MDI Q&A - Safety

At what pressure does the PSV on the Acid Addition Area relieve? And where does it relieve to?

150 PSIG

It relieves into the Vent Gas Header.

What are the differences between Level 1 requirements and Level 2 requirements?

Level 1 requirements are more generic and apply to all substances.

Level 2 requirements apply to a specific list of substances (phosgene, chlorine, anhydrous ammonia, carbon monoxide, nitric acid, and phenol) and are more detailed.

According to plant procedure, what is a confined space?

A confined space is defined as an enclosed space which:

1. Is large enough and so configured that an employee can bodily enter and perform assigned work

2. Has limited or restricted means for entry or exit

3. Is not designed for continuous employee occupancy

When must an entrant of a confined space immediately leave the confined space?

1. When a unit/plant alarm sounds that affects the work area

2. When instructed by the attendant to leave

3. The entrant(s) perceive that they would be in danger by remaining in the confined space

Prior to a person entering a confined space, what must the oxygen content be in the confined space atmosphere?

Entry is prohibited if the percentage of oxygen in the confined space is below 20% or above 22%

What is the length of records retention for all Safety and Housekeeping inspections?

Safety and Housekeeping Inspection reports are to be retained for the current year plus 7 years.

How often do 5 minute escape bottles that are nested in the unit need to be inspected?

Monthly. The technician will verify the bottle, proper air supply, bag, and hose/fittings are fit for use. They will also initial and date the inspection tag.

What are the 3 regulated chemicals that we have in the MDI complex?

MDA

Benzene

Formaldehyde

In the event of a total power failure in the mMDI unit, what should be your first course of action?

Get a SCBA as protection from a possible toxic gas leak in the unit.

What is the length of record retention for the AVO Inspection Report?

Current + 7 years

Can nitrogen be used instead of plant air to power air driven equipment? (Pneumatic tools)

No. This is against plant policies and procedures.

What is the length of records retention for all level 2 work plans (S-042)?

A record of all level 2 work plans must be kept for the current year plus the previous year.

What is S-035?

A plant procedure that describes the minimum PPE requirements.

How often must portable ladders be inspected?

Portable ladders must be inspected every quarter. (Every 3 months)

What documents should be attached to a level 2 work plan?

1. Detailed sketch or P&ID of the equipment including:

   A. Location of lockout devices or danger tags

   B. Location of blinds or double block and bleeds

   C. Associated live process lines and/or equipment

2. Unit vacuum system calculations for line openings

3. Blind list

4. Energy Isolation List

5. List of valve tags for non-routine piping line-ups