malfunction&
General&wear&and&
tear&
SHA02&
Temperature&control&in&
the&reactor&
Overheating&
SHA03&
Allyl&Alcohol&Storage&
Vessel&
Tank&leak&
Reactor&coolant&
system&breaks&
Coolant&levels&are&
too&low&
General&wear&and&
tear&
Valve&leak&
SHA04&
Condenser&
Failure&to&
recondense&all&
allyl&alcohol&
Corrosion&
Tube&fouling&
Air&In0Leakage&
Pressure&buildup&in&
condenser&could&
result&in&explosion&
and&toxic&chemical&
release&
1C&
SHA05&
Rupture&Disk&Relief&
Valve&
Early&rupture&
No&rupture&
General&wear&and&
tear&
Corrosion&
Seal&leak&
1C&
SHA06&
TAC&Storage&Vessel&
Residual&allyl&
alcohol&
Condenser&failure&
Inadequate&filtering&
Inadequate&washing&
Equipment&damage&
and&toxic&chemical&
release&
of&reactor&vessel&
could&lead&to&
explosion&and&toxic&
chemical&release&
Pressure&buildup&of&
flammable&toxic&
chemical&could&result&
in&fires&or&explosion&
1D&
Status&
&
18!
!
I.4.2.4&Subsystem&Hazard&Analysis&
!
System:&TCA&Production&System&
Subsystem:&Reactor&
No.&
Hazard&
Causes&
SSHA01& Over&pressurization&
Reaction&at&wrong&
temperature&
Thermal&expansion&
Valve&malfunction&
SSHA02& Overheating&&
Reactor&coolant&
system&breaks&
Coolant&levels&are&
too&low&
Agitator&motor&fails&
Agitator&shaft&
breaks&off&&
SSHA03& Mixing&failure&
SSHA04& Mechanical&integrity& Corrosion&of&reactor&

failure&
walls&
Analyst:&Andrew&Bohuslav&&
Date:&4/16/14&
IMRI& Recommended&Action& FMRI& Comments& Status&
Subsystem&Hazard&Analysis&(SSHA)&
Effects&
Mode&
Runaway&
reaction&
Explosion&and&
toxic&chemical&
release&into&
environment&
Runaway&
Reaction&
Reaction&
1C&
Ensure&cooling&system&is&
working&properly&&
1E&
Keep&an&up0to0
date&journal&of&
all&inspections&&
Open&
Reaction&
1C&
Keep&an&up0to0
date&journal&of&
all&inspections&
Open&
Unmixed&
reactants&may&
build&up&to&
unsafe&levels&
Unmixed&
reactants&may&
fail&to&produce&
quality&product&
Reactor&leak&
Mixing&
1D&
Ensure&coolant&levels&can& 1E&
be&easily&adjusted&
1E&
Keep&an&up0to0
date&journal&of&
all&inspections&
Open&
Operations&
1D&
1E&
Keep&an&up0to0
date&journal&of&
all&inspections&
Open&
19!
I.4.3%Trend%Analyses%
Utilizing( the( hazards( being( tracked( via( Section( I.3.4,( statistical( analyses( will( be(
implemented(to(analyze(any(safety(and(hazard(trends(present.(All(trends(found(are(to(
be( brought( to( the( attention( of( the( Safety( Committee.( A( reBevaluation( is( done( every(
quarter.(
(
I.5%SAFETY%VERIFICATION%TASKS%
I.5.1%System%Safety%in%the%Design%Review%
During(the(design(review(all(members(of(the(safety(team(review(the(design.(During(this(
review(the(system(is(looked(at(as(a(whole(and(what(is(put(in(place(to(reduce(potential(
harm( from( hazards( and( reduce( the( likelihood( of( occurrence.( (This( design( review( is( a(
critical(step(in(ensuring(the(system(has(been(designed(
I.5.2%Change%Order%Review%and%Signatory%Authority%
OSHAs(PSM(Management(of(Change(regulations(are(to(be(complied(with.(All(change(
orders(are(to(be(approved(and(signed(by(all(facility(managers(in(order(to(ensure(all(
subsystems(of(the(facility(are(aware(of(the(impending(change.(
I.5.3%Inputs%to%Specifications%
I.5.4%Acquisition%Tests%
During(the(Acquisition(process(there(requires(to(be(testing(of(the(system(to(ensure(the(
materials(and(craftsmanship(are(up(to(the(specified(level.(These(testings(are(to(include(
XBray(testing(to(ensure(proper(metal(thicknesses(and(mass(spectrometry(to(ensure(the(
materials(are(of(the(proper(chemical(composition(to(met(the(required(levels(of(strength.(
In(addition,(during(the(building(process(it(is(critical(that(visual(inspections(are(performed(
to( ensure( the( craftsmanship( is( of( the( proper( level( and( everything( is( assembled( in( the(
proper( manner.( These( tests( are( critical( to( ensure( that( the( system( being( acquired( is(
correctly(built(and(meets(the(contract(requirements.(((
I.5.5%Operational%Tests%
PreBstartup(operation(tests(are(to(be(performed(prior(to(each(startup(to(ensure(proper(
working(order(of(the(system.(
I.5.6%Safety%Tests%
PreBstartup(safety(tests(are(to(be(performed(prior(to(each(startup(to(ensure(proper(
working(order(of(all(safety(equipment(within(the(system.(
(
!
20!
I.6%SAFETY%TRAINING%AND%AWARENESS%
I.6.1%Employees%RightOtoOknow%
Employees(have(the(right(to(know(what(hazardous(chemicals(are(present(in(their(
workplace.((In(addition(Employees(cannot(be(discriminated(against(for(asking(for(
Material(safety(data(sheets.(This(information(must(be(available(for(all(employees.(
I.6.2%Safety%Awareness%and%Training%
The( company( is( responsible( for( training( and( keeping( workers( aware( of( the( hazards(
present(in(the(work(place.(All(new(employees(must(complete(the(Safety(Awareness(and(
Safety( Training( workshops( before( they( begin( working.( For( established( employees,( it( is(
expected(that(they(complete(the(Safety(Awareness(and(Safety(Training(workshops(once(
a(year.(Documentation(of(attendees(will(be(kept(and(a(Certificate(of(Attendance(will(be(
presented(to(the(attendees.(
I.6.3%Personnel%Certification%for%Hazardous%Operations%
All(employees(working(in(proximity(to(hazardous(chemicals(must(complete(mandatory(
safety(training(specifically(corresponding(to(the(pertinent(hazardous(chemical.(Safety(
training(is(to(include(the(proper(use(and(maintenance(of(the(required(personal(
protective(equipment((PPE)(for(the(handling(of(that(chemical.(
(
I.7%RISK%MANAGEMENT%
I.7.1%Risk%Assessment%
Risk(assessment(will(be(made(using(the(Risk(Matrix.(The(Risk(Matrix(allows(one(to(assess(
risk(from(the(best(case(scenario((IVF)(to(the(worst(case(scenario((IA).(
(
(
F:(
E:(
D:(
C:(
B:(
A:(
Impossible( Improbable( Remote( Occasional( Probable( Frequent(
I:(
(
Catastrophic(
II:(Critical(
II:(Marginal(
IV:(
Insignificant(
21!
I.7.2%Risk%Acceptance%Criteria%
All(hazardous(risks(within(the(yellow(zone(are(to(be(monitored(and(maintained(but(not(
acted(upon(unless(deemed(worthy(by(the(Safety(Committee.(All(hazardous(risks(within(
the(orange(and(red(zone(are(to(be(addressed(by(the(Safety(Committee.(Refer(to(Section(
I.3.(
I.7.2.1&Employee&Acceptance&
Employee(acceptance(of(the(risk(is(accomplished(by(informing(the(workers(of(the(risk(
and(ensuring(the(risk(is(below(the(level(at(which(their(compensation(allows(them(to(
accept(these(risk.(
I.7.2.1%Public%Acceptance%
Public(acceptance(is(gained(by(demonstrating(the(process(is(safety(to(the(public.(This(is(
done(by(community(outreach,(and(other(educational(programs(which(explain(the(
process(and(what(has(been(done(to(reduce(the(risk(to(an(acceptable(level.((
(
I.8%ACCIDENT%REPORTING,%INVESTIGATION,%AND%RECORD%KEEPING%
I.8.1%Reporting%the%Accident%
An(internal(incident(investigation(should(begin(within(24(hours(of(the(incident.((
The(incident(investigation(report(should(include:(
(
The(date(and(time(of(the(incident(
The(members(of(the(investigation(board(
A(description(of(the(incident(
Root(causes(and(causal(factors(contributing(to(the(incident(
Recommendations(to(reduce(the(likelihood(of(similar(incidents(
A(timeframe(to(follow(through(with(the(recommendations(
I.8.2%Forming%an%Investigation%Board%
The( investigation( board( should( include( those( knowledgeable( of( the( design,(
implementation,( and( operation( of( the( process,( the( key( members( present( during( the(
incident,(and(the(key(members(present(during(the(emergency(response(of(the(incident.(
I.8.3%Documenting%the%Accident%
The( incident( investigation( report( is( to(include( a( diagram( detailing( the( root( causes( and(
causal(factors(contributing(to(the(incident.(A(Swiss(Cheese(Model(and(fault(tree(analysis(
are(highly(suggested.((
An(example(Swiss(Cheese(Model(using(the(MFG(Chemical(Case(Study(is(below:(
22!
(
An( example( fault( tree( analysis( using( the( MFG( Chemical( Case( Study( is( below:( Broken(
down(into(the(failures(that(occurred.((
I.8.3.1%Process%Upset%
The(first(failure(that(occurred(was(the(process(upset.((This(is(shown(in(the(figure(below.((
As( to( what( failures( occurred( and( what( happen( to( cause( this( event( as( a( fault( tree.
23!
I.8.3.2%Hazardous%release%
After(the(process(upset(there(was(a(design(failure(in(the(system,(which(allowed(for(the(
toxic(release.((This(is(documented(below(as(a(fault(tree.(
(
I.8.4%Corrective%Action%&%Verification%of%Corrective%Action%
The(incident(investigation(report(is(to(include(recommendations(to(reduce(the(likelihood(
of(similar(incidents.(A(recommendation(for(each(root(cause(and(causal(factor(detailed(is(
required( along( with( a( timeframe( detailing( when( each( recommendation( should( be(
implemented,(based(on(the(severity(of(the(risk(being(reduced.(
I.8.5%OSHA%and%EPA%Mishap%Notification%Reporting%and%Record%Keeping%
OSHA( and( EPA( are( to( be( notified( within( 24( hours( of( the( incident,( in( compliance( with(
regulations.(
I.8.7%Informing%the%Public%
A( public( announcement( is( to( be( made( within( 48( hours( of( the( incident.( The( incident(
investigation(report(is(to(be(made(public(within(one(month(of(its(completion.(
(
I.9%EMERGENCY%PREPAREDNESS%PLAN%
I.9.1%Emergency%Preparedness%and%Response%Analysis%
Written( procedures( for( an( emergency( response( plan( must( be( created( with( predefined(
teams( with( clear( roles( should( an( emergency( occur.( These( emergency( response(
!
24!
procedures(must(be(posted(throughout(the(facility,(and(keyBcontributing(members(must(
be(trained,(equipped,(and(drilled(quarterly(in(their(roles.(
I.9.2%Emergency%Response%and%Community%Services%
The(emergency(response(plan(is(to(be(shared(with(community(response(organizations,(
such( as( the( local( firefighting( and( police( departments.( This( ensures( a( quick( and( safe(
evacuation(of(the(community(should(an(emergency(occur(as(well(as(the(knowledgeable(
and(equipped(support(of(the(local(response(organizations(should(the(facility(be(in(need(
of(it.((
I.9.3%Emergency%Preparedness%Training%
Quarterly( emergency( response( drills( must( be( conducted( by( the( entire( facility,(
alternating( each( quarter( between( day( and( night( shifts.( New( facility( personnel( and(
visitors( must( be( individually( trained( in( the( emergency( response( plan,( and( pass( an(
emergency( response( test.( All( facility( personnel( must( take( a( refresher( course( on( the(
emergency(response(plan(each(year.((
Should( the( emergency( response( plan( undergo( a( change( by( the( approval( of( the( Safety(
Committee,(retraining(of(all(facility(personnel(in(the(emergency(response(plan(is(to(be(
implemented(ASAP.(
(
I.10%ENVIRONMENTAL%PROTECTION%AND%OCCUPATIONAL%HEALTH%
I.10.1%Hazardous%Materials%and%Chemicals%Control%
Standards( are( to( be( created( in( compliance( with( OSHAs( PSM( regulations( and( posted(
throughout(the(facility.(
I.10.2%Environmental%Compliance%Control%
Standards( are( to( be( created( in( compliance( with( EPAs( RMP( regulations( and( any( local(
environmental(regulations.(Standards(are(to(be(posted(throughout(the(facility.(
I.10.3%Occupational%Health%
Standards( are( to( be( created( in( compliance( with( OSHAs( PSM( regulations( and( posted(
throughout(the(facility.(
(
I.11%SUBCONTRACTOR%SAFETY%PROGRAMS%REVIEW%AND%EVALUATION%
I.11.1%Oversight%and%Methods%
It(is(required(that(each(subcontractor(submit(a(proper(safety(plan.(It(must(be(reviewed(
and(then(unanimously(agreed(upon(by(the(safety(committee.(Each(subcontractor(safety(
25!
plan(must(follow(all(the(requirements,(standards(and(regulations(set(in(place(by(the(
safety(committee.(If(it(does(not,(it(will(not(be(approved.(
I.11.2%SelfOEvaluations%
SelfBEvaluations(will(be(completed(regularly(and(without(repercussions,(these(will(allow(
workers( the( chance( to( look( at( their( work( environment( and( work( routine( for(
hazards.( (This( will( allow( another( chance( to( document( near( misses.( (This( information( is(
vital(in(the(tracking(of(potential(problems(before(they(become(hazards.(This(lends(itself(
to(the(principle(of(if(you(see(something(say(something.((
I.11.3%Evaluation%of%Transient%Contractors%
All(contractors(must(complete(onsite(training(and(prove(competence(in(work(to(be(
completed.((Each(new(Contractor(must(meet(with(the(onsite(safety(team(and(have(a(
working(understanding(of(the(hazards(in(the(workplace.((Addition(each(contractor(must(
be(training(in(all(necessary(PPE.(Holding(transient(contractors(to(this(level(of(safety(
reduces(the(likelihood(of(something(such(as(the(manway(cover(improperly(sealed(
becoming(a(standard(problem.((
I.12%SAFETY%COMPLIANCE%
I.12.1%Documentation%and%Configuration%Control%
The(Safety(Engineering(staff(is(to(maintain(OSHA(PSM(recordkeeping(standards.(
I.12.2%Preparing%for%Internal%Safety%Audits%
Internal(safety(audits(are(to(be(performed(yearly.(Should(a(changeBorder(occur,(a(safety(
audit(is(to(be(performed(regardless(of(how(recently(one(was(performed.(
I.12.3%OSHA%Audits%
OSHA(Audits(are(to(be(helped(and(facilitated.((
(
PART%II:%OPERATIONAL%SAFETY%REQUIREMENTS%
II.1%OPERATIONAL%SYSTEM%SAFETY%PLANS%&%PROCEDURES%
II.1.1%Hazardous%Operations%Procedures%
TAC(production(requires(four(basic(hazardous(operations:(the(handling(of(allyl(alcohol,(
the(handling(of(cyanuric(chloride,(the(mixing(of(the(two(chemicals,(and(the(handling(of(
the( product.( Allyl( alcohol( is( an( extremely( flammable,( toxic( chemical( which( should( be(
handled(in(accordance(with(OSHA(PSM(regulations(29(CFR(1926.152.(Cyanuric(chloride(is(
extremely(reactive(and(a(strong(irritant,(and(thus(should(be(handled(with(extreme(care.(
Protective( equipment( including( gloves,( eye( protection,( long( sleeves,( long( pants,( and(
26!
closed(shoes(should(be(worn(at(all(times(around(these(chemicals.(Mixing(the(reactants(
should(be(done(in(a(rateBcontrolled(manner(and(overseen(by(someone(with(a(working(
understanding(of(the(chemistry(of(TAC(synthesis.(
II.1.2%Construction%Safety%
During(construction(of(the(facility(and(subsequent(construction(projects,(someone(with(
a(thorough(understanding(of(the(chemistry(of(TAC(synthesis(and(the(high(energies(and(
heat(associate(with(the(reaction(should(approve(all(operational(and(equipment(changes(
that(involve(the(chemicals(in(question.(In(addition,(the(Safety,(Health,(and(
Environmental(Committees(must(approve(all(operational(alterations(and(equipment(
changes(for(construction(purposes.(
II.1.3%Safety%Design%Requirements%
The(Design(of(the(system(must(meet(minimum(safety(Requirements.((These(include(the(
addition(of(relief(valves(and(motioning(equipment.(These(design(Requirements(must(
incorporate(the(OSHA(elements(of(PSM.((
27!

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