Document 0g2dqmMb5grrR1VrmdKMvNvDR

VINYL II CONSOLIDATED AUDIT AGENDA FOR PLANT PRESENTATION/DISCUSSION/TOUR 7:30 -11:30 TUESDAY, SEPTEMBER 10, 1991 ORGANIZATION & PLOT PLAN PROCESS & UNIT OPERATIONS (Process Description, Flow Sheets, Chemistry Including Side Reactions, Instrumentation and Critical Instruments) * FURNACE AREA * DISTILLATION *OXY * ECOLOGY REVIEW OF PLANT/DEPARTMENT POLICIES/PROCEDURES AND COMMUNICATIONS REVIEW TRAINING AND RETRAINING PROGRAMS REVIEW OF SIGNIFICANT INCIDENTS/ MAJOR CONCERNS * LOSSES * REACTIVE CHEMICALS * SAFETY * MEDICAL PLANT GENERAL TOUR * PROJECTS * AREAS OF CONCERN * MAINTENANCE SHOPS * MOTOR CONTROL CENTERS * EATING FACILITIES * LABS 10 MINUTES 90 MINUTES 25 MINUTES 20 MINUTES 25 MINUTES 20 MINUTES 20 MINUTES 30 MINUTES 30 MINUTES 60 MINUTES CONFIDENTIAL REDACTED R&S149671 CM:7/91 VINYL II 2Z96nsw <3310 VCI3H rTVIIN3aiJN03 t e/.96ns'gy <3313 VQ3H IVLLNiaGMNOD I CONFIDENTIAL PROCESS & UNIT OPERATIONS 9/6/91 CM R&s 149674 VINYL II EDC CRACKING CHEMISTRY Primary Reaction Major Secondary Reactions Minor Secondary Products CONFIDENTIAL REDACTED R&S149675 9/3/91 Dow Confidential EDC CRACKING FURNACES 9/.96Vl-S^U t I iviiNaauKOD DOWTHERM SYSTEM ZZ961?!. S'StJ aaiovaan lYUMaauNOD i CRITICAL INSTRUMENTS FURNACE AREA T585 HIGH LEVEL SWITCH T585 LEVEL TRANSMITTER 0101/El 12 COMBUSTIBLE GAS MONITOR D101 and D102 CGM GROUND LEVEL 0102 GROUND LEVEL CGM FI 10 CGM F101 AND F103 CGM D101 UPPER CGM D102 UPPER CGM D102 UPPER CGM D101 UPPER CGM F101 AND F102 CGM F104 CGM Dill AND D104 CGM P100 LOW DISCHARGE PRESSURE P100 LOW DISCHARGE PRESSURE (P100 SC) P263 PRESSURE CONTROL VALVE T261 LEVEL LSH-5846 LT-5844 CG-10 CG-11 CG-12 CG-46 CG-48 CG-49 CG-50 CG-51 CG-52 CG-7 CG-8 CG-9 PSL-1003 PSL-1003 CV-2747 LT-2633 CONFIDENTIAL R&S 149678 9/3/9 1 aer Dow Confidential DISTILLATION CONFIDENTIAL REDACTED i R&S149679 DOW confidential'' 9/91 CONFIDENTIAL REDACTED DISTILLATION REACTIVE CHEMICALS R&S149680 DOW CONFIDENTIAI 9/2/91 CONFIDENTIAL DISTILLATION CRITICAL INSTRUMENTS R&S149681 T-230 LEVEL (4months) CHLORINE TO C250 EV (1 year) VINYL SPHERE EBV'S (6 months) VINYL TO OCCIDENTAL EBV (6 months) COMBUSTIBLE GAS MONITORS - C250 (4 weeks) - K125 AND F110 (3 months) - Dill AND D104 (3 months) l DJH 9/1/91 CONFIDENTIAL |C--100/C-l 10/C--111 REDACTED i r&sh9682 t ORIGINAL. REVISED: DJH 9/3/91 12/M.f) C- 120/C--140 CONFIDENTIAL REDACTED R&S149683 ORIGINAL' REVISED: DJH 9/3/91 12/14, 89 Critical Instrument Reactive Ch mical confidential redacted I;C --250/C --255 : 1' R&S149684 DOW CONFIDENTIAL ORIGINAL' REVISED: DJH 9/2/91 12/14, 89 Critical Instrument CONFIDENTIAL REDACTED R&S149685 ORIGINAL REVISED' DJH 9/3/91 13/ ! !, OXY/EDC AND ASSOCIATED EQUIPMENT RAINWATER STRIPPER REFRIGERATION SYSTEMS I. R-202 - Oxy I II. R-202 - Oxy II III. C-220 - 1 & 2 - Oxy water organics stripper IV. C-230 - Oxy EDO lights stripper V. C-235 - EDO Water wash system VI. C-240 - Rainwater organics stripper VII. Wet vent system VIII. K-320 - K330 - Propylene refrigeration compressors >O ,,,i ,, CONFIDENTIAL ^ REDACTED u. II R&S 149688 i CATALYST LOADING DETAIL . s l /^v*:.: >1 CONFIDENTIAL 3p03) <O>) CtoD SAS 4/81 nHW rnunnnm * R-201 AND 202 MAIN REACTION SECONDARY REACTIONS tv. > CONFIDENTIAL /] 9/3/91 PS n> H W o X W fc totoo> o R201 & 202 (cont'd) 9T 9/3/91 j w <i n> H W o ID cn tC(DT>) CONFIDENTIAL CONFIDENTIAL WASH COLUMNS C-203 & C-204 REACTIONS J, W * l W 'W o > o H W o n CO I(DD SroO /V! CRICTICAL INSTRUMENT LIST OXY I AND II Acoustic Emission Detectors R-201 Acoustic Emission Detectors R-202 CV-2245 K-215 Lube Oii Pressure C.V. CV-2259 K-215 Bearing Oil Supply Pressure C.V, FT-2231 K-215 Total Discharge Flow Frequency (Weeks) 26 26 52 52 52 oo 3 PT:9/3/91 393 cn 4(D^ <D CO OXY I INSTRUMENT STARTUP CHECKLIST 1 OXYGEN FLOW 1 HCL FLOW R20i C2H4 FLOW R201 RECYCLE FLOW D201 LEVEL (50'/. GLYCOL) D201 PRESSURE R2G1 HEAD PRESSURE (50-150) R201 DIFFERENTIAL PRESSURE OXY SYSTEM PRESSURE C201 LEVEL (N2 PURGE) C203 LEVEL (N2 AND H20 PURGE) C211 LEVEL (FLUOROLUBE) D130 LEVEL H20 AND EDC I OXYGEN PRESSURE SHUTDOWN 02/ HCL/ C2H4 RECYCLE CONTROL VALVES 3203 PH T222 PH IN AND OUT 0220 EDC FILLED ANALYZERS TITRALYZERS (C201) ALL RECYCLE ANALYZERS (02/ C2H4, CO, C02) LTIALS: OXY I TRIP SHUTDOWN CHECK DATE: MOTE: THE FOLLOWING OXY REACTOR TRIP CHECK SHOULD BE DONE PRIOR TO EVERY REACTOR STARTUP. CHECKS NO. 1 AND 2 SHOULD BE DONE WHILE THE RECYCLE COMPRESSOR IS SLOW-ROLLING AT 500 RPM. THE OTHER CHECKS CAN BE DONE WITH THE RECYCLE COMPRESSOR RUNNING ON MINIMUM GOVERNOR. *# ALL TESTS SHOULD BE DONE WITH ANTI-SURGE CONTROL VALVE WIDE OPEN.** 1. ____ SHUTDOWN: RUPTURE DISC FAILURE TRIP * EVENTS: C2H4, 02, RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. K215 WILL TRIP. C211 VENT VALVE WILL OPEN. PROCEDURE: ACTIVATE THE CONTROL ROOM-MOUNTED RUPTURE DISC FAILURE TRIP SWITCH HS-2078. 2. ____ SHUTDOWN: K215 TRIP EVENTS: C2H4, 02, RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. AUTO MATIC N2 PURGE. K215 WILL TRIP. PROCEDURE: ACTIVATE THE CONTROL ROOM-MOUNTED EMERGENCY TRIP SWITCH HS-2239A. 3. ____ SHUTDOWN: LOW RECYCLE FLOW SETPOINT: 4 DIVISIONS OF' RECYCLE FLOW ' EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: GRADUALLY REDUCE THE RECYCLE FLOW BY MANUALLY CLOSING THE CONTROL VALVE WITH THE ANTI-SURGE CONTROL VALVE WIDE OPEN. THE REACTOR TRIP SHOULD ACTIVATE WHEN THE RECYCLE FLOW REACHES 4. 5 UNITS. DO NOT BRING THE RECYCLE FLOW BELOW 4 UNITS. 4. SHUTDOWN: LOW HCL FLOW SETPOINT: 2 DIVISIONS OF HCL FLOW EVENTS: C2H4, 02 EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: SUPPLY AN EXTERNAL SIGNAL TO F5C-2064 EQUIVALENT TO 4 UNITS. GRADUALLY DECREASE THE SIGNAL TO FSL-2064 THE REACTOR SHOULD TRIP WHEN THE SIGNAL IS EQUIVALENT TO 2 UNITS. CONFIDENTIAL r &s 149695 SHUTDOWN: HIGH HEAD TEMPERATURE SETPOINT: 2 THERMOCOUPLES IN SAME THERMOWELL AT 250 DEG C EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: LIFT ONE LEAD TO INPUT OF CONVERTER 2068A. LIFT ONE LEAD TO INPUT OF CONVERTER 2068B. THESE TEMPERATURE SWITCHES SHOULD HAVE BEEN PREVIOUSLY CALIBRATED: TSH-2068 A/B, 2069 A/B, 2070 A/B SHUTDOWN: HIGH INLET TEMPERATURE SETPOINT: INLET TEMPERATURE AT 250 DEG C EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: LIFT ONE LEAD TO INPUT CONVERTER 2067A. LIFT ONE LEAD TO INPUT CONVERTER 2067B. THESE TEMPERATURE SWITCHES SHOULD HAVE BEEN PREVIOUSLY CALIBRATED: TSH-2067 A/B SHUTDOWN: HIGH OXYGEN IN THE RECYCLE STREAM SETPOINT: IR AND MASS SPEC ANALYZERS OVER 4*/. OXYGEN EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE; RUN SIGNAL TO ANALYZER CONVERTER 2208 UPSCALE. GRADUALLY INCREASE THE SIGNAL TO THE ANALYZER CONVERTER 2214 UNTIL THE TRIP ACTIVATES. REPEAT ABOVE INTERCHANGING CONVERTERS. SHUTDOWN: EMERGENCY MANUAL REACTOR TRIP EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL CONTROL VALVES WILL CLOSE. E217 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: ACTIVATE CONTROL ROOM-MOUNTED REACTOR TRIP SWITCH HS-2089. SHUTDOWN: HIGH OXYGEN HEADER SETPOINT- 210 PSIG OXYGEN PRESSURE DOWNSTREAM OF OXYGEN REGULATORS EVENTS: C2H4, 02 EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE. BREAK THE CONTACTS ON DSH-204S. THE PRESSURE SWITCH DSH-2048 SHOULD HAVE BEEN CALIBRATED R&S149696 O 0 S q f SHUTDOWN: LOW C2H4 FLOW SETPOINT: 2 DIVISIONS OF C2H4 FLOW EVENTS: C2H4i 02, EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: SUPPLY AN EXTERNAL SIGNAL TO FSC-2061 EQUIVALENT TO 4 UNITS. GRADUALLY DECREASE THE SIGNAL TO FSL-2061. THE REACTOR SHOULD TRIP WHEN THE SIGNAL IS EQUIVALENT TO 2 UNITS. SHUTDOWN: LOW OXYGEN FLOW SETPOINT: 2 DIVISIONS OF OXYGEN FLOW EVENTS: C2H4, 02 EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: SUPPLY AN EXTERNAL SIGNAL TO FSC-20&3 EQUIVALENT TO 4 UNITS. GRADUALLY DECREASE THE SIGNAL TO FSL-2063. THE REACTOR SHOULD TRIP WHEN THE SIGNAL IS EQUIVALENT TO 2 UNITS. PROCEDURE: BE SURE THAT ALL INSTRUMENTATION IS RECONNECTED AND IN WORKING ORDER BEFORE THE REACTOR IS STARTED UP. SUCH AS VENT EVV, FLOW AND PRESSURE TRANSMITTERS OXY II INSTRUMENT STARTUP CHECKLIST OXYGEN FLOW !202 HCL FLOW (202 C2H4 FLOW (202 RECYCLE FLOW 3202 LEVEL < 50'/. GLYCOL) )202 PRESSURE (202 HEAD PRESSURE (50-150) (202 DIFFERENTIAL PRESSURE 3XY II SYSTEM PRESSURE :202 LEVEL (N2 PURGE) 3204 LEVEL (N2 AND H20 PURGE) :212 LEVEL (FLUOROLUBE) 3214 LEVEL LEVEL H20 AND EDC HIGH OXYGEN PRESSURE SHUTDOWN 32. HCL. C2H4 RECYCLE CONTROL VALVES !204 PH '222 PH IN AND OUT 3220 EDC FILLED ANALYZERS 'ITRALYZERS (C202) ^LL RECYCLE ANALYZERS (02, C2H4, CO, C02) :NITIALS:______ OXY II TRIP SHUTDOWN CHECK DATE: 10TE: THE FOLLOWING OXY REACTOR TRIP CHECK SHOULD BE DONE PRIOR TO EVERY REACTOR STARTUP. ^^ORE STARTING CHECKLIST 1. SET UP SIMULATORS (@ 5 UNITS) TO CLEAR LOW FLOW TRIPS ON RECYCLE, 02, HCL, AND C2H4. 2. K216 SHOULD'BE DOWN FOR CHECKS NO. 1,2 & 3. HAVE AN ELECTRICIAN UNPLUG CONTROL POWER AND SWITCH TO TEST POWER. THIS WILL ALLOW THE TRIPS TO BE CHECKED WITHOUT STARTING THE MACHINE. PUSH THE START SWITCH IN FIELD WHICH WILL CLEAR THE SHUTDOWN ALARM BUT MACHINE WILL NOT START. 3. BLOCK IN AND BLEED DOWN AIR TO C212 VENT VALVE TO PREVENT IT FROM OPENING AND DEPRESSURING SYSTEM. ** ALL TESTS SHOULD BE DONE WITH ANTI-SURGE CONTROL VALVE WIDE OPEN. ** 1. ____ SHUTDOWN: RUPTURE DISC FAILURE TRIP EVENTS: C2H4, 02, RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E21S STEAM VALVE WILL CLOSE. K216 WILL TRIP. C212 VENT VALVE WILL OPEN. PROCEDURE: 1) ACTIVATE THE CONTROL ROOM-MOUNTED RUPTURE DISC FAILURE TRIP SWITCH HS-2104. 2) DISCONNECT THE WIRING ON RUPTURE DISC PRESSURE SWITCH - PSH2104. SHUTDOWN: K216 TRIP EVENTS: C2H4, 02, RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E218 STEAM VALVE WILL CLOSE. AUTO MATIC N2 PURGE. K216 WILL TRIP. PROCEDURE: ACTIVATE THE CONTROL ROOM-MOUNTED EMERGENCY TRIP SWITCH HS-2287. SHUTDOWN: D214 LEVEL SETPOINT: 100+*/. EVENTS: C 2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E218 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. K216 WILL TRIP. on I S? - 0 PROCEDURE: BREAK THE CONTACTS ON LSH-2281. THE LEVEL SWITCH LSH-2281 SHOULD HAVE BEEN CALIBRATED PREVIOUSLY. g w 4. SHUTDOWN: LOW RECYCLE FLOW $ SETPOINT 4 DIVISIONS OF RECYCLE FLOW AND PROCEDURE: GRADUALLY REDUCE THE RECYCLE FLOW BY MANUALLY CLOSING THE CONTROL VALVE WITH THE ANTI-SURGE CONTROL VALVE WIDE OPEN. THE REACTOR TRIP SHOULD ACTIVATE WHEN THE RECYCLE FLOW REACHES 4. 5 UNITS. DO NOT BRING THE RECYCLE FLOW BELOW 4 UNITS. SHUTDOWN: LOW HCL FLOW SETPOINT: 2 DIVISIONS OF HCL FLOW EVENTS: C2H4, 02 EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: SUPPLY AN EXTERNAL SIGNAL TO FSC-2094 EQUIVALENT TO 4 UNITS. GRADUALLY DECREASE THE SIGNAL TO FSL-2094. THE REACTOR SHOULD TRIP WHEN THE SIGNAL IS EQUIVALENT TO 2 UNITS. SHUTDOWN: HIGH HEAD TEMPERATURE SETPOINT; 2 THERMOCOUPLES IN SAME THERMOWELL AT 250 DEG C EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E218 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: LIFT ONE LEAD TO INPUT OF CONVERTER 2098A LIFT ONE LEAD TO INPUT OF CONVERTER 2098B. THESE TEMPERATURE SWITCHES SHOULD HAVE BEEN PREVIOUSLY CALIBRATED: TSH-2098 A/B, 2099 A/B, 2100 A/B SHUTDOWN: HIGH INLET TEMPERATURE SETPOINT: INLET TEMPERATURE AT 250 DEG C EVENTS: C2H4, 02 RECYCLE'EBV'S AND C2H4, 02, HCL RECYCLE CONTROL VALVES WILL CLOSE. E218 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: LIFT ONE LEAD TO INPUT CONVERTER 2097A. LIFT ONE LEAD TO INPUT CONVERTER 2097B. THESE TEMPERATURE SWITCHES SHOULD HAVE BEEN PREVIOUSLY CALIBRATED: TSH-2097 A/B SHUTDOWN: HIGH OXYGEN IN THE RECYCLE STREAM SETPOINT: IR AND MASS SPEC ANALYZERS OVER 47. OXYGEN EVENTS: C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL CONTROL VALVES WILL CLOSE. E218 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: RUN SIGNAL TO ANALYZER CONVERTER 2267 UPSCALE. GRADUALLY INCREASE THE SIGNAL TO THE ANALYZER CONVERTER 2275 UNTIL THE TRIP ACTIVATES. REPEAT ABOVE INTERCHANGING CONVERTERS. SHUTDOWN: EMERGENCY MANUAL REACTOR TRIP EVENTS. C2H4, 02 RECYCLE EBV'S AND C2H4, 02, HCL CONTROL VALVES WILL CLOSE. E218 STEAM VALVE WILL CLOSE. AUTOMATIC N2 PURGE. 10. ___ SHUTDOWN: HIGH OXYGEN HEADER SETPOINT: 210 PSIG OXYGEN PRESSURE DOWNSTREAM OF OXYGEN REGULATORS EVENTS: C2H4, 02 EBV 'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: BREAK THE CONTACTS ON D5H-2059. THE PRESSURE SWITCH DSH-2059 SHOULD HAVE BEEN CALIBRATED PREVIOUSLY. 11. SHUTDOWN: LOW C2H4 FLOW SETPOINT: 1.5 DIVISONS OF C2H4 FLOW EVENTS: C2H4, 02, EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE SUPPLY AN EXTERNAL SIGNAL TO FSC-2091 EQUIVALENT TO 4 UNITS. GRADUALLY DECREASE THE SIGNAL TO FSL-2091. THE REACTOR SHOULD TRIP WHEN THE SIGNAL IS EQUIVALENT TO 2 UNITS. 12. ___ SHUTDOWN: LOW OXYGEN FLOW SETPOINT: 1. 5 DIVISIONS OF OXYGEN FLOW EVENTS: C2H4, 02 EBV'S AND HCL, C2H4, 02 CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE SUPPLY AN EXTERNAL SIGNAL TO FSC-2093 EQUIVALENT TO 4 UNITS. GRADUALLY DECREASE THE SIGNAL TO FSL-2093. THE REACTOR SHOULD TRIP WHEN THE SIGNAL IS EQUIVALENT TO 2 UNITS. 13. ___ SHUTDOWN: D202 LEVEL SETPOINT: 10 - 20% EVENTS. C2H4,OX EBV'S AND 02 CONTROL VALVE WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: BREAK THE CONTACTS ON LSL2123B. 14. SHUTDOWN: C120 HI TEMPERATURE ON OH SETPOINT: 2 OUT 3 THERMOCOUPLES > -25 DEGC. EVENTS: C2H4, 02 EBV'S AND C2H4,OX,HCL CONTROL VALVES WILL CLOSE. AUTOMATIC N2 PURGE. PROCEDURE: LIFT THE LEAD TO INPUT CONVERTER 1402 AND 1403 AND CONTINUE WITH ALL POSSIBLE COMBINATIONS OF TSH 1402, 1403, AND 1404. ALL SWITCHES SHOULD HAVE BEEN PREVIOUSLY CALIBRATED. --- c; . PROCEDURE: EE SURE THAT ALL INSTRUMENTATION IS RECONNECTED AND IN WORKING ORDER BEFORE OPERATIONAL STARTUP FOR EXAMPLE THE VENT EVV AND ALL PRESSURE AND FLOW TRANSMITTERS n 1 tr> u So C/3 .fi CO -4 O--4 *>l CONFIDENTIAL REDACTED R&S 149702 ; C-220 l CONFIDENTIAL 230 REDACTED R&S149703 1 j CONFIDENTIAL c 235 redacted R&S149704 i SEJ 06/20/90 CONFIDENTIAL REDACTED R&S149705 SEJ 07/01/90 CONFIDENTIAL REDACTED i ` VINYL 2 OXY VENT HEADER MODIFIED SYSTEM R&S 149706 7/2/00 CONFIDENTIAL VI REDACTED R&S149707 r 12/14/89 K-320 AND K-330 CRITICAL INSTRUMENT LIST - FT-3139 - K-320 Suction Flow First Stage FT-3135 - K-320 Suction Flow Second Stage FT-3143 - K-320 Suction Flow Third Stage FT-3161 - K-320 Suction Flow Fourth Stage FT-3211 A/B - Water to MK-320 PT-3171 - K-320 Suction Pressure First Stage PT-3172 - K-320 Suction Pressure Second Stage PT-3173 - K-320 Suction Pressure Third Stage Frequency (Weeks) * 12 12 12 12 12 {ii 12 12 12 CONFIDENTIAL iR&s 49708 RT.9/3/91 K-320 8c K-330 Critical Instrument List (cont'd) PT-3178 - K-320 Suction Pressure Fourth Stage Frequency (Weeks) 12 PT-3162 - K-320 Discharge Pressure 12 LSL-3165 - D-320 Low Level Switch 12 K-330 FT-8317 - K-330 Suction Flow First Stage 12 FT-8311 - K-330 Suction Flow . Second Stage 12 PT-8316 - K-330 Suction Pressure First Stage 12 PT-8312 - K-330 Suction Pressure Second Stage 12 PT-9866 - K-330 Discharge Pressure 12 LT-9872 - D-330 Level 12 soo i > R&S14970 RT:9/3/91 R-400 SYSTEM U6TVS^H / aaiovaara ivixfsjaaMMOD J.R.B. B/30/91 F-410^420 SYSTEMS i LZeHS'SH f aaxavaaa iviivkilimoo J.R.B. 08/27/91 ECOLOGY AREA CRITICAL INSTRUMENTS R-400 (TOX) SYSTEM: 1. DRY QUENCH TEMPERATURE 2. WATER FLOW TO ABSORBER (D-401, J-402, J403) 3. SCRUBBER TEMPERATURE (C-404) 4. COMBUSTION AIR FLOW 5. LIQUID FEED FLOW 6. CONDENSATE FLOW TO DRY QUENCH 7. COMBUSTION AIR SUPPLY PRESSURE 8. FUEL GAS PRESSURE 9. ATOMIZING STEAM PRESSURE 10. SCRUBBER pH PROBES (C-404) 11. INSTRUMENT AIR PRESSURE 12. COMBUSTION CHAMBER TEMPERATURE 13. MAIN FLAME SCANNER 14. WATER FLOW TO SCRUBBER (C-404) 15. AUXILIARY FLAME SCANNER C O N F ID E N T IA L JRB 9/4/91 10 CO A CO l\i CONFIDENTIAL REDACTED ECOLOGY AREA CHEMICAL REACTIONS COMBUSTION REACTIONS: R&S 149713 SCRUBBER REACTIONS: JRB 9/3/91 LAD CONSOLIDATED AUDIT FOR VINYL n REVIEW OF PLANT/DEPARTMENT POLICIES, PROCEDURES, AND COMMUNICATIONS BY C O N F ID E N T IA L REDACTED R&S149714 POLICIES/PROCEDURES 1. Safety 2. Personnel Protective Equipment 3. Industrial Hygiene 4. Training 5. Safe Job Procedure Manual 6. Red Tag Procedure Manual 7. Operations Manual 8. Computerized Procedures/Checklist 9. Project Review CONFIDENTIAL SAS 9/4/91 (9/} --4 CO Or VINYL n PLANT SAFETY POLICY Our objective in Vinyl n is to produce at minimum cost that quantity of product necessary to meet the demand. The product quality must meet specifications at all times. This is to be accomplished while maintaining the highest morale and the highest standards of safety performance. Therefore, safety is equal in importance to production, cost, quality, and morale in the Vinyl n Plant Our safety objective is to eliminate accidents and injuries. Accidents can be very costly, both to you and the company. Proper knowledge of and utilization of the standards, . procedures, and principals established by Dow and the Vinyl II Plant is the surest way to attain this objective. ^ The primary responsibility for safety is yours and your supervisor's. You will be held accountable. Our objective cannot be achieved without a dedicated and continuing effort by each and every one of you. ------. Approved by:. Plant Superintendent CONFIDENTIAL REDACTED R&S149716 Revised by: Revision Date: 9/4/91 IHCI'4 L U PERSONAL PROTECTIVE: EQUIPMENT POLICY The following policy is established to set minimum standard safety equipment requirements for personal protection of personnel working in the Vinyl n block. These requirements shall apply to all personnel including Dow, contract maintenance, construction, and visitors. All personal protective equipment (PPE) used must be approved by the Division PPE Committee. This committee ensures that all PPE is sufficient for the task and meets all applicable OSHA requirements. As a minimum, the following PPE is required whenever personnel are within the Vinyl II operating area: ^ * Hard Hat * Safety Glasses ____ * Hearing Protection (in most areas unless specifically designated not required) * Monogoggles (in posted areas) * Nome* (in posted areas) Nomex fire resistant clothing shall be worn at all times by Dow operations personnel assigned to that days working shift Personal protective equipment shall be inspected regularly by the individual to ensure that it is in good condition. PPE shall not be altered in any manner. Damaged or defective PPE shah be disposed of immediately. For items in question or not covered in the above, refer to S&LP S-101. Approved by: -------------------------------------- ^-- -- Plant Superintendent Revised by: Revision Dale: 9/4/91 VINYL n INDUSTRIAL HYGIENE POLICY The following policy is established to address industrial hygiene concerns and OSHA requirements in the Vinyl n block. All job classifications in Vinyl n shall be evaluated,and documented annually for potential exposure to chemical and physical agents in the block using current division IH guidelines. Any exposure monitoring warranted from this evaluation is mandatory and shall be documented and retained according to Dow Record-Retention Schedules. Only approved sampling and analytical methods will be used- Timely feedback of monitoring results to the persons who were sampled shall be. done and documented. Plant hazards (chemical and physical) shall be communicated annually. Compliance with all of the requirements of theOSHA HazardCommunicatibifStandard is mandatory. Compliance with all Division and OSHA gradelines/requirements for respiratory protection and hearing conservation is mandatory. . . Good hygiene practices are essential for minimizing potential exposure to chemicals used in the block. No food is allowed in any area of the plant where personal protective equipment is required No process materials or chemicals are allowed in eating areas (lunch rooms, control room, office areas). Any clothing or personal protective equipment that becomes contaminated must be properly cleaned or disposed of. No one is allowed to take contaminated articles home. Approved by:_______________ ;_________ Plant Superintendent C O N F ID E N T IA L RFDACTFD B&SU9718 Revised by: Revision Date: 9/4/91 VINYL n TRAINING POLICY The following policy is established to address training needs in the Vinyl II block for Dow personnel. Proper and timely training is essential for the safe, smooth operation of the plant New employees shall be properly trained and evaluated in all aspects of theirjob assignments before they are allowed to work alone. A program for retraining all employes on a regular basis shall be established and maintained. No one shall perform a job or operate a piece of equipment prior to receiving the proper training. Compliance with the above shall be the responsibility of the individual, immediate supervisor, and thfe Training Coordinator. The Vinyl II training program shall develop and use the In-Plant Training'(IPT) program to train employees in the future. This program ensures consistent and thorough training/evaluation for all personnel. This program shall include reviewing and updating the training modules to keep the program up-to-date. Primary responsibility for this program lies with the Training Coordinator. Approved by: ,-_________ Plant Superintendent Revised by: Revision Date: 9/4/91 PROPRIETARY INFORMATION RELEASED OUTSIDE OF DOW The following policy is established to control the release of proprietary information to any individual or company outside of the Dow Chemical Company. All information that is released to any individual or company outside of the Dow Chemical Company shall be reviewed and approved by the Plant Superintendent at Vinyl II. This includes documents, data, photographs, or videotape* The Plant Superintendent must also approve any non-Dow photography or video, taping of any equipment in the Vinyl II plant before it is allowed to take place. Approved by: ------------- ~l----------Plant Superintendent C O N F ID E N T IA L REDACTED Revised bv: Revision Date: 9/4/91 jj 5cn <-veD*l ro o VINYL IT ALARM/TRIP SETPOINT CHANGES The following policy is established to address changes in alarm setpoints and shutdown trip setpoints. Any changes in alarm setpoints must be approved by the Shift Supervisor and the Area Engineer/Supervisor if they are available. If the Area Engineer/Supervisor is not available, the change must be communicated to them in writing. Any changes in trip setpoints must be approved by the Shift Supervisor, Area *. Engineer/Supervisor and the Plant Superintendent or his designee. Approved by: ---------------- C------------Plant Superintendent C O N F ID E N T IA L Revised by: Revision Dale: lV4/91 so n>o H M O p3o3 W *<NDl ro SAFE JOB PROCEDURE MANUAL The purpose of this manual is to collect in one location those policies and procedures, many of which are unique to the Vinyl n Plant which require special guidelines for being accomplished safely. Each operator should be operator Shouid'feeknowledgeable of the details contained within. In addition, each Shift Supervisor should establish his own method of insuring that those SOS's who work Team Leader for him are knowledgeable as well. We will maintain three copies of this manual. (1) Control Room (2) Safety & Training Coordinator (3) Secretary's Office C O N F ID E N T IA L Plant Superintendent Vinyl II Revised: 9/4/91 o S o 9J3 CO A CD ttoo Safe Job Procedure Manual A. Plant Safety Policies B. General Procedures C. Vinyl Area Procedures D. Ecology/Utilities Area Procedures E. EDC Area Procedures F. Emergency Procedures /G. Vinyl Lab Procedures , H. EDC Lab Procedures l//L Waste Area Lab Procedures yi. Chromatograph Procedures K. Safety Equipment and Rules in Lab j/L. SQC Lab Procedures M. Vinyl Tank Car N. Vinyl Product Storage O. Vinyl Product Transfers P. Vinyl Ship Loading Q. Chlorothene VG SAS 9/4/91 C O N F ID E N T IA L R&s 149 723 TABLE OF CONTESTS i PAGE I. GENERAL MANAGER'S LETTER ON SAFETY POLICY ............................... ............ 1 INTRODUCTION ............................................................ 2 VINYL II SAFETY POLICY ..................................................... 3 PLANT EMERGENCY RESPONSE ................................ 4 II. VINYL II PLANT SAFETY POLICIES I. 2* 3. 4. 5. 6. 7. 8. 9. 10. II. 12. 13. 14. 15. 16. 17. 18 . -19. 20. 21. 22. 23. 24. CHEMICAL EXPOSURE PREVENTION & RESPONSE ................................. BREAKING INTO LINES & EQUIPMENT UNPLUGGING LINES & EQUIPMENT ............................................................15 ADDITION TO VESSEL ENTRY................................ ................................... ISOLATING EQUIPMENT, PIPING, & VESSELS WITH AIR-OPERATED............................................. .... . ............................................. INSPECTION OF LIFTING EQUIPMENT AFTER A SPILL..................... WASTE SEGREGATION ......................... ................................................................ DISPOSAL OF ALL PRESSURIZED SPRAY CANS ...................................... SOAPS, SOLVENTS, & LUBRICANTS IN CHLORINE SERVICE........... WORKING IN PIPERACK..................................................................................... WORKING OUT OF A BASKET ........................................................................... ELECTRICAL & INSTRUMENT CABLE TRAYS ............................................. COMPRESSED GAS CYLINDERS .......................... PLUGGING AND/OR BLIND FLANGING QUICK-OPENING BLOCK VALVES ....................................................... .............................................................. WORKING ON ELECTRICAL EQUIPMENT ....................................................... CROSS-TIE 2300 VOLT SWITCUC-EAR IN SUB 3 ................................... SAFE WORKING DISTANCE FROM POWER LINES FOR PEOPLE USING CONDOR LIFTS & OTHER SIMILAR EQUIPMENT...................................... TEMPORARY SHKnsySHRTiTCw.^ ,. ...... .. ................................................ USE OF MOTORIZED LIFTING IQUIPMENT ................................................ USE OF RETENTION PINS & C-RINGS ON IMPACT WRENCHES .... ASBESTOS GASKETS ................................ MAINTENANCE OF BLOCK EQUIPMENT .......................................................... PLUMBER PLUG....................................................................................................... POLICY FOR ISSUING SAFE WORK PERMITS ........................................... 9 10 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 C O N F ID E N T IA L III. GENERAL PROCEDURES 1. 2. 3. 3A. 4. 5. 6. . 7. 8. 9. BLOCK SCAFFOLDING PROCEDURE & CHECKLIST ............................... LOUISIANA DIVISION SCAFFOLD GUIDELINES ................................. HANDLING AIR MONITOR ALARMS ................-...................................... VINYL AT THE COOLING TOWER ALARM ............... ................................ HANDLING COMBUSTIBLE GAS MONITOR ALARMS ............................... TIGHTENING LEAKING FLANGES ............................................................... ENTERING ANALYZER HOUSES .................................................................... TURNING PSV HAMMER BLINDS ................................................................. INSTALLING RUPTURE DISCS ON PSV STACKS GOING TO FLARE HEADER .................................................................................................................. SWAPPING/ PULLING SAFETY VALVES NOT TIED INTO FLARE HEADER............... .................................................................................................. 100 102 106 106A 107 108 109 110 03J" CO 4* CO rao in 112 PROCEDURE AUDIT/DEVELOPMENT STATUS SH INSTRUCTIONS: LOCATE THE PROCH3URES ASSIGNS) TO YOUR SHIFT ON THEVINYL II PROCEDURE UST ON THE VINYL II P.C. IF THE PROCEDURE EXISTS, HAVE SOMEONE ON YOUR SHIFT WHO is knowledgeable OF THE AREA GO THROUGH THE PROCEDURE TO DETERMINE IF IT IS STILL CURRENT. IF NO CHANGES ARE MADE FILL OUT THIS FORM MAKING A NOTE THAT THERE ARE NO CHANGES AND SBJD IT TO TRAINING CO-ORDINATOR. IF THE PROCEDURE IS UPDATE), OR A NEW PROCSDUREWRITTOJ, FILIN ALL COLUMNS ON THE FORM. NOTE : PLEASE REVIEW PROCEDURE AS A TEAM BEFORE SSiDING FORWARD. PROCEDURE NAME p ' 7 XjLUJi QL^X-CV 1f WRITTEN OR UPDATED BY DATE/INITIAL REVIEWED FORWARDED TO BY APPROVED TRAINING SUPERVISOR BY AREA ENG. COORDINATOR DATE/INITIALS DATE/INITIALS DATE mn-f - 3P' 'I3> - 7c-A/n m * n o a2 3w z t>r CD tO tn PROCEDURE BLOCK SCAFFOLDING PROCEDURE & CHECKLIST A SAFE WORK PERMIT IS REQUIRED TO ERECT A SCAFFOLD. ALL SCAFFOLDS MUST CONFORM TO THE DIVISION SCAFFOLD PROCEDURE (1990, SAFETY REFERENCE E-6). ANY DEVIATION FROM THIS PROCEDURE MUST BE APPROVED BY THE SHIFT SUPERVISOR. CRAFTSMEN ERECTING SCAFFOLD IN AND AROUND FURNACES ARE REQUIRED TO WEAR NOMEX CLOTHING. AT THE SUPERVISOR'S DISCRETION, THEY MAY BE REQUIRED TO WEAR NOMEX IN OTHER AREAS IF HAZARDS EXIST. NOMEX CLOTHING WILL BE ISSUED TO CRAFTSMEN AS NEEDED BY THE MATERIAL CONTROLLER OR THE SHIFT SUPERVISOR. NOMEX CLOTHING MUST BE RETURNED BEFORE LEAVING THE BLOCK. AFTER THE SCAFFOLD IS COMPLETED, MAINTENANCE SUPERVISOR OR HIS DESIGNEE WILL GO WITH CRAFT FOREMAN, INSPECT SCAFFOLD, AND FILL IN VINYL II PLANT SCAFFOLD CHECKLIST (NEXT PAGE). CHECKLIST MUST BE SIGNED BY BOTH PARTIES. MAINTENANCE SUPERVISOR WILL GIVE COMPLETE CHECKLIST TO SAFETY SUPERVISOR. C O N F ID E N T IA L R&S149726 REVISED 8/91 -100- VINYL II PLANT SCAFFOLD CHECKLIST (NOTE: REFER. TO SCAFFOLD PROCEDURE 04-28-76) 1. AREA WHERE SCAFFOLD IS ERECTED,: _____________ DATE 2. CIRCLE TYPE OF SCAFFOLD: FRAME OR BUCK TUBE OR COUPLER ALL SCAFFOLDS: YES X. is SCAFFOLD BLOCKING/HINDERING ACCESS TO ANY SAFETY ____ EQUIPMENT? (SAFETY SHOWERS/EYEWASH/FIRE EXTINGUISHER) 2. IS SCAFFOLD BLOCKING/HINDERING ACCESS TO ANY EMERGENCY____ EGRESS LADDERS? 3. IS SCAFFOLD BLOCKING ANY NORMAL WALKWAY AREAS? (IF SO,____ ROPE AREA OFF* ) 4. IF SCAFFOLD IS BUILT IN A ROADWAY, IS IT BARRICADED OR ' ROPED OFF? NO ____ ____ ____ ---- ____ NOTE: TOE BOARDS MUST BE INSTALLED ON ALL PLATFORMS ON SCAFFOLDS ABOVE 13* UNLESS SCAFFOLD IS TO BE REMOVED IMMEDIATELY. BY IMMEDIATELY WE MEAN SAME DAY. FRAME OR BUCK: YES NO 1. FOOTING STABLE? ____ 2. SCAFFOLD LEVEL? ____ ____ 3. TOE BOARDS INSTALLED SECURELY? ____ ____ 4. GUARD RAILS INSTALLED WHERE REQUIRED? ____ ____ 5. SCAFFOLD BOARDS CLEATED AND TIED DOWN? ____ ____ 6. LADDER INSTALLED WITHOUT OBSTRUCTIONS & SECURED ____ ____ PROPERLY? 7. PLATFORM AREA FREE OF HAZARDS? (NO LOOSE OBJECTS, ____ ____ SHARP ENDS #9 WIRE, NAIL HEADS PROTRUDING, ETC.) 8. SCAFFOLD ANCHORED AND TIED OFF PROPERLY? TUBE & COUPLER SCAFFOLD: 1. FOOTING STABLE? * 2. SCAFFOLDING ANCHORED & TIED OFF PROPERLY? 3. POSTS, CROSS BRACES, DIAGONAL BRACES & RUNNERS INSTALLED PROPERLY? (REFER TO SCAFFOLD PROCEDURE, 4. TOE BOARDS INSTALLED SECURELY? 5. SCAFFOLD BOARDS CLEATED AND TIED DOWN? 6. GUARD RAILS INSTALLED WHERE REQUIRED? 7. LADDER INSTALLED WITHOUT OBSTRUCTIONS & SECURED PROPERLY? 8. PLATFORM AREA FREE OF HAZARDS? (NO LOOSE OBJECTS, SHARP ENDS #9 WIRE, NAIL HEADS PROTRUDING, ETC.) YES NO ____ ____ ____ ____ ____ ____ PAGE 100) ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ROLLING & SUSPENDED SCAFFOLDS: 1. INSPECT THESE SCAFFOLDS USING POINTS THAT APPLY FROM CHECKLIST ABOVE AND FROM RULES SET FORTH IN SCAFFOLD PROCEDURE. YES ____ NO ____ REV. 8/91 -loi ros 3S3* in o ts z CO N> H > JANUARY 17/ 1990 VINYL II SUPERVISION >601 BUILDING *E: RED. TAG PROCEDURES MANUAL TO FREFARE JOBS AND TO RED TAG JOBS CONSISTENTLY/ WE HAVE STARTED JUR RED TAG PROCEDURE MANUAL. LET'S START USING THE PROCEDURES. JTHERS WILL BE ASSIGNED/ EVALUATED/ AND ISSUED TO YOU. 1AY I SUGGEST THAT YOU SIT DOWN WITH /CUR PEOPLE AND GO OVER THE INTRODUCTION TO THIS MANUAL. MAKE EVERYONE AWARE OF WHAT OUR ^KNTIONS ARE. CHANGES OR ALTERATIONS SHOULD BE ATTENTION. OUGHT TO THE SAFETY SOS'S CONFIDENTIAL SAFETY SOS -'INYL II 1- - R&S149728 TABLE OF CONTESTS VINYL XT RED TAG PROCEDURES PAGE I. INTRODUCTION...................................... . .^.................................................... II. VINYL AREA A. T--160 SAFETY VALVES .......................... .................................. *; B. DECOKE F--101 ......................................................................... C. DECOKE F-102 ......................................................................... D. DECOKEF--103______ *.......................................................................... E. DECOKE F--104 ......................................................................... F. DECOKE F--105 ......................................................................... G. VESSEL ENTRYF-101 ............................... H. VESSEL ENTRYF-102 ........................................................................ I. VESSEL ENTRYF-103 ........................................................................ J. VESSEL ENTRYF-104 ........................................................................ K. VESSEL ENTRY F-105 ...........-........................................................ L. F--101 DECOKE/VESSEL ENTRY PROCEDURE............................. M. F-102 DECOKE/VESSEL ENTRY PROCEDURE ............................ N. F-103 DECOKE/VESSEL ENTRY PROCEDURE .............................. O. F-104 DECOKE/VESSEL ENTRY PROCEDURE .............................. P. F-105 DECOKE/VESSEL ENTRY PROCEDURE .............................. Q. DECOKING (WATERBLAST) FURNACE........................................... R. VESSEL ENTRY ON FURNACES ............................. S. D--160 DECONTAMINATION.................... .......................................... T. VENT RECOVERY HEADER................................................................. U. DRAINING P-112 A/B ...................................................................... V. WKM ISOLATION VALVE ................................................................... W. VENT HEADER (C-120 TO D-160) ............................................. X. D--186 ....................................................................................................... Y. P-186 ....................................................................................................... Z. K-185 ....................................................................................................... III. EDC AREA A. GETTING INCOMING EDC LINE READY FOR METERPROVING ...................................... -............................................ B. PUTTING INCOMING EDC LINE BACK IN SERVICE AFTER METERPROVING ..................................................................................... C. MK-216 ELECTRICAL SWITCHGEAR.......... .................................. D. K--270 SEAL REPAIR ......................................................................... E. K--584 SEAL REPAIR ....................................... F. R--201 VESSEL ENTRY ...................................................................... G. R--202 VESSEL ENTRY ...................................................................... H. OXY ACID RECOVERY ......................................................................... I. HYDROBLASTING RE-255 ................................................................. I X H 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 33 35 36 37 38 39 40 50 51 52 53 54 55 58 61 62 C O N F ID E N T IA L R&s 149729 3ED TAG PROCEDURE TO DECOKE F-103 EDO FEED STATION UPSTREAM BLOCK VALVE 2. EDC FEED STATION BYPASS BLOCK VALVE 3. COIL BLEED VALVE 4. N2 TO COIL -BLOCK VALVE 5. RADIANT FUEL GAS BLOCK VALVE U/S OF F. T. 6. SUPERCRITICAL FUEL GAS BLOCK VALVE U/S OF F. T. 7. NITROGEN TO SUPERCRITICAL P. C. V. 8. INSTRUMENT AIR TO QUENCH RETURN EBV 9. EDC PURGE TO ISOLATION VALVE 10. EDC PURGE TO ISOLATION VALVE 11. EDC PURGE TO QUENCH RETURN CONTROL VALVE .2. EDC PURGE TO QUENCH RETURN MANUAL SLOCK VALVE % QUENCH RETURN MANUAL BLOCK VALVE COIL VENT TO D-102 BLOCK VALVE S. VENT TO D-112 D/S BLOCK VALVE .6. VENT TO D-112 BYPASS BLOCK VALVE 7. QUENCH NOZZLE BLEED VALVE .a. ISOLATION EBV SWITCH ON MOD V CAN ;#314) .9. ISOLATION EBV SWITCH ON MOD V CAN (#334) (OTE: PULL FUSES FOR ISOLATION EBV DO'S AND TAPE TO RED TAGS ON MOD V CAN. ;/21/90 -14- VALVE POSITION CLOSED CLOSED OPEN* CLOSED CLOSED CLOSED CLOSED ' CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED OPEN* CLOSED CLOSED R&S 149730 C O N F ID E N T IA L PROCEDURE AUDIT/DEVELOPMENT STATUS SHEET INSTRUCTIONS: LOCATE THE PROCHNJRES ASSIGNS) TO YOUR SHIFT ON THE VINYL II PROCSJURE LIST ON THE VINYL II P.C. IF THE PROCEDURE EXISTS, HAVE SOMEONE ON YOUR SHIFT WHO IS KNOWLEDGEABLE OF THE AREA GO THROUGH THE PROCEDURE TO DETERMINE IF IT IS STILL CURRENT. IF NO CHANGES ARE MADE, FILL OUT THIS FORM MAKING A NOTE THAT THERE ARE NO CHANGES AND SEND IT f0 TRAINING CO-ORDINATOR. IF THE PROCEDURE IS UPDATS), OR A NEW PROCEDURE WRITTEN, FILL IN ALL COLUMNS ON THE FORM. NOTE : PLEASE REVIEW PROCSJURE AS A TEAM BEFORE S04OING FORWARD. PROCEDURE NAME T~zo3-3 Seat- '<ed'~ae> h P-U70-.2 beo^- 'ff WRITTEN OR REVIEWED FORWARDED TO UPDATED BY BY APPROVED - TRAINING'' SUPERVISOR BY AREA ENG. COORDINATOR DATE/INITIALS DATE/INITIALS DATE/INITIALS DATE u fi M e/'W &/A 7/4/ S//s /a / REDACTED J o o 2 2 5 w 2 H r> J3 in ISCO CD Computerized Procedures/Checklist A. PDP-11 B. Mod5 C. Plans to move procedures to Reference Library on Mod Vax D. Key Parameter Program E. Red Tag Computer System Being Installed SAS 9/4/91 C O N F ID E N T IA L R&s 149732 KEY PARAMETER PROGRAM * PDP-11 BASED PROGRAM * IDENTIFIED 100 -120 KEY INPUTS FROM PLANT * SET UPPER/LOWER LIMITS TO KEEP PLANT IN CONTROL * COMPUTER DISPLAY HIGHLIGHTS ANY INPUT OUT-OF- UMTTS * EXCEPTION PAGE SHOWING ONLY INPUTS OUT-OF-LIMIT * SYSTEM USED AS PRIMARY OPERATING DISCIPLINE TO KEEP PLANT IN CONTROL SAS 9/4/91 C O N F ID E N T IA L r&s 149733 TAG # description online: operating discipline CURRENT STATUS 10--MAY--91 09: 32: 49 AREA 1 CURRENT DATA UPPER LIMIT v LOWER LIMIT CR CR CR CR CR CR -TC -TC -'TC rTC rTC \AI XAI )AI 1AI :ai iAI *AI m AT AC AC AC AC AC AC AC AC 101 102. 103 104 105 120 10151 10551 11001 11501 951OA 124 224 324 424 524 115 215 315 415 515 2 502 2 502 .2 301 301 301 F1Q1 CALCULATED CRACKING RATE F102 CALCULATED CRACKING RATE F103 CALCULATED CRACKING RATE F104 CALCULATED CRACKING RATE F105 CRACKING RATE CRACKING RATE CC120 OVHD) F-101 EDC FEED FLOW F-102 EDC FEED FLOW F-103 EDC FEED FLOW F--104 EDC FEED FLOW F105 !EDC FEED FLOW F-101 02 IN STACK F-102 02 IN STACK F-103 02 IN STACK F--104 02 IN STACK F--105 02 IN STACK F-101 RADIANT SECTION PRESS F-102 RADIANT PRESSURE F-103 RADIANT PRESSURE F--104 RADIANT PRESSURE F--105 RADIANT SECTION PRESS F-101 SUPERCRITICAL TEMP F-102 SUPERCRITICAL TEMP F-103 SUPERCRITICAL TEMP F--104 SUPERCRITICAL TEMP F--105 SUPERCRITICAL TEMP D-101 V. LEVEL D--102 7. MOD LEVEL D--103 LEVEL 7. 53. 772 57. 500 0. 000 53. S54 57. 500 0. 000 53. 861 57. 500 0. 000 53. 831 57. 500 0. 000 0. 000 57. 000 0. 000 52. 286 60. 000 . 50. 000 70041. 937 92000. 000 80600. 000 70119. 227 92000. 000 80000. 000 70041. 937 92000. 000 80000. 000 70048. 969 92000. 000 80000. 000 3. 513 94000. 000 40000. 000 5. 441 4. 900 3. 900 5. 311 5. 600 4. 600 5. 222 4. 400 3. 700 4. 658 4. 100 2. 700 19. 656 6. 200 5. 100 258. 621 400. 000 0. 000 246. 286 400. 000 0. 000 228. 210 400. 000 0. 000 266. 712 400. 000 0. 000 19, 766 400. 000 0. 000 291. 025 292. 000 290. 000 291. 910 292. 000 290. 000 291. 940 292. 000 290. 000 290. 933 292. 000 290. 000 21. 851 292. 000 290. 000 47. 713 80. 000 40. 000 47. 771 80. 000 40. 000 -0. 793 80. 000 40. 000 r> COMMUNICATIONS 1. Dally Production Meeting at 8 a.m. 2. Weekly Maintenance Planning 3. Weekly Project Reviews 4. Control Room Operations Logbook 5. Operations Instruction Logbook 6. Communications Manual 7. Daily Shift Tailgate Meetings 8. Safety Meetings 9. Bulletin Boards 10. Letters SAS 9/4/91 CONFIDENTIAL R&S149735 VINYL II WEEKLY WISH LIST FOR MAINTENANCE AND PROJECTS EOR WEEK OF: DATE AREA: (LIST ONLY JOBS FOR WHICH MMR'S HAVE BEEN SUBMITTED!!!!) DESCRIPTION 1 CRAFTS REQUIRED () PF EDO INST ELEC OTHER MATERIALS AVAILABLE YES NO SKETCH REQUIRED YES NO J I ! ! | ip i i ' - _______________ . 01-13-84 i I < --------- r 1 i i i! ! ii jf !j j !1 ' i: i: I ! 1 ! i . O o z1 - ,J \1 !z 1-5 > r r f! ... j -- 3] -- C/5 CD '-J CoO> *' ' ' ` ''l1;- -.'Jf>' :' Z ~ '" - 1 '.'...jh DON CHEMICAL COMPANY CHLORINATED ORGANICS PLANTS VINTL II DAILY MAINTENANCE PLAN SUPERVISOR________ DATE Oy-py- 9/ MAT'L TOOLS JOB DESCRIPTION WORK ORDER HC TAGS OBSV Y N T N GRAFT HVT . EQOIP TIME EST ACT INSTRUCTIONS ------ GOtMENTS II Scnpe. ~Pcu.fuLi/\a 41------^^ :i A7o.i ivte.AcL.nce. t^Xin~tcna ^----------------------------------------- uati------- ------------------------------- * -X'nS u.Lo^te. jLLp /ca-nir dleeun. llP .ij r S i A** Sui'iLl f* Demo oCLfPoic/ TWl/J Ve^ ~?3a /./iLiiiaJ-gr "Td/uJis T-446's .U , . -StfHa.na 4tnf s an \jD\Jvs in . Dd J Ike ft 1 Move. Sf&a.m CV- /o hicLre (dioon-sfirtfO-Wl Op BV. ($)'&/ ny n. /repiXfi *7~ 2 ror* \/* VoJ ' On 1 i f 7a.p ~P~iC! A bouj) 7tr I .rVnJall Dc Sa-ooplti 077 /i'fin. iiJ ^ 1 t-lij.ild VlaAtarm (2'III iar 1 /viii Sleel aoiJef- -/ini aJ t>l<la L>L>o y' ** r* J Inc __ y* S is* i AVAIIJIBLE MANHOURS (EDO/CONTR) MANHOURS PLANNED EDO/CONTR ACTUAL MANHOURS ON PLANNED JOBS TOTAL "E" MANHOURS WORKED * Po"par mib 4 IL Vis r AM 4o S.O. ...................... .. i 7 Hs Sfl- MM iJark ~Prm\Y 4 4<La Pc* "7Am /Urea-Ay "fkL^poM "feuT Pa* 7Am 1 "T L L L L t C "T ~T -L fa S-0- fiai LUavis TCnli StiiPP______ !__________ : TOTAL BREAK-IN MANHOURS WORKED TOTAL TILL-III MANHOURS WORKED 1 WORKED zezens^n a:iLo\(i:m ivixNaawMoo CATION: SUGGEST I ON: VINYL II PLANT _____ SAFETY--ENVIRONMENTAL--PROCESS' SUGE5TIQNS .. __^. .'Trt&s/n. ^Ce ^ -AjLzZ/ji-J^yiL BENIFITSl _ _ %rROX COST: LABOR COST <*20/HR>, MATL COST__________________________ TOTAL. INITIATED BY: ^__________ ____ ,,___ DATE: jBdJLz3J,, >FORWARD TO SUPERVISOR ANSWER':__ _^5_ <*_ c--; __ fz__ ______________ ____________ >^r^~ _________ __ _________________________' _ --d 0 ' __________ JzzZzzz--^_____ -%SzlJL__________- 7" -/;- i ANSWERED BY:_________________________________ ____ 0 EXPECTED COMPLETION DATE: >FORWARD TO PLANT SUPERINTENDENT SUPERINTENDENT:_______________________ ___________ LETION DATE: >RETURN FORM TO INITIATOR ______ i <r/s-r/^i DATE: ESTIMATED COST: ________ DATE: n o s- 5 CJ nF5 > !Z *1 iQ}o CO CO Pi CO a CO P.ROJECT 'no t f V'fc'b'*,____fc_g_._ fk*vr*--Qp rff/efgcbu^ 0O -- 'hltYvul'C. D?A Z?so /,*,* / / $/v7\,p So pC d' ^ ^ fly BY / ^ / /h~*3 -- y3- --> 4 ifIj+eZp ST CO^zvp*^- 3/6-r^ -- .;': Y'Kt 7^M !(pO -- floYl* *]& Rhwiffacfr* ft, Fen. i--%ty^fLu___ nJr~^ Ifal&J) 19 'c.i&. H%q SHi-- rfccrn- ilefr-cryb* ( _____ sysT^+rL*__________ ^D/ L ttcjsls h Cr(~\--- sft /> -- Ty^rtlU Oy-0S $a$r#Lt'i SS^ / DATE SCH COM COMP. PLETE COST uui iss iKtiii IS riOM>iL SAVED YPE COMMENTS APR hf^-^K 2. <3LX^. % bar pOtfa- 4^ Jj?_ AML Ago. jJo -t- dPO IZ_ A)ak.hpp Z-^/fTk^ '^fTSry.'*'j_ X / IX z z z z 4 eezensw aaiovaan ivixMaauM03 z 35 <Lr > , > f ,-g, pgg- T^q/^ 0*ui C^O^F) rI/WT^I <3 ^ OJtC.ftr*<i.eO TW c-v-uo -svt^ fwo Z'orkTWu MCV*. To 10,7^0 */(4fc, KKf A. v c-fc-o^P'SC. T^O<VV l PUS ^ 2 'f) THC rc.fi.r C*r,.*T- 1*0(1- rH- Tt>)? - QfSCKlf'fL <su, a r rn^Kl .imi<' U/s? T `,/l(7C SU I'ltjy. 6 STOfltif !// l'7G(i<ft~ ./'C *0 TO Tfte Tex'. T#Z+' *T?.q AS r- 400 AsiC T- d/ -rv^v Till tn i 't'l i'ru;.)I r- r /irOCT FTk'C) \<,F GA' A//U OTrcrr.rU >rj R,- ^CC . ///V 1 ll A ?. Pt^se ^ S* -33C /^7/W ^ S$7V4&,-Zc-j^ Ate hesB*<j .--=>/ *-syrupy,/P. oA^'A /w^i- /-iGt'.su 'f'e/zs^^,__ J.j~yh d.c.rGc/f^ ^i^O. /%Ar-,,K /l-rr tAs_ SshytG- <4t5 Ov'tMt /4-S /&<_ /AjAlXAA,^--, ., A^oA - Ss+TiyO^-- AJe?y'/ztrf& jfZ/AJ\ k' ^/V/VZ _ a > n H O =9**> &E?k -T^- Q1 iV/ w//.4. /7^ r^--X^o an___TojfiL-__ Otdjl +-/- -4jn+y----- 41-'* ' L, <~is-f nW /W/7 Dl H-l^fC A / ;. ^ OkT__ -- Pl/-l&s3'. ---LlflV)' T- -4 + T'U^ UlL\Z_J^L___ J2P--J. / ^ Ka*7 ~7 __________ L____-- TtWnK.6*_______________ AA f)^_ 3 <'7'VXvC-7\^-'^'! QL.d''dO /(jJSujl/. --\jLAxlvi ^-c3 ^/^LccAja .4/6/- '-^'unm A/10/3 CchZj? jyf___ Tjrmjrtn r^- QAa-a e A^Oilc <3? fi^LfZJ-,r-tj tOnj^kj. '33<^C^/ - c.j^. . t -^juluj, Of. ,y .. (P27o33 C-fcD. ^J O DATE i !ze/&\ i&tfU m ii Fefill us* if>i Uirh' fifth (W 2* fe.*^ fili z/2.7/4 / \Z&kr(hl ffll 3//zz/Al_/____ 3/22/9! 3/zt. Mi /Ca , S ' >. /(fs v,. nil y^f/n//V/ An -Vv;. .-r>i A V>- */l9 A/ Z\ c7 i`y 16 mt-a ill i A-----3-f-/-S--O--- i-/-9---!---- --| 199! n O 2 ENTRIES FOR COMMUNICATIONS MANUAL NAME -------------------- -------------------------------- TOPIC M 2 H >r F-105 MODS PRCG&AM CMAA<=S u5{&m & cbjcuctes SuvjstetM ScilichesV J (SL&M'zk nuA/cput. . - IE'2^1 Atfo C.tiLQU<S(= M/X.fcf- lyC 1t s, Sot&ri&u. ^cLaaj^CS More A cUcv)C5 *" . av '* * 0 AHC-L Quality*----------------- >a Q-40O AIOO V C/MA/C55 SH JJ /?~#0 M60 V tZMMkS&S Yshqn&pe /V Cir'-bo S,\-\ YSa ij,/ y/*v r >y/A//AJG- S-2S~\ --/mS...G. SAC/ SS..y.>..-/s/*L- /JasA< 1 ------ iw5t*u' 0 V - .; ,^ Cxtuki^ rdt c*yrw& \,*V:rau:--nCi fl~ 06>0 M&o 1/ C/JAAJ*#? ^lu -hr!j-A:Uis^; --' i./ ajcrx mjSEkEERKJ& PLAkIS J. i ^ 9/^ iUP JMg i/a^jP-Go f,cl PLs7cmma ihC A<- CONFIDENTIAL P-105 MOP 5 PROGRAM CHANGES JANUARY 28, 1991 #1. A NEW F--105 DRAFT CONTROLLER, AO(505) , HAS BEEN ADDED TO SYSTEM C MOD 5 PROGRAM. THIS CONTROLLER IS A MASTER/SLAVE WITH THE MASTER CONTROLLING THE FURNACE OXYGEN BY SETTING A DRAFT PRESSURE SET POINT. THE SLAVE CONTROLS THE DRAFT PRESSURE BY POSITIONING THE DAMPER ACCORDING TO THE OXYGEN CONCENTRATION. AIR ONTO THE FURNACE IS CONTROLLED BYJTWO DIFFERENT METHODS (WITH ONLY THE SECOND ONE BEING A NEW METHOD): 1) DRAFT PRESSURE CONTROLLER WHICH IS USED FOR MOST OF THE FURNACE OPERATIONS HAS A LOW DRAFT PRESSURE CONSTRAINT SO AS TO KEEP A LOW DRAFT PRESSURE FROM TRIPPING THE FURNACE (THE SAME METHOD AS BEFORE). 2) AN OXYGEN CONCENTRATION MASTER WITH A DRAFT CONTROL SLAVE IS USED TO ACHIEVE OPTIMUM FURNACE EFFICIENCY. TO ENABLE THIS CONTROLLER : A. MUST BE IN STEP(500) (AND) B. SET AK(31) EQUAL TO A SPECIFIC 02 CONC. BETWEEN THE VALUES OF 6.2 AND 7.4 _ (AND) C. SET DK(200) = 1 NOTE* A VALUE OF 6.7 IS GIVEN TO THE MOD BY DEFAULT IN STEP(500) UNTIL THE ABOVE CRITERIA IS MET BY THE OPERATOR. #2. A CRACKING RATE CONTROLLER IS ALSO INCLUDED IN THIS PROGRAM LOAD; HOWEVER, THIS CONTROLLER IS NOT READY TO BE ENABLED AT THIS POINT. A NEW PROGRAM FOR SYSTEM A MUST BE LOADED BEFORE A CC14 LEVEL CAN BE READ BY THIS CONTROLLER. NOTE* SETTING DK(107) = 1 ENABLES THIS CRACKING RATE CONTROLLER. PLEASE AVOID DOING SO UNTIL SYSTEM A RECEIVES A NEW LOAD. REDACTED R&S149742 February 15, 1991 Dow U.S.A. The Oow Chemical Company P.O. Box ISO Plaquemine, Louisiana 70765-0150 Vinyl IX Communications Manual E--251 ADD CHLORINE MIXER TRIPS On Monday it was discovered that the North E-251 top bleed valve had formed an external leak, possibly a leaking gasket. In order to stop this leak two options were considered, the first was to by-pass E-251 and replace the valve and the second was to install a furmanite box around it. After more evaluation of by-passing the exchanger, this option was ruled out for several reasons. First, Methanes' reactor cannot handle the acid at such a cold temperature. Second, the downstream piping between E-251 and Methanes is not cold service rated. By definition cold service is generally' considered -20 deg C and below. It was determined that: ah -40 deg C the maximum pressure normal carbon steel could handle would be 52 psig. Although this exchanger had been by-passed once some years ago, chances were very good that the piping would probably not withstand this temperature this time. In fact, failure under these conditions is considered to be catastrophic, meaning that the piping would not just leak, but would shatter. In the next plant shutdown we will be replacing the _ valve and modifying the piping on E-251 such that by-passing it under the current arrangement would not be possible. Another item evolved from this evaluation. It was discovered that the Chlorine trip on MX-250 was set at 175 deg C, but that the alarm for the trip was set at 125 deg C. There were several concerns with this setup. First, the alarm and the trip should have been set for the same temperature. Second, nobody realized that the trip had been changed to 175 deg C, it was originally 125 deg C. After talking with from the Reactive Chemicals Committee, he informed me that the latest data he has states that 155 deg c is considered to be the temperature for an Iron and Chlorine reaction. This temperature also has * R&s149743 REDACTED CONFIDENTIAL REVIEW OF VINYL H PLANT/DEPARTMENT POLICIES, PROCEDURES, AND COMMUNICATIONS STRENGTHS * Safety Program * Employee Commitment * Safe Job Procedure Manual * Key Parameter Program * Project Review Program * Daily Tailgate Meetings * Goal Setting For All Employees CONFIDENTIAL SAS 9/4/91 33 U) A CD 'sj 4* REVIEW OF VINYL U PLANT/DEPARTMENT POLICIES, PROCEDURES, AND COMMUNICATIONS OPPORTUNITIES " * Update Operations Manual - * Procedures Located In Several Places (Manuals, Control Vax, Mod5 Vax, PDP-11, etc) y* More Emergency Drills (Hands On) v* Standardized Redtagging (In Progress) * * Goal Setting Process Is Still New l* No Mechanism Established To Ensure Communications Read By All Needed Personnel SAS 9/4/91 CONFIDENTIAL R&S 149745 LAD CONSOLIDATED AUDIT FOR VINYL n REVIEW OF TRAINING AND RETRAINING PROGRAMS BY CONFIDENTIAL REDACTED REVIEW OF TRAINING AND RETRAINING PROGRAMS * OPERATOR TRAINING * STAFF TRAINING * IPT PROGRAM * SUMMARY * STRENGTHS * OPPORTUNITIES SAS 9/4/91 OPERATIONS TRAINING 1. Safety Orientation A. Block Indoctrination Film B. Environmental (SPC, SPCC, RCRA, HAZCOM, ETC) C. New operator checklist D. Walkthrough 2. Area Training A. Plant Areas 1. Load Rack 2. Lab/Samples 3. Oxy Area OS 4. Vinyl Area OS 5. EDO 6. Oxy Area SOS 7. Vinyl Area SOS B. One on One Training C. Training Checklist D. Must Pass Board Review to Operate Alone 1. Shift Supervisor 2. Area Engineers/Supervisors 3. Production Supervisor 4. Other Experienced Staff E. Classroom and hands-on for new equipment 3. Goal Setting with Periodic Reviews During the Year 4. Retraining A. Protective Equipment B. Combustible Gas and Oxygen Meters C. JLG D. Fork Truck E. 5/15 Ton Cherry Picker F. Hazard Communication Training G. Environmental (SPC, SPCC, RCRA) H. Retrained All Operations in last 5 years SAS 9/4/91 CONFIDENTIAL r &s 149748 NEW EMPLOYEE INDOCTRINATION (NON-EXEMPT) CONFIDENTIAL 1. Introduction to Staff and Personnel 2. Meeting with Supervisor A. Job descri pt i on/JPR/mi 1 eage/overt inie/promoti ons/ salaries B. Chain of command C. Brief description of other peoples job (ex. Bill & Freddie, Inst, people. Computer people, etc-) 0. Work schedule and necessary phone numbers/PI and FI 3. Meet with Superintendent 4. Meet with Block Safety & Training Coordinator A. Quick overview of training program B. Block Safety Program/ring policy/gloves C. Make sure safety gear has been issued and proper care is taken/locker has been issued D. Make sure Nomex is ordered E. Individual Safety Responsibility F. Accident Investigation/reporting 5. Block Indoctrination A. Safety showers and eye wash B. Major pieces of equipment/chemicals contained C. Fire extinguishers and deluge guns D. Sub stations/lab/analyzer houses/inst. junc. houses . Scott air pacs F. Smoking areas/break areas/phones/intercoms G. Review dictionary of terms and equipment 6. Review of hazardous Materials and Vinyl Standard. Inform new employee of the Right to Know Act. Let employee know we have a Hazardous Communication book located in the Environmental Specialist Office and that it contains Material Safety Data Sheets for all chemicals in our block and their purpose. 7. DOT Training 8. Review Safety and Loss Prevention Standard A. Modules 9. Introduction to Safe Job Procedure Manual 10. Work Loading Job under Direct Supervision A. Observe loading routine B. learn how to work ramDS. valves, start and stop Dumps 5* C/3 Avl CD 11. Complete Load Rack Modules 12. Two Weeks of Plant Operator Training Basics 13. Complete Safety Observer Modules 3/89 CONFIDENTIAL R&S149750 NAME NEW EMPLOYEE EVALUATION SHEET .1- COMPLETE DOW ORIENTATION .2- EXPLAIN VINYL II CHAIN OF COMMAND 3. COMPLETE SAFETY OBSERVER MODULES 4. DRAW GENERAL PLANT LAYOUT 5. CERTIFIED ON JLG AND FORKLIFT 6. CERTIFIED ON EXPLOSIMETER AND BODY HARNESS 7. COMPLETE NESHAP, LESHAP AND HAZMAT MODULES 8. DRAW BASIC FLOWS OF THE FURNACES AND THE QUENCH DRUMS 9. DRAW BASIC FLOWS OF HEAT RECOVERY 10. DRAW BASIC FLOWS OF C-lll,C-110,AND C-120 11. DRAW BASIC FLOWS OF T-120 TO THE SPHERES 12. DRAW BASIC FLOWS OF OXY 13. DRAW BASIC FLOWS OF C-250 AND C-255 14. DRAW BASIC FLOWS OF C-230, C-260, C-270 AND D-270 15. DRAW BASIC FLOWS OF C-235 AND FEED TANKS 16. DRAW BASIC FLOWS OF^ K-320 AND K-330 17. DRAW BASIC FLOWS OF F-110 AND THE COOLING TOWER 18. DRAW BASIC FLOWS OF R-400,F-410 AND F-420 19. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE FURNACES, QUENCH DRUMS f AND HEAT RECOVERY 20. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-lll 21. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-110 22. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-100 AND C-120 23. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR T-120 THROUGH C-140 24. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE SPHERES 25. DRAW INSTRUMENTATION, LIST TRIPS AND EXPLAIN BASIC CONTROL SCHEME FOR R-201 AND R-202 26. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-201, C-202, C-203, AND C-204 27. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-211, C--212, AND D-214 28. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-230 AND S-230 29. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-260 30. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-270 AND D-270 31. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-250 AND C-255 32. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-235 33. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR K-320 34. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR K-330 g ^ I CONFIDENTIAL 35. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR F-110 36. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE COOLING TOWER 37. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE FUEL GAS SYSTEM 38. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE VENT SYSTEM 39. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE STEAM AND CONDENSATE SYSTEMS 40. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL-SCHEME FOR THE CHILLED EDC SYSTEM 41. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE CHILLED WATER SYSTEM 42. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR THE CELL EFFLUENT SYSTEM 43. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-220 44. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR C-240 AND PIT 430 45. DRAW INSTRUMENTATION AND EXPLAIN BASIC CONTROL SCHEME FOR D--541 46. EXPLAIN THE PLANT NITROGEN SYSTEM 47. DRAW A TYPICAL LUBE OIL SKID INCLUDING INSTRUMENTATION AND EXPLAIN THE TRIPS ASSOCIATED WITH EACH SYSTEM 48. DRAW INSTRUMENTATION AND LIST TRIPS FOR R-400 49. DRAW INSTRUMENTATION AND LIST TRIPS FOR F-410 AND F-420 50. DEMONSTRATE HOW TO MAKE THE OUTSIDE ROUND IN THE VINYL AREA 51. DEMONSTRATE HOW TO MAKE THE OUTSIDE ROUND IN THE EDC AREA 52. DEMONSTRATE HOW TO MAKE THE OUTSIDE ROUND IN THE OXY AREA 53. DEMONSTRATE HOW TO MAKE THE OUTSIDE ROUND IN THE ECOLOGY AND THE UTILITIES AREA 54. EXPLAIN THE PROPER WAY TO REPORT PROBLEM IN THE OUTSIDE ROUND 55. DEMONSTRATE THE PROPER PROCEDURE FOR SWAPPING THE FEED TANKS 56. DEMONSTRATE THE PROPER PROCEDURE FOR RESETTING AMOTS AND LIGHTING BURNERS ON FURNACES 57. EXPLAIN THE PROPER PROCEDURE FOR BLEEDING DOWN AND RED TAGGING EQUIPMENT 58. DEMONSTRATE THE PROPER PROCEDURE FOR SWAPPING AIR DRYERS 59. DEMONSTRATE THE PROPER PROCEDURE FOR SWAPPING THE OXY PURGE FILTERS 60. DEMONSTRATE THE PROPER PROCEDURE FOR LINING UP THE T-590'S 61. DEMONSTRATE THE PROPER PROCEDURE FOR LINING UP C-240 62. DESCRIBE WHO TO CONTACT TO REPORT LEAKS AND THE PROPER PROCEDURE TO USE TO REPAIR THEM 63. EXPLAIN THE PROPER WAY TO DO THE WEEKEND CHECKLIST AND WHEN TO DO THE WEEKEND CHECKLIST 64. DEMONSTRATE HOW TO SET UP THE SAMPLE ROUND IN THE LAB COMPUTER 65. DEMONSTRATE HOW TO MAKE CHANGES IN THE COMPUTER LINE UP AND HOW TO ADD EXTRA SAMPLES 66. DEMONSTRATE HOW TO CHANGE A SYRINGE AND SEPTUM ON THE CHROMOTOGRAPHS 67. DEMONSTRATE HOW TO SHOOT A STANDARD AND PLOT THE RESULTS OF THE CHROMOTOGRAPH 68. EXPLAIN WHEN TO CALL BILL OR FREDDIE TO WORK ON A CHROMOTOGRAPH OR ON THE COMPUTER 69. DEMONSTRATE THE PROPER WAY TO CATCH VINYL SAMPLES, AND EXPLAIN WHEN TO CATCH THEM 70. DEMONSTRATE THE PROPER WAY TO CATCH EDC SAMPLES, AND EXPLAIN WHEN TO CATCH THEM 71. DEMONSTRATE THE PROPER WAY TO CATCH CONDENSATE AND WATER SAMPLES AND EXPLAIN WHEN TO CATCH THEM 72. DESCRIBE PROPER SAMPLE CONFIGURATION AND EXPLAIN HOW TO REPAIR FAULTY SAMPLE POINTS 73. DEMONSTRATE HOW TO RUN ALL VINYL CHROMOTOGRAPHS 74. DEMONSTRATE HOW TO RUN ALL EDC CHROMOTOGRAPHS 75. DEMONSTRATE HOW TO RUN EDC AND VINYL WATER ANALYSIS ON THE KARL FISCHER MACHINE 76. DEMONSTRATE HOW TO RUN RECIPE AND UTILITY SAMPLES 77. LIST ALL THE SAMPLE SPECS AND EXPLAIN WHY THEY ARE SET WHERE THEY ARE AT 78. HAS COMPLETED BETZ WATER TREATING CLASS 79. HAS COMPLETED ALL THE LAB MODULES 80. HAS COMPLETEDPILOT 1, UNITS 1&2 81. HAS COMPLETEDPILOT 3, UNITS 1&2 AND 3&4 82. HAS COMPLETED PILOT 4, UNITS 1, 2, 3, AND 4 83. HAS COMPLETED PILOT 6, UNIT 1 SECTIONS 1&2 AND SECTIONS 3 THROUGH 5 84. HAS COMPLETEDPILOT 7, UNIT 1 85. HAS COMPLETEDPILOT 14 86. HAS COMPLETEDPILOT 16 87. HAS COMPLETED "RIGHT WAY TO OPERATE" CLASS OS EDC TRAINING- CHECKLIST-- Chloroprene Removal 1. What is the purpose of c-250 and.' c-255? What are their feeds? 2. Be able to draw one line diagram of C-250 and C-255. 3. Give the locations of the following control valves, pumps and fans. a. C-250 reflux C.V. b. C-250 bottoms C.V. c. Chlorine to MX-250 c,Vd. C-255 bottoms C.V. e. C-255 reflux C.V. f. CL2 to'MX--255 C.V. * C-255 feed C.V. h. E-255's iU E--250'S f- E-251'S It.. HE--250*s r_ ME-255's BC. " E--572 ir- E-256 4. Where does C-250 and C-255 bottoms go? 5. Where does the condensed liquid in D-250 and D-255 go? 6. Where do we vent D-250? D-Z55T E-256? E-573? Where else can these veniz go? . - ,.i 7. What cooling do .we use on E-255 and E-573? V 8. What pressure steam do we use an- RE-250 and RE-255? EDC Finishing and Heavies Removal 1. What is the purpose of C-260T What are the feeds to C--260? 2. Be able to draw one line diagram of c-260. 3. Give the locations of the following equipment: a. C-260 feed C.V. b. P--261's c. P--260's d. P-262's e_ ME-260'a - C--260 bottoms C.V. g. C-Z60 reflux C.V. hv D-260 n. C. V. 4. What is the purpose of D-260? E-261? CONFIDENTIAL R&S 149754 Date Completed 1/89 Trainee signature -1- Trainer signature SOS - OXY & EDC AREA TRA] KL CHECKLIST Name Pat oxy coluxans 1. What is the function of C201 and C203? 2. What is the difference between G201 and C203? 3. What should the pH run on C203 bottoms? 4. What should acid run on C201 bottoms? 5. Where does C201 and C203 bottoms go? 6. Where does the water to C201 and C203 came from? 7. List the locations of the following control valves: (a) water to C201 and C202r (b) C201 and C202 level control valves r (c) C211 reflux C/V 8. List the locations of the following control valves: (a) water to C203 and C204, (b) caustic to C203 and C204 , (c) C203 and C204 bottoms level controller 9. Where does C203 overheads go7 10. ' C203 bottoms level is high and rising. The bottoms out control valve is wide open but showing a small flow. What is the problem and how can this be corrected? 11. Why do we use a purge on C201 C203 instrumentation? 12. What kind of purge do we use on C201 and C203 instrumentation? What kind on C202 and C204? 13. What is the purpose of C211? 14. Why is the top of C211 cold and the bottom hot? 15. Where does C211 overheads go? 16. 4iere does C211 bottoms go? 17. Draw a diagram of the C2U system, include pumps, exchangers, and control valves. 18. What is the coolant used on E213? 19. Draw a diagram of C212 system, include pumps, exchangers, drums, and control valves. 20. Where does C212 overheads go? Where does 0214 overheads go? 21. What are the tie-ins to the suction of C212 bottoms pumps and why should this be used very carefully? 22. What is the purpose of D214? 23. What trip is associated with 0214? 24. What is the first thing to do when C203, C204, or T222 pH indications drop to zero during normal operation? 25. What should D214 overhead temperature run? 26. What does the temperatures on C211 middle and overhead usually run? 27. What sure the major differences between Train I and Train II? jg cn CO -4 3/89 STAFF TRAINING 1. Safety Orientation A. Block Indoctrination Film B: Environmental (SPC, SPCC, RCRA, HAZCOM, ETC) C. New Technical employee checklist D. Walkthrough 2. Training Checklist A. Safety B. Environmental C. Organization Review/Tour D. Policies E. Process F. Division Tour G. Miscellaneous Items (Phones, Computers, Mail, etc) H. Job Assignment/Goal Setting I. Training Curriculum Thru First 3 Years 3. One on One Training 4. Classroom Training 5. Goal Setting with Periodic Reviews During the Year 6. Retraining A. Protective Equipment B. Hazard Communication Training C. Environmental (SPC, SPCC, RCRA) D. Division S&LP's SAS 9/4/91 CONFIDENTIAL R&S 149756 VINYL II DEPARTMENT ORIENTATION FOR NEW TECHNICAL EMPLOYEES PURPOSE 1. TO FAMILIARIZE THE NEW TECHNICAL EMPLOYEE WITH THE VINYL 2 DEPARTMENT. 2. TO INSTRUCT THE NEW EMPLOYEE IN THE THINGS THAT . NEED TO BE LEARNED IMMEDIATELY. 3. TO REVIEW PROSPECTIVE JOB ASSIGNMENTS AND TRAINING PLANS. 4. TO PROVIDE THE NEW EMPLOYEE WITH BASIC MATERIALS NEEDED FOR TRAINING AND THE JOB. RESPONSIBILITY THE EMPLOYEE IS RESPONSIBLE TO SCHEDULE AND ATTEND ANY REQUIRED TRAINING, AND COMPLETE THE CHECKLIST IN THE TIME SPECIFIED. THE IMMEDIATE SUPERVISOR OF THE TECHNICAL EMPLOYEE IS RESPONSIBLE IN ASSISTING THE EMPLOYEE AS NEEDED BY PROVIDING TRAINING, DIRECTION TO THE APPROPRIATE PERSONNEL, ASSIST IN SCHEDULING AS NECESSARY, AND FOLLOW-UP TO ENSURE THE CHECKLIST IS COMPLETED ON TIME. WHEN &T.T. TJEMS IN THIS CHECKLIST MUST BE COMPLETED WITHIN 8 WEEKS OF EMPLOYEES START DATE AT VINYL II UNLESS OTHERWISE NOTED. HOW FOLLOW THE CHECKLIST. AS A SPECIFIC ITEM HAS BEEN COMPLETED, THE INSTRUCTOR OR SUPERVISOR MUST INITIAL AND DATE THE APPROPRIATE BLANKS. DURING USE, THE CHECKLIST SHOULD BE KEPT BY THE EMPLOYEE UNTIL ITEMS ARE COMPLETED DURING THE INITIAL EIGHT WEEK TRAINING PERIOD. AT THAT TIME, THE-CHECKLIST SHOULD BE PLACED IN,THE.-EMPLOYEE.'S PERSONNEL _FOLDER AND USEDTAT EACH GOAL REVIEW/PLANNING SESSION UNTIL THE ENTIRE CHECKLIST IS COMPLETED'. REVISION DATE: 9/4/91 sas C O N FID EN TIAL r&s 149757 VINYL II DEPARTMENT NEW TECHNICAL EMPLOYEE ORIENTATION CHECKLIST SAFETY EMPLOYEE: SUPERVISOR: HIRE/START DATE AT VINYL 2: DATE ________ ________ ________ ________ ________ ________ ________ ________ ________ ________ _______ ________ ________ ________ BY 1. ISSUE BASIC SAFETY EQUIPMENT: _______ A. HARD HAT _______ B. SAFETY GLASSES ______ C. MONOGOGGLES ______ D. NOHEX CLOTHING (ORDER) _______ E. RAIN SUIT & RUBBER BOOTS _______ F. HEARING PROTECTION _______ G. FULL FACE RESPIRATOR ______ H. RESPIRATOR LOCKER ______ 2. DEMONSTRATE PROPER USE OF MONOGOGGLES _______ 3. TAKE EMPLOYEE TO RESPIRATOR FITTING FACILITY TO CHECK RESPIRATOR FIT. ______ 4. ISSUE A COPY OF BLOCK SAFETY RULES AND REVIEW WITH EMPLOYEE. _______ 5. SEAT BELT POLICY _______ 6. SPEED LIMIT _______ 7. MOTOR CYCLE HELMETS 8. FACIAL HAIR POLICY CONFIDENTIAL R&S i 49758 REVISION DATE: 9/4/91 sas SAFETY (CONT) 9.DRESS CODE 10. SMOKING POLICY 11. RED TAGS 12. DIVISION SAFETY & LOSS PREVENTION STANDARDS AND IPT MODULES. GIVE COPY OF S&LP STD TO EMPLOYEE. 13. EMERGENCIES A. 333 B. BLOCK SPILL ALARM C. DIVISION EMERGENCY ALARM; DISCUSS OUT OF BLOCK SPILLS THAT COULD AFFECT THIS PLANT. 14. SAFETY SHOWER AND EYE WASH FOUNTAINS; DISCUSS LOCATION, SHOW HOW TO USE, EXPLAIN ALARM SYSTEM. 15. REPORTING INJURIES. 16. INTERVENTION DURING AN UNSAFE ACT 17. STAFF SAFETY PROGRAM 18. DISCUSS HAZARDOUS CHEMICALS AND POINT OUT ALL AREAS WHERE THEY EXIST. 19. DISCUSS HAZARDS OF FLAMMABLES, LIQUIDS AND VAPORS. 20. DISCUSS HAZARDS OF INERT ATMOSPHERES AND POTENTIAL HAZARD AREAS IN PLANT (I.E. ANALYZER SHACKS) 21. DISCUSS HAZARDS OF HOT WATER AND STEAM. 22. REACTIVE CHEMICALS PROGRAM 23. INDUSTRIAL HYGIENE: REVIEW COPY OF BLOCK'S HAZCOM MANUAL. 24. MINIMUM REQUIREMENTS: BRIEFLY REVIEW AND ISSUE COPY OF BOOKLET. CONFIDENTIAL r &s 149759 REVISION DATE: 9/4/91 sas SAFETY (CONT) 25. FIRE FIGHTING EQUIPMENT: ________ _______ A. SPRINKLER ______ ^ _______ B. DELUGE GUNS ________ _______ C. EXTINGUISHER ________ _______ D. DIESEL PUMPS ________ _______ E. FOAM, ETC. ________ ________ _______ 26. i _______ 27. OTHER SAFETY EQUIPMENT, FIRE BLANKETS, AIR PACS, SCOTT AIR PAC (DEMONSTRATE USE) . DEMONSTRATE USE OF SAFETY HARNESS. J______ _______ 28. PRESSURE VESSEL PROGRAM _______________ 29. CRITICAL INSTRUMENT PROGRAM _______________ 30. PSV PROGRAM _______________ 31. SAFE JOB PROCEDURE MANUAL _______________ 32. REVIEW "CM SAFE HANDLING GUIDE ENVIRONMENTAL ________________ ________________ ________________ ________________ ________________ 1. REVIEW EXPECTATIONS. 2. REVIEW ENVIRONMENTAL GUIDELINES AND REFERENCE. 3. REVIEW ENVIRONMENTAL CHECKLIST. 4. ENVIRONMENTAL SERVICES (INTERACTION WITH PLANT) . 5. ENVIRONMENTAL REDBOOK (REVIEW) . ORGANIZATION REVIEW AND BUILDING TOUR ________________ 1. REVIEW DIVISION ORGANIZATION. 2. REVIEW PLANT ORGANIZATION. CONFIDENTIAL R&S 149760 REVISION DATE: 9/4/91 sas A HOW TO GET THINGS DONE IN THE PLANT B. HOW TO GET THINGS DONE IN THE ENGINEERING DEPARTMENT. 3. TOUR OFFICE BUILDING, LAB, CONTROL ROOM, AND WAREHOUSE. 4. SHOW EMPLOYEE HIS/HER OFFICE. PROCESS ________ _______ 1. REVIEW GENERAL PROCESS (NOT TOO MUCH DETAIL) . ________ _______ 2. MAKE OUTSIDE TOUR OF PLANT. ________ _______ 3. GIVE EMPLOYEE FLOW SHEETS AND P&IDS ________ 4. SPEND 1 DAY WITH OUTSIDE VINYL OS ________ 5. SPEND 1 DAY WITH OUTSIDE EDC OS ________ 6. SPEND 1 DAY WITH LAB/SAMPLE OS ________ 7. SPEND 1 DAY WITH I/E GROUP IN PLANT _______ 8. SPEND 1 DAY WITH EDO/MAINT (ATTEND 7 AM CONTRACTOR SAFETY MEETING, GO WITH PERMIT WRITER AS HE/SHE ISSUES PERMITS, SPEND REST OF DAY WITH MILLWRIGHTS). _______ _______ 9. SPEND 1 DAY WITH LOADING CREW LOADING TANK CARS, OR SHIP. 10. SPEND 1 DAY WITH SOS IN CONTROL ROOM (ATTEND 6:30 AM TAILGATE MEETING. SPEND 1/2 DAY WITH VINYL SOS, 1/2 DAY WITH EDC SOS). POLICIES 1. SAFETY/ENVIRONMENTAL 2. WORK HOURS 3. REPORTING ABSENCE 4. VACATION 5. PERSONAL ILLNESS 6. FAMILY ILLNESS REVISION DATE: 9/4/91 sas R & S 149761 O o I 3 H C 7. FUNERAL LEAVE 8. WEEKEND CALL 9. PLANT SHIFT SCHEDULE 10. OVERTIME 11. INSURANCE 12. EMPLOYEE'S INFORMATION FILE (GREEN BOOK) 13. PASSOUT'S 14. VISITORS (SALES PEOPLE, FAMILY, SIGN-IN LOG, ETC.) DIVISION TOUR 1. CREDIT UNION 2. CAFETERIA 3. MEDICAL DEPARTMENT 4. STOCK 5`. MACHINE/ FAB. SHOP 6. MTS BUILDING 7. LAS&TL 8. CONFERENCE CENTER 9. DOW LEARNING CENTER 10. DOW STORE 11. ENGINEERING 12. R&D LIBRARY (GET COPY FLOW OF FLUIDS BY CRANE) 13. VARIOUS GATES AVAILABLE FOR EMPLOYEE USE 14. PURCHASING REVISION DATE: 9/4/91 sas s* CO -CsFO]t CONFIDENTIAL MISCELLANEOUS 1. FILL OUT PAPERWORK(ATTENDANCE SHEETS, TIME, COST CENTER, PERSONAL INFO, ETC). 2. ISSUE OFFICE SUPPLIES/TELEPHONE BOOKS, SHOE TICKETS, ETC. 3. TELEPHONE - ASSIGN NUMBER AND HOW TO USE. 4. INTERCOM - HOW TO USE. 5. COPY MACHINE - HOW TO USE. 6. MAIL SYSTEM - ASSIGN MAILBOX AND HOW TO USE. 7. LOCATION OF EQUIPMENT FILES. 8. TIME CARDS/ATTENDANCE RECORDS. 9. PAY DAY 10. LOCATION OF FORMS AND SUPPLIES. 11. HOW TO USE VOICE MAIL. 12. COMPUTER SYSTEMS - GET ACCOUNTS AND HOW TO USE 13. NAMEPLATES FOR OFFICE AND MAILBOX 14. FRANKLIN DAY PLANNER - ORDER AND HOW TO USE 15. GENERAL PLANT COMMUNICATIONS A. MORNING STAFF MEETING B. WEEKLY PROJECT REVIEW C. MONTHLY MAJOR MANAGER REVIEW D. LOGBOOK, OPERATIONS COMMUNICATIONS MANUAL, INSTRUCTION LOGBOOK, ETC) 16. BUSINESS CARDS (ORDER) 17. REVIEW COPY OF PRODUCTION SECTION OF RECORDS RETENTATION BOOKLET REVISION DATE: 9/4/91 sas CONFIDENTIAL r &s 149763 JOB ASSIGNMENT 1. MEET WITH PLANT SUPERINTENDENT (DISCUSS WHAT IS EXPECTED OF ENGINEERS). 2. ASSIGN AREA/PROJECT OF RESPONSIBILITY. 3. SET 3 TO 5 GOALS BASED ON AREA/PROJECT OF RESPONSIBILITY, SAFETY, ENVIRONMENTAL, AND TRAINING NEEDS. 4. MEET WITH MAJOR MANAGER (DISCUSS WHAT IS EXPECTED OF ENGINEERS). C O N F ID E N T IA L REVISION DATE: 9/4/91 sas 3) co 1t0*. a> TRAINING CURRICULUM FIRST MONTH TRAINING ________ _______ 1. VINYL 2 BLOCK INDOCTRINATION FILM(FIRST WEEK ON THE JOB) ________ _______ 2. VINYL 2 HAZCOM TRAINING ________ ________ _______ 3. VINYL 2 RCRA TRAINING _______ 4. VINYL 2 SPC AND SPCC TRAINING * ________ _______ 5. VINYL 2 VINYL STANDARD TRAINING ________ _______ 6. VINYL 2 HAZARDOUS WASTE OPERATION AND EMERGENCY RESPONSE (HAZWOPER) TRAINING J______ 7. VINYL 2 CPAI TRAINING ________ _______ 8. MSDS SHEETS (SHOW LOCATION AND EXPLAIN USE) . FIRST YEAR TRAINING ________ 1. ORIENTATION (DPS-6397) ________ ______ 2. DOCUMENT CREATION & RETENTION(DPS-6796) ' _______ 3. ENVIRONMENTAL COMPLIANCE (DPS-7097) ________ 4. SAFE WORKING STYLES (DPS-5128) ________ 5. ENGINEERING TRAINING (DPS-7210) ________ 6. MECHANICAL WORKSHOP (DPS-7102) ________ 7. SHARING DOW'S VISION (DPS-7106) ________ _______ 8. QUALITY PERFORMANCE REQUIREMENTS FOR SUCCESS (DPS-7114) ________ 9. INTRODUCTION TO COMPUTERS AT DOW (DPS-7489) ________ 10. INTRODUCTION TO THE VAX (DPS-6283) ________ 11. BASIC INSTRUMENTATION AND METERING FOR TECHNICAL EMPLOYEES ('DPS-7118)' 12. TSCA TRAINING (DPS-6157) REVISION DATE: 9/4/91 sas CONFIDENTIAL 3aJ ft GU1i 13. EXISTING FOR THE CUSTOMER (DPS-7107) 14. PERSONAL LEADERSHIP (DPS-7110) 15. TIME MANAGEMENT (DPS-8701) 16. ENVIRONMENTAL AMBASSADOR TRAINING (DPS-9044) 17. MICROSOFT WINDOWS 18. MICROSOFT WORD FOR WINDOWS 19. MICROSOFT EXCEL * 20. HARVARD GRAPHICS 21. MOD5 USERS PART 1 22. MODS USERS PART 2 23. MODS PROGRAMMERS CLASS (IF PROGRAMMING) 24. MODS HARDWARE (IF MODS PROGRAMMING) 25. DSS USERS CLASS (IF MOD5 PROGRAMMING) 26. FIRE FIGHTING TRAINING SECOND YEAR TRAINING 1. DOWVILLE SAFETY WORKSHOP (DPS-722) 2. ELECTRICAL EQUIPMENT AND DISTRIBUTION (DPS-4741) 3. SPC - INTRO FOR TECHNICAL EMPLOYEES (DPS-5136) 4. COMMUNICATIONS SKILLS WORKSHOP (DPS-6348) 5. CAPITAL OVERVIEW (DPS-7288) THIRD YEAR TRAINING ________ ______ 1. ENHANCING VERSATILITY SKILLS (DPS-5400) ________ ______ 2. TURNAROUND PLANNING (DFS-429) ________ ______ 3. CAPITAL PROJECT MANAGEMENT (DPS-6081) O o 1 R&S149766 REVISION DATE: 9/4/91 sas ITT TRAINING PROGRAM STATUS * Development Complete And In Use Loading Area Gold Hat Safety Training * Operations Personnel Trained on Development IPT Flowsheet Developed 5% of Modules Complete * Lab Program Under Development SAS 9/5/91 CONFIDENTIAL R&S149767 VINYL IIIPT FLOWSHEET R&S149768 BASIC EXPECTATIONS PURPOSE: To familiarize the safety observer/new hire wzth THE EXPECTATIONS OF THE VlNYL II PLANT DURING VESSEL ENTRY JOBS. RESOURCES: Assigned Trainer, Safety and Loss Prevention Standards, and Safety Reference i REQUIRED LEVEL OF PERFORMANCE: 100%' Correct * OBJECTIVES: 1. Before entry into the vessel, what should you check? A. Make sure there is adequate breathing air equipment LOCATED ON THE JOBSITE. B. Check for the proper equipment used in removing a PERSON FROM THE VESSEL (HARNESS, ROPE, TAG LINE) C. Good ventilation 0. Sniff inside of vessel for oxygen and combustibles. 2. What action should be taken in case of the following problems? A. Spill inside the Vinyl II block 1. If the vessel is down stream of the spill, the vessel should be cleared. After vessel is CLEARED, CONTACT CONTROL ROOM FOR UPDATE ON SPILL. 2. If you are not sure, clear the vessel and CONTACT THE CONTROL ROOM FOR MORE INFORMATION. 3. After the all clear is given, an air sample should be taken and analyzed before going back INTO THE VESSEL. B. Ventilation shutdown 1. Clear vessel until ventilation is restored and SNIFF VESSEL AGAIN. C. Supplied air runs out 1. Clear vessel D. Lighting malfunction 1. Clear vessel n 0 z 33 1 9 tn z1 H u* > to r REVIEW OF VINYL H TRAINING AND RETRAINING PROGRAMS SUMMARY Vinyl II in the past has been very strong in operations. We had many operations personnel here in plant since it started up in the late 70's. Everyone knew their job and operations training was not a major focus because of this high level of knowledge. During the last three years, promotions and new plants/positions have given these experienced people opportunities and has led to a major decrease in job knowledge at Vinyl II. 'We feel a good training program is in place but it can be improved. A major shift is underway to swap to the IPT Training System to improve this training effort and to update all our training materials. We have recently developed a new technical employee training checklist that is currently being implemented. STRENGTHS Excellent Teamwork and spirit to help each other Strong experienced SOS personnel Excellent new operations personnel with will to learn Set Goals with all Vinyl II Personnel Load Rack, Gold Hat Safety Training, IPT System In Place SAS 9/5/91 CONFIDENTIAL Gso CO OVvCO|I REVIEW OF VINYL II TRAINING AND RETRAINING PROGRAMS OPPORTUNITIES Complete Development and Implement the IPT Training System in Operations and Lab Update Training Materials Swap back from Outside Exception Rounds to Written Rounds (In Progress) Continue Improving the Goal Setting Process Update and Resume Use of Operator Training Checklist Implement Technical Training Checklist Begin Testing after Safety Orientation for Block (In Progress) Retraining on S&LP Standards Fire Fighting Retraining Asbestos Retraining Reactive Chemical Training Program CONFIDENTIAL SAS 9/5/91 a 9 C_^Dk to -4 CONFIDENTIAL SIGNIFICANT INCIDENTS/MAJOR CONCERNS 9/6/91 `CM R&SH9772 Vinyl II Incident Review Current Statistics Significant Incidents from 1990-1991 Repetitive Incident Causes Areas of Concern SRC:8/91 PERILLOUX AREA SAFETY DATA TO: INDUSTRIAL INJURIES OSHA RECORDABLE INJURIES DAW-S TOTAL INJURIES INJURIES CLASSIFIED AS A PSA LIGHT DUTY DAYS DUE TO AN INJURY LOST DAYS DUE TO AN INJURY CONTRACTOR INJURIES (BANDAID CASES) CONTRACTOR OSHA RECORDABLE INJURIES DAWS TOTAL INJURIES PLANT VINYL II MONTH JULY YEAR 1991 UNSAFE CONDITION REPORTS WRITTEN NUMBER CORRECTED ON THE SPOT FROM PREV. YRS NUMBER OF ACTIVE REPORTS NUMBER PAST EXPECTED COMPLETION DATE IIP TOTAL ITEMS ON LIST TOTAL NOT IN COMPLIANCE Mi NUMBER OF PEOPLE ELIGABLE NUMBER OF PEOPLE ATTENDED PERCENT ATTENDANCE NUMBER WRITTEN NUMBER OF ERRORS PERCENT COMPLETION VINYL II SAFETY COORDINATOR O n H M a on nn a tn IH--< .PBS tT JO Ca> to 'j QUALITY PERFORMAN^WmPROVEMENT INDEX INDUSTRIAL INJURIES OSHA RECORDABLE INJURIES OFF THE JOB DAW'S INCIDENTS NOT PSl/PSA INCIDENTS PSA/PSI SAFETY MEETING ATTENDENCE C-9 COMPLIANCE RED TAGS COMPLETION CONTRACTOR INJURIES (BANDAID CASES) CONTRACTOR RECORDABLE INJ. __________ ^ (OSHA RECORDABLES) PLANT: VINYL II DATE: JULY 91 : TOTAL cmiovaan VINYL II SAFETY COORDINATOR TVIIN3CIMN03 "1 Vinyl II 1990-1991 Significant Incidents src:8:91 iviiNaaiiNOD * SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90 DOW CHEMICAL U.S.A.-LOUISIANA DIVISION A SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ()D-RMTC#__()C-RMTC# OD-RWC# __OC-RWC# OD-DAW# __OC-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:04/27/91 INJURY NQN-INJURY_ TIME OF ACCIDENT:04:45 PM S&LP STD. VIOLATION __ DATE INVESTIGATED^^/? / ENVIRON.XX RxCHEM. _ DATE REP SUBMITTED: 05/01/91 OPSA# __()$50000PD__ Block and Location of Accident VINYL II. F105 SYSTEM--P103B ON D103 Name of Injured/Involved Employee ",Class. -- ___________ Time at Dow (Mos.) --Master No. -- Time on Job (Mos.) -- Contractor Involved/Supervisor ~______ ! Chemical Released (Environ/RxChem only) Ethylene Pi Chloride Amount/Unit of Measure (Environ/RxChem only) 881#'s to grade. 434 i's to atmT Accident/Incident Description (10 Words or Less) Seal Failure "F1Q3B .. ACCIDENT/INCIDENT DESCRIPTION (Full) At 4:45 pm outside operator called in seai leak ON P103B. Block vales_on pump would not hold to isolate, -isolated pump with EBV's and hooked up NZ to seal purge outlet and blew back INTO PUMP" to stop leak while pressuring out D1Q3 to D112. Notified security and reported CALCULATED QUANTITY TO ENVIRONMENTAL PERSON ON .CALL (ADDITIONAL INFO ATTACHED) . RESULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART g 300 Equipment Failure _____________________________ 5 355 Air Release__________ _____________________________ ______________________________ ^ H JOB BEING PERFORMED (List one from Group I and all that apply from Group II) S O 200 Operation/Non-Routine______________ 999 D103 Decont. 095 Operation/Product Transfer________ ______________________________________________ CAUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING ~ 810 Equipment Failure 010 Improper Install/Maint.___________________________ 800 Procedures not Followed____________ _____________________________________________ 3 401 Inattention___ ___________________________________ 982 Inadequate Job Planning____________ _____________________________________________ FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Review with all teams Responsibility: .Expected CompletionTXSZ Actual Completion: C/r7, Action: Change out seats on all block valves invvoollvveed in incident _ . Responsibility: iExpected Completion:/!<?/<?/ Actual Completion: ion: ________ 77 onsibility: .Expected Completion: .Actual Completion: , Superintendent's Signature Investigated By Signature of Injured CONFIDENTIAL JPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISORS INVESTIGATION OF ACCIDENT/INCIDENT ( ) OSHA# _ OCOSHA# __ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:8/9/90 ( ) O-RES# ()CO-RES# INJURY _ NON-INJURY __ TIME OF ACCIDENT: 1725 p .H. t S&LP STANDARD VIOLATION^ INVESTIGATED: 8/10738^ ( )0-DAW#__ () CO-DAW#__ ENVIRON. X RxCHEM. _ REPORT DATE: 8/10/90 O o (X)PSA# _ OJSOOOOPD z lock and Location of Accident Vinyl 2 Block 66 Furnace Area \me of Injured/Involved Employee_____________________ Class. - cme at Dow (Mos.) _______ _ Master No. Time on Job (Mos.) _ 3NTRACTOR INVOLVED/SUPERYISOR ________________ _________ ;________ _ WIRONMENTAL IMPACT: l NO AlR X WATER OTHER o w Z H > r CCIDENT/INCIDENT DESCRIPTION: Operator was preparing the F-103 feed station to >JT IT BACK in SERVICE AFTER A PIPING MODIFICATION WHEN HE WAS INTERRUPTED AND ITER RETURNED TO JOB. THE BLEED VALVE AND BLIND FLANGE WERE LEFT OPEN AND THE gEP STATION WAS PUT IN SERVICE. WHEN THE FIRST BLOCK VALVE WAS CRACKED JPPEN. 3C SPILLED OUT THE BLEED ONTO THE GROUND. 12.500 LBS. EDC WAS SPILLED AND 3NTAINED BEFORE THE_BLOCK VALVE COULD BE CLOSED. ZOO# EDC_WAS ESTIMATED gLEASED TO THE AIR. NATIONAL RESPONSE CENTER WASNOTIFIED OF THIS RELEASE. ^OSSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 50 Spill 3B BEING PERFORMED (List one from Group I and all that apply from Group II) O >n H M O 30 Operation/Routine____________________ ______________________________________________ 75 Operation Start-up__________________________ AUSES (List all that apply with code number and description from back page' jj ON SITE PRE-EXISTING | 31 Inattention_________________________________________________________________________ 3 3LL0W UP ACTION TO PREVENT RECURRENCE: :tion: Review incident with all shifts emphasizing Take 2 and SWS. ESPONSIBILITY .EXPECTED COMPLETION:8/24/90 ACTUAL COMPLETION! ction: Check fire sprinkler nozzles for proper operation,L_ ^onsibility: __ Expected Completion:8/20/90 Actual Completion: Install additional spill button in new control room area. r^pnucTRTi tty; EXPECTED COMPLETION: 9/1/90 ACTUAL COMPLETION! ; ^rrwATMDr TKlUF^TTr,flTFD RV Signature of Injured VINYL 2 EDC RELEASE T t OLD FEED STATION 6ZZ6t?VS181d t aaxovaan ; xvuNtaauNOD * I ; NEW FEED STATION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-9C DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ()D-RMTC#__()C-RMTC# . OD-RWC# __OC-RWC# . OD-DAW# __OC-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:6/18/91 INJURY _ NON-INJURY__ TIME OF ACCIDENT:11:30 P.M. S&LP STD. VIOLATION _ DATE INVESTIGATED:6721/9i ENVIRON.XX RxCHEM. _ DATE REP SUBMITTED: 6/21/91 OPSA# __()$50000PD_ Block and Location of Accident VINYL II COOLING TOWER Name of Injured/Involved Employee _____ Class. Time at Dow (Mos.) ________ Master No. Time on Job (Mos.) Contractor Involved/Supervisor Chemical Released (Environ/RxChem only) VINYL CHLORIDE MONOMER Amount/Unit of Measure (Environ/RxChem only) 28.5 LBS. Accident/Incident Description (10 Words or Less) VINYL CONDENSER TUBE LEAK INTO COOLING TOWER WATER____________________________ ACCIDENT/INCIDENT DESCRIPTION (Full) SOUTHWEST COOLING TOWER AIR MONITOR ALARM WAS ACTIVATED AT 11:30 P.M. ON VINYL CHLORIDE. OPERATIONS BEGAN - INVESTIGATING with hnu at_the tower, no vinyl was registered; but when THEWATER WAS SAMPLED IT SHOWED 5 PPM VINYL. FURTHER SAMPLING ON ET OF VINYL COOLING TOWER EXCHANGERS USINGMASS SPEC INDICATED VINYL L OCCURRING AT E-140; SHUTDOWN E-140 AND FOUND ONE TUBE LEAKING. c 2 >r 5 tr 2 > r so H O > n H M a sULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 355 AIR RELEASE JOB BEING PERFORMED (List one from Group I and all that apply from Group II) 100 OPERATIQN/ROUTINE__________________ _________________________________________ ~035~ NO TASK ~~I CAUSES (List all that apply with code number and description from back pagi ON SITE PRE-EXISTING - 810 EQUIPMENT FAILURE015_ INADEQUATE DESIGN S 33 5 | FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: SHUT PLANT DOWN & FIX TUBE LEAK.__________ _____________________________ Responsibility: ^Expected Completion:6/20/91 Actual Completion:6/20/93 Action: EVALUATE NEW EXCHA'NGER DESIGN FOR INSTANTANEOUS HIGH RATES. Responsibility: Expected Completion:11/1/91 Actual Completion: Action: IMPROVE HEAT RECOVERY & STEAM CONTROL ON C-140.____________________ ' Responsibility:!____________ Expected Completion:7/21/91 Actual Completion: Superintendent7Signature Investigated By Signature of Injured CONFIDENTIAL REDACTED SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT AD-RMTC#_()C-RMTC# ()D-RWC# __OC-RWC# OD-DAW# __OC-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT: 6/15/91 INJURY _ NON-INJURY__ TIME OF ACCIDENT:9:10 A.M. S&LP STD. VIOLATION _ DATE INVESTIGATED!^/15/91 ENVIRON._ RxCHEM. _ DATE REP SUBMITTED: 6/16/91 OPSA# XX 0 S50000PD__ Block and Location of Accident VINYL II BLOCK 66__ Name of Injured/Involved Employee Class. _____________________________ ___________ Time at Dow (Mos.) ________ Master No. Time on Job (Mos.) Contractor Involved/Supervisor_________ _________________________________________ Chemical Released (Environ/RxChem only) NONE ~ Amount/Unit of Measure (Environ/RxChem only) NONE Accident/Incident Description (10 Words or Less) FURNACE 106 SUPERCRITICAL VALVE FAILURE ---- ACCIDENT/INCIDENT DESCRIPTION (Full) SEE ATTACHED - ' _. RESULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART # EQUIPMENT FAILURE I0B BEING PERFORMED (List one from Group I and all that apply from Group II) 100 OPERATION ROUTINE__________________ OPERATION/STARTUP R&S149781 :AUSES (List all that apply with CODE NUMBER AND DESCRIPTION FROM BACK PAGE) ON SITE PRE-EXISTING 310 EQUIPMENT FAILURE 015 IMPROPER DESIGN " 010 IMPROPER INSTALL/MAINT -OLLOW UP ACTION TO PREVENT RECURRENCE: Action: CHECK VALVE FOR PROPER DESIGN. Iesponsibility: Expected Completion:6/17/91 Actual Completion: 6//7/4, action: CONTACT tfch FFNTFR TO GET APPROVAL TO REMOVE AO ABORTS., , lESPONSIBlLITYL EXPECTED COMPLETION: 6/21/91 ACTUAL COMPLETION .6/5// .CTION: EVALUATE MECHANICAL STOPS. Iesponsibility: Expected Completion: 6/17/91 Actual Completion: uperintendent's Signature Investigated By Signature of Injured JUME.1.5..1991 F-106 INVESTIGATION OF INCIDENT WHILE BRINGING UP F-106, WE WERE AT A POINT OF HAVING EDO FEED AT 50,000 LBS./HR. FLOWING THROUGH THE FURNACE. THE BOTTOM ROW OF LOWER RADIANT BURNERS HAD BEEN LIT AND WE WERE WAITING FOR THE SUPERCRITICAL PRESSURE TO RAMP UP. WE HAD INCREASED THE FEED RATE FROM 20,000 TO 50,000 TO GET THE PRESSURE UP AFTER WAITING ABOUT FORTY MINUTES. WE HAD ALSO CLOSED THE SUPERCRITICAL VALVE BACK MANUALLY TO TRY AND GET THE PRESSURE UP AND VERIFIED THE VALVE POSITION AS NOT BEING COMPLETELY CLOSED. AT THIS POINT, IT WAS DECIDED TO LIGHT FOUR MORE BURNERS TO ASSIST AS WELL THE PRESSURE SEEMED TO WANT TO EASE UP SOME BUT FELL RIGHT BACK OFF (200#). WE THEN STARTED LOWERING THE FEED BACK TO 20,000 LBS./HR. BECAUSE THE LEVEL IN D-108 HAD COME UP PRETTY HIGH. SHORTLY THEREAFTER, THE SUPERCRITICAL PRESSURE STARTED GOING UP AS IT SHOULD HAVE IN THE FIRST PLACE. IT WAS THEN THAT THE SUPERCRITICAL CONTROL VALVE HAD GONE CLOSED AD WOULD NOT COME BACK OPEN. THE EDC FEED FELL OFF TO ZERO AS THE SUPERCRITICAL PRESSURE WENT ABOVE 1000 PSIG. F-106 TRIPPED ON LOW FEED FLOW AND WE COULD NOT CLOSE THE FEED CONTROL VALVE TO STOP THE FLOW NOR COULD WE OPEN THE SUPERCRITICAL CONTROL VALVE TO RELIEVE THE PRESSURE ON THE COIL THE FEED EBV WAS CLOSED TO STOP THE FLOW INTO THE FURNACE AND THE ABORT KEY WAS USED TO TRY TO OPERATE THE FEED AND SUPERCRITICAL CONTROL VALVES. MEANWHILE, THE FURNACE BEGAN TO PRESSURE UP FROM ALL OF THE HEAT PRESENT IN THE FIREBOX. THE OUTSIDE OPERATOR ATTEMPTED TO SLOWLY BLEED THE AIR PRESSURE FROM THE SUPERCRITICAL CONTROL VALVE, BUT THE VALVE DID NOT FAIL OPEN AS IT SHOULD HAVE. THE FURNACE AREA WAS CLEARED AND SECURITY WAS ALERTED THAT THE PLANT WAS IN AN UNSTABLE CONDITION. WE THEN SWAPPED TO THE LOWER PRESSURE P-100 AND OPENED THE FEED EBV AND CONTROL VALVE TO RELIEVE THE PRESSURE FROM THE COIL WE ALSO OPENED THE DAMPER TO 100 % TO HELP COOL THE FIREBOX. WE ALSO OPENED THE P-100 DISCHARGE PRESSURE CONTROL VALVE BACK TO THE FEED TANKS BEFORE SWAPPING THE P-100`S AND INCREASED THE FEED TO THE OTHER FURNACES TO HELP LOWER THE PRESSURE. THE PRESSURE GOT AS HIGH AS 1471 PSIG ON THE COIL . WE IMMEDIATELY DROPPED THE PRESSURE TO 950 PSIG AND FROM THAT POINT ON THE PRESSURE CONTINUED TO EASE DOWN. INSTRUMENT PERSONNEL WERE CALLED OUT TO CHECK THE VALVE AND THEY CONFIDENTIAL Cfl CD DISCOVERED THAT THE VALVE HAD BEEN TUBED UP WRONG. THE SUPPLY PRESSURE WAS SET AT 25 PSIG AND SHOULD HAVE BEEN 110 PSIG. THE AIR TO THE I/P WAS SET AT 83 PSIG AND SHOULD HAVE BEEN 25 PSIG. THE VALVE WAS RETUBED AND TESTED BY PUTTING EDO THROUGH THE COIL WITHOUT LIGHTING ANY BURNERS. THE SUPERCRITICAL VALVE WAS OPENED TO 15% AND PUT ON MANUAL WHEN THE FLOW WAS STARTED, THE VALVE WOULD OPEN AND CLOSE ON ITS OWN SWINGING THE PRESSURE FROM 100 TO 900 PSIG. THE CONTROL VALVE RESPONDED IN THIS SAME MANNER ON THE ORIGINAL FURNACE STARTUP BACK IN MARCH. IT WAS REPAIRED THEN, BUT IT IS DOING THE SAME THING AGAIN. 3S3o C/3 (D WCD C O N F ID E N T IA L SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) ^ A DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ()D-RMTC#__()C-RMTC# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:03/09/91 OD-RWC# __OC-RWC# _ INJURY __ NON-INJURYXX TIME OF ACCIDENT: 2Tl9Pr----S&LP STD. VIOLATION _ DATE INVESTIGATED;03 / H/ 91-- OD-DAW# _()CrDAW# _ ENVIRON.XX RxCHEM. _ DATE REP SUBMITTED: 03/12/91 OPSA# __()$50000PD__ Block and Location of Accident Vinyl II F101______________ ________________________ Name of Injured/Involved Employee -- Class. -- Time at Dow (Mos.) -rMaster No. "________ Time on Job (Mos.) -- Contractor Involved/Supervisor ______ _________________ __________________ ___ Chemical Released (Environ/RxChem only) Vinyl and EDC Amount/Unit of Measure (Environ/RxChem only) 3,7 lb VCM. 43.5. lb. EDC (past flare) Accident/Incident Desc. (10 Words or Less) F101 Tailpipe PSV Failed Prematurely ACCIDENT/INCIDENT DESCRIPTION (Full) AtJ2:19 we received an alarm of vinyl in the flare at V260 of 2060 ppm.___ Shortly thereafter outside operator called in TO SAY THE OUTLET OF F101 TAILPIPE PSV WAS VERY WARM AND WAS RELEIVING. THE PRESSURE GUAGE UPSTREAM OF PSV WAS READING 160# BEFORE PSV FAILED. PSV SETTING 212#. Furnace was shutdown and PSV isolated and changed out. .^^LtFcLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 300 Equipment Failurei_____________________________ ______________________________ 355 Air Release__ JOB BEING PERFORMED (List one from Group I and all that apply from Group II) 100 Operation Routine___________________ ___________________________________ CAUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING 310 Equipment Failure 999 Investigating PSV for defects 'OLLOW UP ACTION TO PREVENT RECURRENCE: \ction: Inspect PSV for premature failure______ Responsibility: ^Expected Completion:03/15/91Actual Completion: \ction: Based on PSV findings--decide immediate s/d of equipment Responsibility:^Expected Completion: 4 ^ Actual Completion: - - \omon: _______________________________________________________________________________________________ ?^PBnsibility:Expected Completion:Actual Completion: ft ft a n a f8zdwsh T Y U .N tfm U M O D uperintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ()D-RMTC#__()C-RMTC# OD-RWC# __OC-RWC# OD-DAW# () C-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:05/15/91 INJURY _ NON-INJURY__ TIME OF ACCIDENT:ifsTlPM-----S&LP STD. VIOLATION _ DATE INVESTIGATED"05 /15 / 91 ENVIRON.XX RxCHEM. _ DATE REP SUBMITTEDT05/16/Q1 OPSA# _ ()$50000PD Block and Location of Accident Vinyl II, T/C Loading Rack Name of Injured/Involved Employee Class. -- Time at Dow (Mos.) --Master No. -- Time on Job (Mos.) --~ Contractor Involved/Supervisor --__________ ___________ Chemical Released (Environ/RxChem only) Vinyl Chloride Amount/Unit of Measure (Environ/RxChem only) 149122 Lbs. _________ Accident/Incident Description (10 Words or Less) Put Vinyl to ~Atmosphe o o o wz H > ACCIDENT/INCIDENT DESCRIPTION (Full) Loading rack operator was in the process of setting up T/_C to load after repairing small leak. Atmospheric vent valve was mistakenly left cracked open and liquid valve from car_was opened releasing VINYL TO VENT FOR A FEW MINUTES. OPERATOR IMMEDIATELY ISOLATED LINE AND called control room. Security was notified and calculations reported to Environmental.________________________________________________________________________ ___________________ % ULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE). ACCIDENT/INCIDENT INJURY BODY PART 355 Air Release___________ _____________________________________ ' ____ JOB BEING PERFORMED (List one from Group I and all that apply from Group II) so o n> H H C? 100 Operation Routine 030 Product Load/Unload 025 Valve Operation - CAUSES (List all that apply with code number and description from back pagi ON SITE PRE-EXISTING 800 Procedure not Followed 401 Inattention 999 Pre-Occupied Training New _____ Loading Rack Personnel 0 w A CD 0007 FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Review in detail with all loading personnel. ,, / Responsibility: Expected Completion:05/25/91Actual Completion: Action: Evaluate spring closed valves for vent system.V Responsibility: Expected Completion:07/04/91Actual Completion: A^iion: Brainstorm with loading rack crew on system improvements. onsibility:Expected Completion:07/04/91Actual Completion: VJ*i y/&/ Superintendent's Signature Investigated By Signature of Injured JUPERV R'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S. A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT *SHA# __ OCOSHA# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT: ()O-RES#__ ()C0-RES#^_ INJURY NON-INJURY )L TIME OF ACCIDENT: S&LP STANDARD VIOLATION__ INVESTIGATED: 09/14 0 O-DAW#__ () CO-DAW#__ ENVIRONRxCHEM. _ REPORT DATE: JEZmM 0 PSA# JC OS50000PD lock and Location of Accident Vinyl n 0-186 ame of Injured/Involved EmployeeN/A ime at Dow (Mos.) _________Master No. ONTRACTOR INVOLVED/SUPERVISOR nvironmental Impact: Iis No Air X Class. Time on Job (Hos.) Water Other CCIDENT/INCIDENTDESCRIPTION: At 3:35 PM a high pressure alarm sounded >om'an DCCA/LWEa. te%rATtTaHnkIS. Upon investigating, the pressure on the TIME THE LOADING RACK WAS CALLED TO STOP tank had-rachep WASHING f VINYL full HLORIDE TANK CAR. THE CROSS-TIE FROM THIS SYSTEM TO OUR FLARE WAS OPENED T 3:40 PM TO TO LOWER THE PRESSURE ON THE T-ZZ0/T-ZZ1 SYSTEM. BY 3:45 PM THE ANK PRESSURE WAS_BACK -TO NORMAL. WHAT WAS FOUND_UPON INVESTIGATION WAS THE INYL TANK CAR STILL HAD LIQUID VINYL CHLORIDE IN IT WHICH WAS TRANSFERRED TO HE T-220/T-221 SYSTEM CAUSING THE OVER-PRESSURE AND THE PVRV TO RELIEVE. TS CLASSIFICATION (List all that apply with code number and description' FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 50- Spill------------ ----------------- ---------------------------------------------------------- w----------------1____________________ TO Procedure Violation^ )B BEING PERFORMED (List one from Group I and all that apply from Group II) So w o >n H W a JO Operations Rrooutine 095 Operation Prod. Transfer SC Product Load/Unload \USES (List all that apply with code number and description from back page ON SITE / PRE-EXISTING ?0 Poor Communications )0 Procedure Not Followed 200 Poor Communications m. Inadequate Enforcement nj co c(-Osoi )LL0W UP ACTION TO PREVENT RECURRENCE: c :tion: Follow and enforce existing procedure..ll. ____________________ :sponsibility: Expected Completion:09/21/90Actual Completion: :tion: Communicate incident to al^l^ sVIhI4ifI tf ws. _______ a [[ mwsibility: sExpected Completion:Q9/30/90Actual Completion: ^ sponsibility: Expected Completion: Actual Completion: -erintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT *OSHA# _ OCOSHA# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:8/25/90 0O-RES#__ ()CO-RES#_ INJURY __ NON-INJURY X_ TIME OF ACCIDENT:llTOO a.m S&LP STANDARD VIOLATION_ INVESTIGATED: 0O-DAW#__ ()CO-DAW#_ ENVIRON. X RxCHEM. _ REPORT DATE: OPSA# _ ()$50000PD Slock and Location of Accident Vinyl II C-120, Same of Injured/Involved Employee ________________ 'ime at Dow (Mos.) Master No. Contractor Involved/Supervisor ______________ Environmental Impact: Yes NoAir X Class. Time on Job (Mos.) Water X Other o o z w z H > r OCCIDENT/INCIDENT DESCRIPTION: We were preparing to drylRE-120Cj,with EDC , 1SING EDC FROM E-112,__RE-120C IS A NEW piece of equipment that has not been ut in service. RE^120C was tubed up to purge to T-2Z5 and the FDC purge was ITARTEDj, Area was inspected and purge was stopped and a _M_A__L_L__T_U__B_I_N_G___LEAK WAS igPAipED, "Purge was restarted and no leaks were found. AIpproximately 10 f1INUTES after operators left area the control room got a combustible alarm at C-120 AREA- OUTSIDE OPERATOR WENT TO CHECK AND FOUND EDC COMING OUT THE TOP OF 'E-12QC. Purge was blocked in and reboiler drained to T-225, After inspecting IE FOUND A SPLIT GASKET HAD BEEN PLACED BETWEEN THE VAPOR OUTLET SPOOL AND THE *blind. Approximately 30 gallons of EDC was spilled._ CESULTS CLASSIFICATION (List all that apply with code number and description from back page) ACCIDENT/INCIDENT INJURY BODY PART 150 Spill ______________________________________________________________________________ P3 M O > O H OB BEING PERFORMED (List one from Group I and all that apply from Group II) 00 Operations/Non-Routine_____________ ___________________________________ ; )99 Drying Reboiler ___CAUSES (List all that apply with code number and description from back page! ON SITE PRE-EXISTING 120 Poor Communication_________________ 982 Inadequate Pre-Job Plan 1)1 Inattention 33 Qo CO -si CD 0LL0W UP ACTION TO PREVENT RECURRENCE: ction: Block policy to pressure test with H20 or nitrogen before putting any equipment in service,_____________________ esponsibility:Expected Completion:8/27/90 Actual Completion: o/z7fd .ction: ___________________ 7/ e1sconsibility:. Expected Completion: Actual Completion: jperintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCTENglNODBjr^g^;;.y.u. ^ rfo OD-RMTC#__OC-RMTC# ACCIDENT CLASSIFICATION 5 * i>/y. ..>,, - * DATE OF ACCIDENT: 2/1/91 OD-RWC# 1_()C-RWC# i__ INJURY 11 NON-INJURY; TIME OF.ACCIDENT:lt58P7ff7 S&LP STD. VIOLATION * DATE INVESTIGATED;, JVl 0 D-DAW# _1() CrDAW# 'Jil ENVIRON.& RxCHEM DATE REP,SUBMITTED: WiITT opsa# JiloisoooopuIT Block and Location of,. Accident _________ ___________________ Name of Injured/Involved Employee N/A -*^^*^**^ >v~ Time at Dow (Mos.) Master NO.JI/A Contractor Involved/Supervisor N/A ^,... - Chemical Released (Environ/RxChem only) SEE ATTACHM^T ^^^- y ^ ^ w- - Amount/Unit of Measure (Environ/RxChem qnlyX .SEE ATTACHMENT ; Accident/Incident Description (lp^WoRDs^R^^^^^^R^RE1^^5JE-^eN^r-220^ ^> ACCIDENT/INCIDENT DESCRIPTION (Full! SpERATOR^PRKSURING' ----------------------- - - LINE _ggO THE 4" HEADER -Ttf iSzO. ^D-j ****** onz WI--JI o Mz H >r1 ifil ULTS CLASSIFICATION (List all that apply?: with code: number and descriptiok -v. FROM BACK PAGE) ACCIDENT/INCIDENT ^ 355- AIR RELEASE, " - > - ><,*!.- - v--- a n> H aW JOB BEING PERFORMED (List one from Group and all that apply from Group IT 100 OPERATION/ROUTINE m65 ,0PERATI0N/PRESS-DEPRESS 03g~ PRODUCT LOAD/ONLOAI .' iwt*.*r<T. i :'i'-- ' -'jySS' CAUSES (List all that apply with code number,and: description from back pagT ON SITE ^^PRE-EXISTING "f-5. T-ct>. 810 EQUIPMENT FAILURE___ r 015" -IMPROPER DESIGN 0OJoJ) A coC-odDJ FOLLOW UP ACTION TO PREVENT RECURRENCE: . : :3r Action: WRITE UP A PROCEDURE FOR USING WET HEADER ______ ,,______________ ____ Responsibility: ; Expected Completion^2/18/91 zActual-Completion : //</ Action: EVALUATE EXISTINGJjET HEADER SYSTEM. Responsibility: Expected Completion:8/1991 Actual Completion: ^0N: WORK ON K-ZIO B AUTO START-UP PROBLEM ^Ponsibility: Expected Completion:2^8/91 Actual Completion: : Superintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT OD-RMTC#__OC-RMTC# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:10/19/90 OD-RWC# OC-RWC# . INJURY _ NON-INJURY__ TIME OF ACCIDENT: lltoOAM mrS&LP STD. VIOLATION _ DATE INVESTIGATEDTEt^ OD-DAW# OC-DAW# . ENVIRON.X_ RxCHEM. OPSA# __()$50000PD_ _ DATE REP SUBMITTED: zon Block and Location of Accident Vinyl II P-104 Name of Injured/Involved Employee __________ Time at Dow (Mos.) ~~Master No. -- Contractor Involved/Supervisor -- Class. -- ~~ Time on Job (Mos.) -- zM a > Chemical Released (Environ/RxChem only) EDC Amount/Unit of Measure (Environ/RxChem only) 30 pounds Accident/Incident Description (10 Words or Less) "BMI: SEAL FAILURE (DOUBLE mechanical seal)__________________ _____________________ ! ACCIDENT/INCIDENT DESCRIPTION (Full) We were intoe process of decontaminating THE PLANT. ONE OF THE_OUTSIDE OPERATORS FOUND P-104B SEAL LEAKING. THE OPERATOR SWAPPED THE PUMPS AND MANUALLY BLOCKED THE LEAKING PUMP, jS^JU^CLASSIFICATION (List all that apply with code number and description m FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 300 Equipment Failure _____ MZA _______________________ 'll NZA________________ 5 o > 2 JOB BEING PERFORMED (List one from Group I and all that apply from Group II) 200 Operatoion/Non-routine_____________ _______________________ ~ ' CAUSES (List all that apply with code number and description from back page On SITE "PRE-EXISTING 810 Equipment Failure 999 Under Investigation J3 Cf) & CD -s| 00 CD FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Repair seal, test, reinstall and identify cause for failure._______ Responsibility: Expected Completion: 10/19/90Actual Completion: Action: __________________________________ ______________________ _// Responsibility: .Expected Completion:. Actual Completion: m;on: __________________ onsibility: Expected Completion: Actual Completion: , Superintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT S-305 DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT L-63 (REV. S-90) \-f- * 0 D-RMTC#__OC-RMTC# __ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:11/06/90 OD-RWC# __OC-RWC# : INJURY __ NON-INJURYXX TIME OF ACCIDENT:Z?15am . - / - - - S&LP STD. VIOLATION _ DATE INVESTIGATED?!'!/07/90 OD-DAW# _()C-DAW# ENVIRON.XX RxCHEM. , _ DATE REP SUBMITTED: OPSA# ^jsoooopilI ! .? .'TUVf.'.T : : /vv- . `>5 <!'* j-/. '-: . Block and Location of Accident Vinyl II Name of Injured/Involved Employee N/A - Class. Time at Dow (Mos.) -- ^ ^ -Master No. -- Time on Job (Mos.) -- Contractor.Involved/Supervisor Chemical Released (Environ/RxChem only) EDC f.. Amount/Unit of Measure (Environ/RxChem only) 15 <5I\Li LQNS Accident/Incident Description (10 Words or Leessss) E- ^jI n o 2 w2 z H ACCIDENT/INCIDENT DESCRIPTION (Full) Boiling C-lll and C-110 to dry^ E-HO DRAIN LINE AT PUPBLE STARTED LEAKING. AT Fl^.Ngg^!^ALS, OF EDC" WAS SPILLED 1=0 HE GROUND AND CONTAINED WITH OIL ABSORB PADs7 C-lll UH PRESSURE WAS SHOWING Z6# AT TIME OF LEAK. PRESSURE GAUGE WAS THEN INSTALLED ON C-110 AND PRESSURE SHOWED 74# C-lll OH CHECK VALVE HAD CHECKED AND WAS NOT ALLOWING US TO GET GOOD READING.----;---------;_____ --____U.- ___ ;:______________ " ^ ' kcSULTS CLASSIFICATION (List all that apply with code number and description ' ' '^;, FROM BACK PAGE) ." ;vVw'.. -*, ACCIDENT/INCIDENT , INJURY `i BODY PART 300 Iei cage t/1 ^Ati Equipment Failure i"~' v - ' ' - SO M O > JOB BEING PERFORMED (List one from Group I and all that apply from Group II) 200 Operation/Non-Routine ' 4 . . ' M. / * * 075 Operation/Start-up__ ^______ `' ~ V-IV'*' IAUSES (List all that apply with code number AND DESCRIPTION FROM BACK PAGE ON SITE-^ PRE-EXISTING "'1\ 310 Equipment Failure 010 Improper Installation/Maint. r- ** * * r0LL0W UP ACTION TO PREVENT RECURRENCE: action: Change out old gaskets, before start up ___________________________ Responsibility: Expected Completion:11/14/90Actual Completion: //////fd Action: __________________: 4~ Responsibility:, .Expected Completion:. .Actual Completion: lon: ________ onsibility:. Expected Completion: Actual Completion: jperintendent's Signature Investigated dy Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT OD-RMTC#__()C-RMTC# . ACCIDENT CLASSIFICATION DATE OF ACCIDENT:1/11/91 OD-RWC# OC-RWC# . INJURY _ NON-INJURYXX TIME OF ACCIDENT:TtsOAM OD-DAW# OC-DAW# . S&LP STD. VIOLATION ENVIRON.XX RxCHEM. _ DATE INVESTIGATEDtlyll/Dl _ DATE REP SUBMITTED: 1/11/9) n oz OPSA# __()$50000PD_ Jlock and Location of Accident Block 66. Vinyl II (ame of Injured/Involved Employee ~________ Class. -- a zm H Time at Dow (Mos.) --Master No. Time on Job (Mos.) -- > Contractor Involved/Supervisor -- Chemical Released (Environ/RxChem only) EDC. Vinyl,_HCL > is ac. ,R HnImount/Unit of Measure (Environ/RxChem only) IS gal ma m m. 1 Iccident/Incident Description (10 Words or Less) P-101 B BlownTseal * -T OCCIDENT/INCIDENT DESCRIPTION (Full) P-101 B developed a bad seal, leak spraying :dC. HCL. and S0M_e_vinyl. The a pump was tagged to install the same type. . eal and design as the B pump. P-101 B HAD just the day beforeIhad a new YPE SEAL AND DESIGN INSTALLED. CALLED THE FRONT GATE AND ENVIRONMENTAL ONCERNING THE SPILL. INVESTIGATION SHOWED THAT THE BELLOWS FOR THIS SEAL AS MARGINAL FOR THE PRESSURE OF THIS SYSTEM WHICHPROBABLY CAUSED THE SEAL AILURE ,TS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART a n> 00 51 Equipment Failure ______________________________ Air- Release________________________________________ ____________________________ H H u OB BEING PERFORMED (List one from Group I and all that apply from Group II) 00 Operation Routine____________________ ________________________________ - AUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING 10 Equipment Failure 010 Improper Install/Maint. 015 Improper Design Co GO fc. CD CO )LLOW UP ACTION TO PREVENT RECURRENCE: ;tion: Change design and go to cartridge push type seal with flow through seal JRGE. iSPONSIBILITY: ^Expected Completion:2/14/91 Actual Completion: :tion: sibility: Expected Completion: .Actual Completion: :sponsirti TTY* Expected Completion: .Actual Completion: ocDTMTCwnFWT ' <; 5 T G U AT1J R F Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-9( DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT CONFIDENTIAL ()D-RMTC#__()C-RMTC# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:07/06/91 OD-RWC# OC-RWC# _ INJURY _ NON-INJURYxx TIME OF ACCIDENT:2:38----S&LP STD. VIOLATION _ DATE INVESTIGATEDTMMZElI OD-DAW# OC-DAW# _ ENVIRON.__ RxCHEM. _ DATE REP SUBMITTED: 07/08/91 OPSA# __OSSOOOOPD__ Block and Location of Accident Vinyl II. F-106____________ __________________________ Name of Injured/Involved Employee -- Class. -- Time at Dow (Mos.) ________ Master No. __________Time on Job (Mos.) -- Contractor Involved/Supervisor ____________________________________ Chemical Released (Environ/RxChem only) -- Amount/Unit of Measure (Environ/RxChem only) Accident/Incident Description (10 Words or Less) Pressure Control Valv^Bailed and Tripped Furnace - ACCIDENT/INCIDENT DESCRIPTION (Full) The stem on the Pressure Control Valve BROKE AND SINCJ^THE FLOW ENTERS THE PCV FROM THE TOP. THE VALVE WAS SHUT. NO FLOW COULD PASS THROUGH THE VALVE AND THE PRESSURE INCREASED TO THE TOP OF THE SCALE (0-1000#). BLED THE PRESSURE OF THE S.C. SECTION THROUGH TUBING TO THE WET HEADER. ACTUAL PRESSURE ON COIL WAS UP TO 1300# BECAUSE OF THE P-100 SWINGING UP. REDAC RESULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 300 Equipment Failure ----------------------------------------------------- -------------..-.-.--------------------------------------------------------------------------------------------------- w H JOB BEING PERFORMED (List one from Group I and all that apply from Group II 100 Operation Routine 075 Operation Startup CAUSES (List all that apply with code number and description from back page ON SITE PRE-EXISTING 810 Equipment Failure 015 Improper Design u jg g FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Pull PCV to investigate failure________ ______________________________ Responsibility:Expected Completion:07/08/91Actual Completion:7/8/91 Action: ______________________________________________________________________________________ #ponsibility:. ion: ________ sponsibility:. .Expected Completion: .Expected Completion: .Actual Completion: .Actual Completion: \^r . , Superintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ()D-RMTC#__()C-RMTC# __ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:01/18/91 OD-RWC# OC-RWC# _ INJURY N0N-INJURYXX TIME OF ACCIDENT: li tlflSTH------ S&LP STD. VIOLATION _ DATE INVESTIGATED?? 1/21751----- OD-DAW# OC-DAW# _ ENVIRON.__ RxCHEM. __ DATE REP SUBMITTED?1)1/21/91 (X) PSA# __OSSOOOOPD__ 5lock and Location of Accident Vinyl _II_C-270 System Iame of Injured/Involved Employee -- Class. -- *ime at Dow (Mos.) -zMaster No. ^ Time on Job (Mos.) -- Contractor Involved/Supervisor --______ Chemical Released (Environ/RxChem only) Imount/Unit of Measure (Environ/RxChem only) iccident/Incident Description (10 Words or Less) High Oxygen in c-270 n 2 *ri o w 2 H > tr CCIDENT/INCIDENT DESCRIPTION (Full) A flange corroded on K584 Sutton header NP A PARTIALLY OP_EN BLEEP ON D583 RUPTURE DISC ALLOWED OXYGEN AND WATER TO E SUCKED INTO THE C-Z70 SYSTEM WHICH RUNS UNDER A VACUUM. THE OXYGEN GOT AS IGH AS 17_% AND THIS VENTED INTO THE VENT HEADER PRODUCING AN EXPLOSIVE MIXTURE I^J^CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 99 Fire/Explosion Potential JB BEING PERFORMED (List one from Group I and all that apply from Group II) w w >o o H W o 30 Operation/Routine 35 No Task____________ R&S 149793 \USES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING .0 Equipment Failure 010 Improper Install/Maint HL Procedure not Followed __________________________________ )LL0W UP ACTION TO PREVENT RECURRENCE: j :tion: Review with Tech Center on how to operate column outside flamable limit :sponsibility: Expected Completion:2/21/91 Actual Completion: aAr7/9/ ;tion: Evaluate_oxygen analyzer for C-270 :sponsibility: Expected Completion:3/Z1/91 Actual Completion:J^7x Ai: Check for oxygen TWICE A WEEK UNTIL LONG TERM SOLUTION IS REACHED^ isibility: "ExpectedmmCompl+e* tion: 6ZlZiLL_ACTUAL Completion'-/M/jy*--?/<r ?/ 'ERINTENDENT'S SIGNATURE Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 DOW CHEMICAL U.S.A.-LOUISIANA DIVISION L-63 (REV. 1-90) SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT OSHA# __ OCOSHA# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT: 6/22/90 OO-RES#__ 0CO-RES#__ INJURY _ NON-INJURY X_ TIME OF ACCIDENT:4rSo P.il. S&LP STANDARD VIOLATION_ INVESTIGATED: 6/227T 0O-DAW#__ 0 CO-DAW#__ ENVIRON._ RxCHEM. _ REPORT DATE: 672171 OPSA# _ ()$50000PD Block and Location of Accident VINYL II K-I85 Name of Injured/Involved Employee N/A Time at Dow (Mos.) N/A_______ Master No. N/A___ Contractor Involved/Supervisor RENE TASSIN Environmental Impact: Yes NoAir X Time of'joT*^(Bos.) N/A Water "Other' ACCIDENT/INCIDENT DESCRIPTION: D-185 GOT A HIGH LEVEL DUE TO LIQUID IN THE VmENT mLINE. JRIED TO ^RE|SUREfc L|QUID_gyT_gF_l" LINEBlOCg E Pis MifRYiwa TO 7~gRESSURE WAS RAISED3.. _______ HE RUPTURE DISC ON the m. while REHAfURELY~Ar7 nRUPTURE DISC REC REQUIRE REPORTING K) n o 2 NN O W 2 H > t-1 RESULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY b\ BODY PART 150 SPILL N/A \V NZA. HZA SZI n H o JOB BEING PERFORMED (List one from Group I and all Jthat apply from Group II) IQQ_ OPERATION NON-ROUTINE______________ MS OPERATION/PRESS-DEPRESSURE !AUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING HO EQUIPMENT FAILURE 015 IMPROPER DESIGN 2S5_ INADEQUATE PROCEDURES 0o CO CD -vl CD OLLOW UP ACTION TO PREVENT RECURRENCE: ction: INSTALL NITROGEN REGULATOR TO PREVENT OVERPRESSURE___ espons__ib__il__it_y_ : :Expected Completion: 7/25/90 Actual Completion: 27^57%. ction: INSTALL SAPETY~ySCyE INSTEAD OF RUPTURE ~~ esponsibility: TneExpected Completion: 10/1/96 Actual Completion: / .ction: WRITE A PKUCEDURE FOR REMOVING -LEVEL FROM D-ISS, nsibility: Expected Completion:6/26/90 Actual Completion:6/26/90 !PERINTEWDENT;S SIGNATURE Investigated By Signature of Injured SUPERVISOR'S INVESTIGAT--I-O--N- OF _A_C_C__ID__E_N_T_/_IN__C_I_D_E__NT - S__-3__0_5 ..Si L-6J (REV. 5-90) ^ - vDOW CHEMICAL U.S.A. -LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ^ ^ = ()D-RMTC#_()C-RMTC# ACCIDENT CLASSIFICATION J ? in . - c. DATE OF ACCIDENT: OD-RWC# OC-RWC# " INJURY 11 NON-INJURY___ TIME OF ACCIDENT-: S&LP STD. VIOLATION DATE INVESTIGATED OD-DAW# _()CrDAW# ENVIRON.XX RxCHEM. DATE REP ^SUBMITTED: OPSA# . 0 $50000PLl1 ' 'vr 2 Block and Location of'Accident Vinyl II E-112 Exchanger&; s m Name of Injured/Involved Employee -- class, i-- * 3 Time at Dow (Mos.) -- .&?.'** Master No. -- * *Jime on Job (Mos.) ~g Contractor Involved/Supervisor --~j**;^* -*->/-.^ Chemical Released (Environ/RxChem only) Ethylene Dichloride ^ Amount/Unit of Measure (Environ/RxChem only) .15 lbs. -EDC ..... Accident/Incident Description J10 Words or Less) Hydraulic Pressure CausepHead TO Leak --,J~r - , ACCIDENT/INCIDENT DESCRIPTION (Full) P-263 discharge line to E-112 was shutdown during plant outage^ ^Although B/V's were left open on discharge of p||m^ THE check valves seated causing hydraulic pressure to build and leak out head Pressure was relieved by way of copper tubing from discharge of pump to suction AMD LEAK STOPPED, -jftto***' ^ u^is pe^' ^ - ; vua< % i- r v' w/'* *^il3 , (r ,l> , 4*, 1 *y .^. ^\Ttr v iSLTS CLASSIFICATION (List all`that apply with code number and description 1_6_1__ Air Release--------------99 Release to Concrete '?w ..*. {<thp 4ilv*r JOB BEING PERFORMED (List one from Group I and all that apply from Group II) SS H >O n H w o 200 Oper/Non-Routine 011 No-Task *,<*u V / r- ^<3 >;S- -ir; CAUSES (List all that apply with code number and description from back page) i ' - ION SITE " ' '- '''PRE^ExisTING ^ 300 Procedure not Followed j- r*y# ^ '* - SBO Inadequate Enforcement ' - - " i *' -- 0LL0W UP ACTION TO PREVENT RECURRENCE: 1 '.i i \ction: Communicate to all shifts --- - - V.. f k '- 'i?- lESPONSIBILITYl I EXPECTED COMPLETION:; lUftMActual Completion: j - Action: Tag Valve by P-263 open to keep pressure^^ff^line Responsibility: Imon: nsibility: .Expected Completion: -' . 1' i' ' "Expected Completion: ctual Completion:10/29/9 Actual Completion: R&S149795 uperintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 DOW CHEMICAL U.S.A.-LOUISIANA DIVISION ^ SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT L-63 (REV. 5-9 f()D-RMTC#_OC-RMTC# OD-RWC# __OC-RWC# OD-DAW# __OC-DAW# ACCIDENT CLASSIFICATION uai t OF ACCIDENT: 01/01/91 INJURY NON-INJURYXX TIME O..F _A_C_C_I_D_E__N_T_:_s_T__I_T__a_T S&LP STD. VIOLATION _ DATE INVESTIGATEDW^!/0r4/91 ENVIRON.M RxCHEM. _ DATE REP SUBMITTEDiul/ffTToT OPSA# __0 S50000PD__ oo Block and Location of Accident P-102 B Vinyl II__________ ____________________ Name of Injured/Involved Employee -- Class. -- Time at Dow (Mos.) --Master No. -- Time on Job (fros.) -- Contractor Involyed/Supervisor -- ______________________________________ Chemical Released (Environ/RxChem only) EDC Amount/Unit of Measure (Environ/RxChem only) 5 gals. Accident/Incident Description (10 Words or Less) ~ ^ - -' o z H r ACCIDENT/INCIDENT DESCRIPTION (Full) P-102 B had just been installed after installing a new_type of seal. This seal lasted about 5 minutes spilling about 5 gallons of EDC on the ground. Investigation showed that the new seal could not handle the system pressure so we went back to the old seal. Installed old seal with flush in and out.______________________________ ' P* O H m LTS CLASSIFICATION (List all that apply with code number and description from back page) ACCIDENT/INCIDENT INJURY BODY PART 300 Equipment Failure 361 AiRff Release JOB BEING PERFORMED (List one from Group I and all that apply from Group II) 300 Maintenance 080 Equipment Repair CAUSES (List all that apply with code NUMBER AND DESCRIPTION FROM BACK PAGE ON SITE PRE-EXISTING 310 Equipment Failure 015 Improper Design 5Tcn*I -n| oCO :0LL0W UP ACTION TO PREVENT RECURRENCE: Action: Find out what caused the seal to fail. RESPONSIBILITY.*:. EXPECTED COMPLETION: iHZXFjJLIActual Completion:01/04/~9i tCTION: ________ Responsibility: Expected Completion: Actual Completion:. oanN: _________ nsibility: Expected Completion: Actual Completion:. A jperintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT <)D-RMTC#__()C-RMTC# OD-RWC# __OC-RWC# OD-DAW# __OC-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:12/21/90 INJURY _ NON-INJURY__ TIME OF ACCIDENT: nnOMl S&LP STD. VIOLATION __ DATE INVESTIGATEDni/2l/90 ENVIRON.XX RxCHEM. _ DATE REP SUBMITTED: OPSA# __()$50000PD__ Block and Location of Accident VINYL II P-160B________________________ ___ Name of Injured/Involved Employee --Class. -- Time at Dow (Mos.) --Master No. -- Time on Job (Mos.) -- Contractor Involved/Supervisor -- _________________________________ ___ Chemical Released (Environ/RxChem only) Vinyl Amount/Unit of Measure (Environ/RxChem only) 5.8 LBsVCM Accident/Incident Description (10 Words or Less) P-160 B Seal Leak * 8 2 3 g z d fe ACCIDENT/INCIDENT DESCRIPTION (Full) P-160 B seal started leaking to the ATMOSPHERE. LEAK CALLED IN TO SECURITY AT 11:10 AM AND P-160 B~WAS ISOLATED BY 11:15 AM. THE contents of the piping between isolating block valves was RELEASED TO ATMOSPHERE. % ULTS CLASSIFICATION (List all that apply with code number and descrxptioo FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 300_ Equipment Failure_________________________________ 355 Am Release_____________________________ ______________________________ JOB BEING PERFORMED (List one from Group I and all that apply from Group II) m >o n H H e 100 Qperation/Routine 035 No Task CAUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING 810 Equipment Failure -9J02 CO -<-t4D* C--O4 FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Communicate procedure for inner seal failure. Responsibility: Expected Completion: 1/4/91 Actual Completion: !/^/~ Action: Communicate what is considered as a seal leak Responsibility Expected Completion:1/4/91 Actual Completion: j/Zy mon: Class on mechanica'l Seals.___________________ onsibility:Expected Completion:3/15/91 Actual Completion:.; Superintendent's Signature Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. S-90) DOW CHEMICAL U. S A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT () D-RMTC#__() C-RMTC# ACCIDENT CLASSIFICATION DATE OF ACCIDENT: OD-RWC# _()C-RWC# _ INJURY _ NON-INJURYXX TIME OF ACCIDENT: ,. S&LP STD. VIOLATION __ DATE INVESTIGATED?! OD-DAW# _()C-DAW# ^ ENVIRON.XX RxCHEM. _ DATE REP SUBMITTED : O- r-SKt : OPSA# ^ Jl()0000PD_l 9J9SL Block and Location of Accident Vinyl II. P-104 --^ Name of Injured/Involved Employee - *^class. -- ; Time at Dow (Mos.) Master No. -- Jime on Job (Mos.) -- Contractor Involved/Supervisor r=_ -v?..- Chemical Released (Environ/RxChem only) EDC ___- _ _vt_-t__, _-<__*._.._. _____ __ Amount/Unit of Measure (Environ/RxChem only) One half gallon EDC Accident/Incident Description (10 Words or Less) " c'_" ""AX"LURE to * t o o 2 NN O M Z H > t4 ACCIDENT/INCIDENT DESCRIPTION (Full) Operator making a round outside'found P-104B seal leaking to the slab. He put oil rags DOWN TO catch the EDC after SWAPPING PUMPS AND BLOCKING THE LEAKING PUMP IN. THE PUMP WAS REPAIRED AND T was put in service. May have been a victim of the recent turnaround. iISTQRY. THOUGH. HAS SHOWN THIS _PUMP TO BE A PROBLEM,- `---------------------------------]: "i - LftlV- RESULTS CLASSIFICATION (List all that apply with code number and description y*FR(M BACK PAGE)' ' ' ^ -v 'V- ' ACCIDENT/ INCIDENT ^ INJURY ^ . BODY PART :r 3fif73 Internal plant Reportable A*. : -ic. -f.- * '^1*. JOB BEING PERFORMED (List one from Group I and ALL THAT APPLY FROM GROUP II] 100 Operation Routine - CAUSES (List all that a.pply^hith code number and description from back pad'' ON SUE--' " -U S' PRE-EXISTING ' 310 Equipment Failure___ L' __ _ ~` rOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Evaluate new seal design for P-104 pumps ______________ - Responsibility: Expected Completion:3/91 Actual Completion:. 4^ to "4 CO CO m on:__________ onsibility:. " i" 7 Expected Completion: ^Actual Completion:. uper!ntende!ntSignature Investigated By Signature of Injured ' /i.7 0- SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT OOSHA# _ OCOSHA# _ ()O-RES# 0 CO-RES# () O-DAW# 0 CO-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:6/25/90 INJURY NON-INJURY X_ TIME OF ACCIDENT:7715 S&LP STANDARD VI0LATI0N_ INVESTIGATED: ENVIRON. v^RxCHEM. __ REPORT DATE: 6/26/90 ()PSA# _ ()S50000PD Block and Location of Accident VINYL II FLARE HEADER MONITOR Name of Injured/Involved Employee __________________ ______ Class. Time at Dow (Mos.) __________Master No. Time on Job Contractor Involved/Supervisor Environmental Impact: Yes No ________ Air X ZZ Water _____ _ (MosTT Other ACCIDENT/INCIDENT DESCRIPTION: D-186 BLEW ARUPTURE DISC WHEN LOADING RACK,; WAS FILLING A TANK_CAR_WITH WATER TO CLEAN. iWM wffgl;jiyxNc a~ JO-jMMj iHmaK WATER ANfDn ALARMS CLEArEO IR PLARE flEAoEfe AT V-tlo'S. C O N FID E N TIA L REDACTED R&s 149799 LTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 300 EQUIPMENT FAILURE JOB BEING PERFORMED (List one from Group I and all that apply from Group II) 100 OPERATION/ROUTINE_______________________________________________________ : mr VALVE OPERATION ____ ______________________________ _______________ CAUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING 310 EQUIPMENT FAILURE____________________ IMPROPER DESIGN -'OLLOW UP ACTION TO PREVENT RECURRENCE: Vction: INSTALL VACUUM PROTECTED RUPTURE DISC._______. _______________________ Responsibility: Expected Completion:7/17/90 Actual Completion: Action: REPLACE RUPTURE DISC WITH SAFETY VALVE,___________________ : ?B^fcpNSTBility: Expected Completion:10/1/90 Actual Completion: \^Rn: --------------------------------------------------------------------------------------------------- -------------- ----------------------- Responsibility: Expected Completion: ________Actual Completion: UPERINTENDENT'S SIGNATURE Investigated By Signature of Injured SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA. DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT l)0SHA# _ OCOSHA# _ 0 0-RES#__ 0 CO-RES#__ 0 0-DAW# 0 CO-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:09/15/90 INJURY NON-INJURY X_ TIME OF ACCIDENT: 12:03 AM S&LP staRdard VI0LATI0N_ INVESTIGATED:09/l*/til ENVIRON.RxCHEM. _ REPORT DATE: 09/19/90----- OPSA# _ ()$50000PD Name of Injured/Involved Employee N/A Time at Dow (Mos.) __________Master No. Contractor Involved/Supervisor N/A Environmental Impact: Yes NoAir X *< . " ---------------- 1 IVSTS"1-- class. . - Time on Job (Mos.) Water Other '2 *1 O m z H r1 ACCIDENT/INCIDENT DESCRIPTION: After receiving Vinyl alarms in~our EDC wash AREA SEVERAL OPRATORS INVESTIGATED THE AREA AND FOUND NOTHING. VINYL ALARMS fONTINUEP AND OPERATORS BROUGHT AN HNU WITH THEM TO HELP LOCATE LEAK SOURCeT FTER OVER 4 HOURS OF INVESTIGATING. A NUT WAS FOUND MISSING ON-THE VACUUM DISC RETAINER BOLT ON ONE_OF THE WASH TANKS PVRV'S ALLOWING GAS TO PASS OUT OF-THE PVRV TO THE ATMOSPHERE. THIS RESULTED IN 3.75 POUNDS OF VINYL CHLORIDE EMISSIONS TO THE AIR. ;J-______________________________________ REDACTE ULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 300 Equipment Failure___________________________________________ _________ ' MI Spill _____________ ____________ _________________________ ' ____________________ JOB BEING PERFORMED (List one from Group I and all that apply from Group II) ~ 100 Operation Routine- CAUSES (List all that apply with code number and description from back page ON SITE PRE-EXISTING 810 Equipment Failure 015 Improper Design 0ID in CO CO oo FOLLOW UP ACTION TO PREVENT RECURRENCE: Action: Double nut vacuum disk retainer bolt on all PVRV's in the block. Responsibility:Expected Completion:1O/15/90Actual Completion: Action: Cover incident with all shifts. __________> _ : -_____ ________________________ Responsibility:' Expected Completion:O9/3O/$0Actual Completion: 'uperintendent's Signature Investigated By Signature of Injured L- SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 5-9( DOW CHEMmL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT D-RMTC#__() C-RMTC# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:02/17/91 OD-RWC# __OC-RWC# _ INJURY __ NQN-INJURYXX TIME OF ACCIDENT:iftod S&LP STDrvIOLATION __ DATE INVESTIGATED:02/18/91 OO-OAW#__OC-OAW# _ ENVIRON.__ RxCHEM. -- DATE REP SUBMITTED: 02/1879f OPSA# __OSSOOOOPD__ Time at Dow (Mos.) L_________ Master No. timirfAgNE CONTRACTOR InVOLVEO/ST ------------------ #un I ll/lb I wn WHV mw m SUPERVISOR jiz.____________ _ UB 'nos*/ Chemical Released (Environ/RxChem only) VSmwouSntIn/Utn/IitncoidfenMteaDsuersecr(iEpntivoirnon(1/R0xWCohermds oonrlyL) es--s) -TKtaL-HtiA--g--t-t-.rWra--te--r Entepep ^.,$--YgTi iCCIDENT/INCIDENT DESCRIPHON (Full) A decontaminated, -Water_washed railcar. !*ei wt^ utth fi0#'s NITROGEN PRESSQREt THE CAR WA$ RUINED TO TP5 LOADING, AND TgkATED LIK^A CAR UNDER VINYlJVAPOR. ~ WHEN THE CAR ?2Kng;pQC.PpS TO THE VINYL PROCESS f FREE HATER WAS INTRODUCED TO >37 _ Tiji CONTENTS TO 8E 0UT~OF SPEC IN WATER AND IRON. ABOUT -- 72 OF A RAILCAR OF~VINYL WAS gflNTAMINAJEPt -----------------------------------------:----------- IKTS CLASSIFICATION (List all that apply with CODE NUMBER AND DESCRIPTION FROM BACK PAGE) ACCIDENT/INCIDENT. INJURY . BODY PART Pressure .Violation 0 Plant Upset/Trip _____ -- ------------- ---------------- ------------- )B BEING PERFORMED (List one from Group I and all that apply from Group II) r c 2*r c t* 2 > f 23 W >nO H M a 10 Operation/Routine --------------------------- ------------ ------------------------------------1------------------------ig_ npFRATION/PRESSURE/QEPRESSURE___________________________ ____ _T USES (List all that apply with code number and description from back page,' ON SITE PRE-EXISTING 0_ Procedure Not Followed________________ 985 Inadequate Procedures____________ 3_ Poor Communication _________________ ______________ --------------------------------------------------------- g | J.0W UP ACTION TO PREVENT RECURRENCE: ion: Tag railcas_yalyes_when opened to introduce water into the rati pad- ~ER IN RAILCAR. ------ ;ponsibility: ___ Expected Completion:Q2/20/91Actual Compi fttow m ................... 02 ANALYSIS ON ALL RAILCARS BEFORE EVACUATIO Expected Completion:Q2/20/91Actual Completion:^ - 'rowI: _R_e_v__iew tht<$ INCIDENT WITH THE LOADING TEAM. ponsibility:. Expected Completion:02/18/lActual Completion:02/18/9 'SUUPPEERVISOR'S INVESTIGATION OF ACCIOENT/jTOgmNTI^^^gg^i: L-63 (REV. 5-90) DOW CHEHICAL U.S.A. SUPERVISOR'S INVESTIGATION OF ACCIDENT^NCIDENT - OD-RMTC#__OC-RMTC# _ ACCIDENT CLASSIFICATION WUBSSS^S&/f--c- - .DATE OF ACCIDENT: 01/12/91 OD-RWC# __OC-RWC# _ INJURY NON-INJURY^ TIHE.0F ACCIDENT: 7: SO AM ------- S&LP STD~VI0LATI0N ,^$: DATErlNVESTIGATEotJl/14/ 91------ OD-DAW# __OC-DAW# _ ENVIRON.M RxCHEM^M^ .mmjEP .suBHiTTEnr8i7ig7or OPSA# __()$50000PD__ -. s ... .. | Block and Location of Accident Vinyl II I vmiw VI Time at Dow (Mos.) __________ Contractor Involved/Supervisor -- g*______________________ Chemical Released (Environ/RxChem only) - Vinyl- 4mount/Unit of Measure (Environ/RxChem only) ~ ^ccident/Incident Description (10 Words orTHess* > eader It lea\ \CCIDENT/INCIDENT DESCRIPTION (Full) F10I haqt been^shutdown for a number of jOURS. F101 ISOLATION VALVE STUCK OPEN. 1?NZ WASI HOOKED UP TO ISOLATION VAL rHE VALVE BROKE FREE & WENT CLOSED. UPON CLOSURE. OF VALVE. ^TWO ALARM mUNDED )N Mob V Can--ISOLATION VALVE POSITION PROBLEM---RUPTURE7^ DISC FAILURE /F102. These came on at 7:48 AM and were 4 seconds apart^Furnace condition prior to r--H---i-s------P--R-E--DE--SC- -S--UF--R-E--EE---DE&QUQAULEIZNECDH WLIIQTHU-I-D-D--R---UM--MA- -N--P-U-R-A--E-U-S-LSYU:-RgLEP. C**KFgTPEaIHTKT.HWEAgA"LOA"FR--MFS^c -oT--iH-l--E- 'orlpnleSjni *tG-o--A--U0--G1--E0- 1. REMOVED FROM PSY^WTURE DIS(p ftSSEMpL^ ANP CKfffpvUflSv FOUN^ ^IjARE gggjR, iL ALARMS WERE, V260 948 PPM AT gftCK-VP AT 8:21 AM ESULTS CLASSIFICATION (List all that appl^wtthS description FROM BACK PAGE) 1 ACCIDENT/INCIDENT - - INJURY^ ^ - * '*as9^ 00 Equipment Failure 61 Air Release Sgsfo'r-*; BODY PART OB BEING PERFORMED (List one from Group H andapply from Group II) . ^sn n> H m 00 Operation/Non-Routine 25 Valve Operation >5^ AUSES (List all that apply with code number: anh descriptionfrom back page) on site - 44e^N8BBW^EfetTCTTiB SbitS% ___ 10 Equipment Failure______________ __ 999 WQtHEir t^v-l . 3P005 -f"- to COIND5 SitiSv* 3LL0W UP ACTION TO PREVENT RECURRENCE:* life? :tion: Check with Engineering on Rupture Drsc^FarcURg ff PSV to be sent to iSEIOPNNSIBILITy:_____ Expected Completion:#/14/91 Actual Completion: Check companion furnace rupture disc* ______________ nsibility:iI Expected Completionrl726/91; Actual Completion: SHOP perintendent's Signature B .Investigated y Signature of Injured * i*r+ SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT^ 5of ^tiw.^^DOW CHEMICAL U.S.A.^LOUIS________ -SUPERVISOR'S INVESTIGATION ,OF,ACCIDEffi ICIDENrJ iyi . ??***> L-63 (REV- 5T-90) lTD-RMTC#_()c-|W'n:# accident .CLASSiEiiunoN. *tV*?- llMlllilllllWWWH DATgbFSlCCIDENT:10/06/90 OD-RWC# m()C-RWC# .: INJURY ^NON^jOrS cHMEIOFsACCIDENT: 8:15 AM - S&LP STD. VIOLATION DATOINVESTIGATED?lo/fl6/90 OD-DAW# v ()C-DAW# ENVIROI^^^^^gg OPSA# Srl;<) J50000PD^ VINYL;2 0XrT; Name of ,,Injured/Involved EmployEeEeN//A/ Time at Dow (Mos.i jg*^^SS*-MASTERjt Contractor Involved/Supervisor N/A 'LS'ir.''- Chemical Released (Environ/RxChem onlyU,h_ i immffm___m____a__m___m________ 3TiMm Amount/Unit of Measure (Envxron/RxChemjmly Accident/Incident DescriptionJ10 WordsTqr^ vi" ACCIDENT/INCIDENT DESCRIPTION (Fuufig MrBMain ueBt' iiiilr&MiiBi-ai^BtiBn mm*1 :ir-tf3S8Z/! .. + ._J^i4.i ...<. ; ''AASwR.'. --rracaSRt. Joe? fflC !REC MAID tvs.--' WBawto .* .;*< w"V o w 2: NH > r .IS OASSinTIOM"aJsV ALi:^T^ . FROM BACK 'PASky ACCIDENT/XNCIDENT *,"*. .' DESCRIPTION BODY PART M k 3M_ EQUIPMENT FAILURE ^^S^HZA - L -'-:C . - ..:'-'i":5^ *:.% JOB BEING PERFORMED (List one from GroupITand w THAT 'APPLY FROM GROUP II) 100 OPERATION/ROUTINE .; V . '.Vf- , - I -..--^:.r ;. ^y.-OTa3gl.*--'WS*glP- CAUSES y. -i * &*ists&f^i_ _____ (List . all .. ; tha, t` *"*'a pp" 1lyL.-- with code^umbei CON SITE illL EQUIPMENT FAILURE ' ^ ... - 1 --*o ;tr?y f NTTOI (^DESCRI_P_T__IO_N ____ back page) "Listing SI DEVICE TNOPRAnVE *- 70LL0W UP ACTION TO PREVENT RECURRENCE^ action: INSTALLED DOUBLE NUTS WITH SELASTIC^iS^^^SM^^^tjrty6v >:.;? ' ' -4 Responsibility:SHIFT '-**?. Expected CoMPLETioirI0/06/90ACTUALrCoM"PLETioN: 10/06/90 Action:._______________ -?***^ ^ -r.,- Responsibility:. Expected CoMPLETiaM^ga^-^^ACTUALNCoMPLETioN: \ction: ' nsibility: Expected CompletionActual: Completion: JPERINTENDENTrS SlG NATURE Investigated By Signature of Injured -A - - SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - Sl-305 ' V r DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT L-63 (REV. 5-90 ()D-RMTC#__()C-RMTC# __ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:03/19/91 OD-RWC# __OC-RWC# _ INJURY XX NON-INJURY__l TIME OF ACCIDENT:lfsEPM------S&LP STD. VIOLATION _ DATE INVESTIGATED?ft375fe75T----- OD-DAW# __OC-DAW# __ ENVIRON.__ RxCHEM. _ DATE REP SUBMITTEDiJBZMZII: OPSA# __()$50000PD__ Block and Location of Accident Vinyl II--Old ChlorotheneArea__________ Name of Injured/Involyed Employee Class. Time at Dow (Mos.) _________ Master No. Time on Job (RosTT Contractor Involyed/Supervisor National Maintenance, Chemical Released (Environ/RxChem only) -- Amount/Unit of Measure (Environ/RxChem only) -- ---. ~ Accident/Incident Description (10 Words or Less) Chemical Exposure" o o z wz HI--I > it ACCIDENT/INCIDENT DESCRIPTION (Full) .____ was preparing to demq^qld 2w line IN RACK BY U3JX THAT HE THOUGHT WAS A STEAM LINE ANP- WAS OPEN ON ONE END-.- While cutting into line (cold cut): Cl2 gas escaped AND WAS BREATHED BY Job was shutdown and i sent to Medical to BE CHECKED. HE RETURNED to work approximately 3:20 pm back on full duty.___ THERE WAS A COMMUNICATION BREAKDOWN BETWEEN THE PERMIT WRITER AND CRAFTSMAN. ,,. >ULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 180 Chemical Exposure !500 Respitory 5IL First Aid JOB BEING PERFORMED (List one from Group I and all that apply from Group II) to pn B n H M a 500 Demolition Hr Cutting (Cold Cutting) CAUSES (List all that apply WITH code number AND DESCRIPTION FROM BACK PAGE) ON SITE PRE-EXISTING 300 )40 320 Procedure not Followed Unauthorized Practice Poor Communication 200 Poor Communication W Unauthorized Practice jpoj C/) 4*. CD CO4D^ :0LL0W UP ACTION TO PREVENT RECURRENCE: \ction: Craft review demolition procedures and line identification proc. Jesponsibility:Expected Completion:3/21/91 Actual Completion:3/21/91 Action: All shifts review demolition procedures and line identification proc. 7^ppNsiBiLiTY: Expected Completion:4/11/91 Actual Completion: ^ jpertntfnofnt j s Signatijrf TwvFCTiniTcn By HC TuiHDCr SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT OOSHA# _ OCOSHA# __ 0O-RES# 0 CO-RES# 0O-DAW# ()CO-DAW# ACCIDENT CLASSIFICATION DATE OF ACCIDENT:6/5/90 INJURY NON-INJURY __ TIME OF ACCIDENT:STlrXTr S&LP STANDARD VIOLATION_ INVESTIGATED: 8)5/90 ENVIRON.RxCHEM. __ REPORT DATE: 6/5/90 OPSA# 0 S50000PD Block and Location of Accident Block 66 F-101____________________________ Name of Injured/Involved Employee Class. Time at Dow (Mos.) __________Master No. Time on Job (Mos.) _ Contractor Involved/Supervisor __________________ ______________________ Environmental Impact: Ies No Air Water Other n o z g z H >r ACCIDENT/INCIDENT DESCRIPTION: One of the supercritical^tbanSmTtters was / taken out of service because it was reading incorrectly. Then the combustible ANALYZER DRIFTED OFF "O" UNTIL WE GOT THE HIGH ALARM, HAD THE ANALYZER MAN CALIBRATE THE ANALYZER. WHEN THE ANALYZER WENT UP SCALE THE FURNACE TRIPPED DUE TO ONE SUPERCRITICAL TRANSMITTER SHOWING LOW AND THE COMBUSTIBLE SHOWING HIGH. WHEN THE FURNACE TRIPPED THE ISOLATION VALVE CLOSED, THE FURNACE ____ PRESSURED UP AND THE TAILPIPE SAFETY LIFTED. BECAUSE THE TAILPIPE VENT EBV FAILED TO OPEN - CAUSING THE TAILPIPE SAFETY LIFT. ULTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY BODY PART 350 Spill 450 Plant U^set/Trip NZA ML JOB BEING PERFORMED (List one from Group I and all that apply from Group II) n $ a 300 Maintenance 060 Computer/Instrument Work CAUSES (List all that apply with code number and description from back pagi c 810 800 ON SITE Equipment Failure Procedure Not Followed 981 PRE-EXISTING Inadequate Training Cp 0oU0l FOLLOW UP ACTION TO PREVENT RECURRENCE: 7//// Acti iiUoNn:. nNetteud tiuo pruuti tiwrwanrisamniiti ters/analyzers inn nmwannuuwail- r/tHnEwNuWnOrvRjK.InNuG uOnN TmHEcSjcE INSTRUMENTS. IF IT TAKES 2 OUT OF 3 THEN YOU CAN SELECT & PUT 2 ON MANUAL. Responsibility: . ^Expected Comp:7/5/90/ Actual Completion:/*/^ Action: Have ModJU-stroke vent EBV every 7 days or/on a prescribed time fr<Ai ME, Responsibility: _________ Expected CoMpr^S^O- Actual Completion: ~ Action; Review^procedur1=~fqr--mAintenance on instrumentation.________ ______________ ^ppONSiBiLiTY: Expected Comp:7/5/90 Actual Completions^ S.L Superintendent's Signature Investigated By Signature of Injured Lr6X(REV. 1-90) DIVISION- .- :V* * ****.<. *i i / SUPERVISOR*? 'INVESTIGATION OTACC1 PENT/INCIDENT m ) OSHA *_____(.) COSHA *L i_ 'rr`* ' accident classification v * J ^ DATE.OF ACC1DFMT__3/27 / 90 ( ) O-RES*___ -(') CO-RES1_ ( ) 0-OAW*_!--( ) CO-OAW*Z_ ( ) PSA .( ) J50000PD IM JURYNON-INJURYTM ' S&LP STANDAgJX VIOLATION. ENVIRON RxCHEM-- TIME OF ACCIDENT 13:45 INVESTIGATED:REPORT OATF 3/29/90 '- _ O o Block and Location of Accident- vinyl 2: Name of Injired/InvolvedEmployee--- Time at Dow (Mos.) ____Master Nol Contractor I nvolved/Sunervlsor Block. 66 VV,` ________ Class. -- .Time on Job (Mos.) o w z HHH r Environmental Impact: Ye<T * No. ^ Air--X. , Water. Other. ACCIDENT/INCIDENT" DESCRIPTION: On 3/27790 atlfftOO a-.nr. . an alirmonitor~atr tfte cooling tower indicated VCK was present In area.r^Sanpreg were 'dniglit and posslEldrsources were evaluated. At ID; 45 n.m.,a Leak was confirmed, present Itl E--140 CvCM finishing column condenser) from water samples: taken an tBie-waterr Inlet and, outlet: of the exchanger.-. The column was- shutdown and, the. leak.;wag stopped- at: 9;30 p.m;.- that night., .the, heads, were removed'and" one tube wag found leaking. "VE&ijs: tube was plugged and the entire exchanger was leak- checkeSI No other leaks were, found-- A-The exchanger' was reassembled anou startea hack up. ft-tr.- >-:/ 'Cr.r.W RESULTSC^TIC^ ;v^7-*v ^.f &X' * ACCI DENT/MNC! DENT? 300 EquipmentrTFhjtlUrt 350 Spill V-.-43; --- r-'.t'.7>!*; "-is*<-.-. JOB BEING PERFORMED (List one from Group l and aJl that apply from Group II) 100 - ' Routine Operations- * ; -- - - ' `"ith ' * '*'J' W .1 -."l . , ,; - ` -1.;- ' CAUSES (List all that apply with code number"and description from back page) ON SITE i;': ,.7^-vj '' .I 810 Equipment- Fatlure PRE-EXISTING o n> H W O naC/5 AC0oO0 05 FOLLOW UP ACTION TO PREVEJFTRECURRENCE: ' Action: Test entire tube sheet for leaks, plug/repair- l>kg. Responsibility: _ . Fyperted Completion bate: 3/29/90 Arfiial rAmpiAflnn DatP- 3/29/S Action: Review exchanger design For possible vlbration/design problems & plug high risk tubes Responsibility: Fyper.ted Completion Date: 3/29/90 Art,,ai rAfnpioHnn nate- ^on; Pull failed tuEe for rallure evaluation during next shutdown/ ^ sponsIPIllty: Fxnerted Completion Date- bnmpiptinn nate- Actlon: Tarplement any required design changes from engineering study., Responsibility; _ _ Expected Completion Date: JiZi5/90 Actual Completion Date: SL SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT OSHA# _ OCOSHA# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:8/16/90 ()O-RES#__ ()C0-RES#__ INJURY _ NON-INJURY X_ TIME OF ACCIDENT:7:30 A.M. S&LP STANDARD VIOLATION_ INVESTIGATED:8/17/90 0 O-DAW# 0 CO-DAW# ENVIRON. X RxCHEM. _ REPORT DATE: 0 PSA# _ ()$50000PD Slock and Location of Accident VINYL II BLOCK 6 Mme of Injured/Involved Employee ____________________ Class. Time at Dow (Mos.) __________Master No. Time on Job (Mos.) Contractor Involved/Supervisor _ :NVIRONMENTAL IMPACT: YES No Air Water Other \CCIDENT/INCIDENT DESCRIPTION: AT 7:30 A.M. A LEAK WAS DISCOVERED-IN THE EDC HJRGE HEADER. THE LEAK WAS CAUSED BY_EXTERNAL CORROSION NEAR A U-BOLT CLAMP. Seal And inStrument_purgeS7which1)riginated from thisZheader ^ere_ supplied rom an Alternate sOurcejQrder to depressure the_header, a clamp was INSTALLED TO SfOP THE LEAK AND A FURHANITE BOX INSTALLED OVER THE CLAMP \BQliT 25 GALLONS LEAKED (CONTAINED)'WITH 25 LBS I TO THE AIR AT 10% EVAPORATIVE LOSS (REPORT LIMIT -100 LBS) CONFIDENTIAL LTS CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) accident/incident injury body part 00 EQUIPMENT failure _J__________________________ ______________________________ 150 SPILL_____________________________ ______________________________ 'OB BEING PERFORMED (List one from Group I and all that apply from Group II) n H .00 OPERATION ROUTINE 035 NO TASK CAUSES (List all that apply with code number and description from back page) ON SITE PRE-EXISTING S1Q FOIITPMENT FAILURE 2fiZ_ LACK OF MAINTENANCE J929 CD tOt* 0o0 OLLOW UP ACTION TO PREVENT RECURRENCE: ction: INSTITUTE AREA RESPONSIBILITY FOR CORROSION AUDITS., / ESPONSIBILITY _ EXPECTED COMPLETION:8/20/90 ACTUAL COMPLETION: XIZoJTc ction: :esponsibility:Expected Completion:Actual Completion: iCTION: _______ __ _____________________________________________ '^^onsibility:Expected Completion: Actual Completion: uperintendent's Signature Investigated By I. Signature of Injured //Of 7%/ //?SA SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT - S-305 , -j- . -- L-63 (REV. 1-90) DOW CHEMICAL U.S.A.-LOUISIANA.DIVISION SUPERVISOR'S INVESTIGATION OF ACCIDENT/INCIDENT ^OSHA# _ OCOSHA# _ ACCIDENT CLASSIFICATION DATE OF ACCIDENT:9/17/90 ()O-RES#__ 0 CO-RES#^. INJURY NON-INJURY _ S&LP STANDARD VIOLATION__ TIME OF ACCIDENT: 9:30 INVESTIGATED: 9/197^5 am 0O-DAW#__ ()CO-DAW#_ ENVIRON.2L RxCHEM. REPORT DATE: OPSA# _ OJ50000PD Block and Location of Accident Vinyl II Chlorothene Pipeline at Bine* a Name of Injured/Involved Employee ...... -Class. -......... Time at Dow (Mos.) Master No. ........... - _ .Time on Job (Hos.) Contractor Involved/Supervisor _ ENVIRONMENTAL IMPACT: YES NO Air Mater "Other" > OCCIDENT/INCIDENT DESCRIPTION: Pipefitters cut 1/3 of the way through the ft" Chlorothene(R) -Pipeline between Vinyl II and the Old Dock. ChlorqtoeneYr) STARTING DRAINING FROM _THE CUT INDICATING THE PIPELINE_STILL CONTAINED LIQUID \C>Nh*mDloTTrHouErtNuheAnNue(ARADn)An. MtieS Z/C*gL! AAaMUllPDonuWasAcS spilled lUieScEnD rTnO before the leak SiTTnOnP wTHieE tLEeAtvkT was contained, ~6ray tape TTHuEe iLtINuEb tHiA.nD HBEuEmN DRAINED SEFORE STARTING BUT APPARENTLY SOME DEBRIS HAD PLUGGED, THE DRAIN VALVE AFTER SOME HAD DRAINED OUT. THE VALVE WAS OPEN DURING THE CUT77 7 t0U5~CLASSIFICATION (List all that apply with code number and description FROM BACK PAGE) ACCIDENT/INCIDENT INJURY 50 Spill BODY PART :!'. t- OB BEING PERFORMED (List one from Group I and all that apply from Group II) : V-:- : " r-nirv.'.-J.J M.. M_ Demolition_________________________________ Ml Melding/Cutting 020 Line/Equipment Opening So > rs AUSES (List all that apply with code number and description from back page ONSITE ...... } 7. PRE-EXISTING : ::^r _____________________________ ___________ ____ L'r- 9B2 Inadequate~'JfC3ioJfl b Pl to CO o CO 3LL0H UP ACTION TO PREVENT RECURRENCE: r f ; -ii -tion: Add "rod low point bleed nearest point of line opening before cold cold cutting or prilling_a_hole in a pipeline and confirm that a vacuum does not exist" to modify breaking into lines procedure. f^spnsibility: .EExpected Completion: W/g//rrr//?y* Actual Completion: /<>//#?. perintendent's Signature Investigated By Signature of Injured .^tlSUPSWISOHKlNVESTlQA'1 iikV ( ) U-RMTCX () D-QAW# -- 0-C-OAW# OriBtJBSC. S50(X>bFl^ B<viRo'r^Si5OTSi^SSffi| Block and.Location"df Arreri^nfr^vInyl? TU -Shu Name ofInjured/Involved Bnployee .EOF^Acan^-luV^/^r EOFfrCCIDBfr ^8 rra ft': M ktE3NVE5ITGATHJ: inyTp/on tTERS3 sURMfTTPn- "TlV 05/9 3&. TTaborer- ;r> mtractor iTMwif^/siipnrinf- JjgftNafcional Maxrrfcenaiii^tj/ Chemical Released:(Environ/RxChem only) -- sf/K Amount/UnitofMeasure (B^ron/FbcChem only) Iwm/ff.' Acddent/InddemD'escriptionCICfWords orlies3)._i2[l ACCIDENT*^INCIDENT DESCRIPTION (Full)'.____ gultsTwlAJi-^ `ul^ri^^ScixiSEfe^^'^h^ fi^agttgBgKgTSSaaiB '** RESULTS CLASSIRCATIONCD^ailthal apply whjrcodanumt _______________ _ TracffijEM) fringe* i*"' vj. *"l stv 'TP-: - ' - , JOB BEING PERFORMED (List one from Group l and all that 300 itntffnance fft3nfGiroup.il),*; MatrlVEtr. 070 XTsincr Hand Tool' CAUSES (List all that aappppllyy--ww_iitt.hh.. aood-a in,,;u,m*i>iV.b-..er and description fromfcwwk' page)* ON SITE. '..::*:-i5ff'**r * ' - -V> :^;iS^^7*rTOeCIST(NG^*i; rV7 - - --`"iilfj "- -aHQ_ Prnro^iirpe Mo-H Phi 1 i-'Tjq/I - ".4^- '" EbQir`'Cbinnmni.cat.xons FOLLOW UP ACTION TO PREVENT RECURRENCE: -<**. - .v*,- Action: Will cover accidentr in tailcrate next: saftv meetincf throughout the Divisi Responsibility: r.i 1: 1' Expecteed Completion Dale: 311/ 04/90 Actual.'Ccmpletion Dale: d^-yt^y 'irp jnsibility: _ -etion: :esponsibiiity: Hip nsft *.*&* ^ . - nf n hnntt--..nnhVphnar'ff glnyp-' whpn usinnctLr': rBazyonr kmni'vveps.___________ Expectedd Completion Dale: 3111/03 /90 Actual Completion Dale: : .-'F'e*--' - -., -^csi-. --- ~-----/- Expected Completion Dale: Actual Completion Hate: n/l REPETITIVE INCIDENT CAUSES 1990-1991 Weeping PSV's; Failed Rupture Disks Pump Seal Failures Loading Operations Corrosion Scrubber Stack Excursions Unintentional Equipment Overpressure AREAS OF CONCERN Furnace Coil Pressure Protection PSV System Improvements Pump Seal Performance Corrosion; High Point Bleeds Ecology Area Reliability SRC:8/91 Areas of Concern Possible Opportunities Concern: Equipment Overpressure Opportunities: Furnace Supercritical Coil Protection Mod5 Redundant Instrumentation Areas of Concern Possible Opportunities Concern: PSV System Reliability Opportunities: Define and correct deficiencies found in engineering study during 1992 shutdown Review PSV/rupture disk setpoints vs. operating pressures Review PSV materials of construction Define appropriate applications for rupture disks under PSV's and implement during 1992 shutdown src:8/91 CONFIDENTIAL R&S149814 VINYL 2 PSV STUDY DEVICE LOCATION --t>"'4t>4 AR,BR ^MOO SURVEY RESULTS INLET DP OUTLET DP HAZARD FLARE? % OF SET % OF SET PRIORITY RECOMMENDATIONS 7.40 17.90 12 YES /->' . e -i ' >*' , . > ^ (' o r ' r t - q, r (i c '^ l ! ^117 AR.BR 1^140 OVHD / ' 130 A,B ^T-160 149 A,B,S ^T-130 29.50,.----- 48.70 9 11.00 zoo CXcAji/f,' 7) ^/m^} 1a^^\1&30 9 A9 YES. VALVE OK, CHANGE INLET TO 10' AND OUTLET TO 12" (aZb uj ca oi<. ^ NO REPLACE 4P8 WITH 6R10 AND MODIFY PIPING TO FIT YES^^EPLACE 2J3 WITH 4P6 , CHANGE INLET TO 6M AND OUTLET TO 11T, RUN LEVEL < 8.5 FT Coa:S 2 * 1 /\A fo u j? ^ ^ / 216;217 ^ V-260A/B 14.00 * 9 NO REPLACE 2J3 WITH 4M8, CHANGE INLET TO 1 ^ ^ "i 315 A,B v/E-325 l/^D-541 V; 541 A,B -* 133 A,B `/^D-165 / E-181 172 A,B l//T-120 113 A,B !}* `^Y 9 YES 'o^Yy VALVE OK, CHANGE INLET TO 6" AND V OUTLET TO Iff1 Li ^ A6 21,60---------~A40 9 NO uv^ REPLACE 4N6 WITH 6Q8, CHANGE INLET AND OUTLET TO 8", RUN LEVEL < 8.5 FT Xofc'i > U> ^ D ^ t4/v 1200 <- 7.30. `-vjrfT " 6 REPLACE 2J3 WITH 4M6, CHANGE INLET TO 4\ RUN LEVEL <5.5 FT Ac 3">>' ,s (J c A S) l 0 5 J 11 7.00 2a10 4r- ) i )i J-.>' 6 NO"*/;' AALVE OK* CHANGE INLET TO 3" AND r* ?Mt ' on 11 ET TO 4", RUN LEVEL < 1.5 FT 2. < y . t- ^ a. t \ ^ l, 3 YES ^ /REPLACE 3L4 WITH 6Q8, CHANGE INLET TO '3x4( C^'^j 8" AND OUTLET TO 12" SP 0 3s"?'? - vi- AMU V"L A * Areas of Concern Possible Opportunities Concern: Corrosion Opportunities: Dedicated painting funds Repair/Replace cold service insulation during 1992 shutdown High/Low point bleed audit with corrective actions implemented during 1992 shutdown Reinsulate R-202 OXY reactor in 1992 src:8/91 o o z 25 wz H >r 9Cfl 0CtO0i. 01 Areas of Concern Possible Opportunities Concern: Ecology Area Reliability Opportunities: Minimize VCM in flare header by addressing PSV system problems Replace R400 dry quench section (1992 planned) Provide liquid feed stability for R-400 F410/420 improvements including: - Improved combustion control - Increased instrumentation - Direct stack flow measurement - Automatic start-up control - Mod5 control src:8/91 o o a z H > r 33 Scn -Pt CO CD a / / Dow U.S.A. Louisiana Division Consolidated Audit Program Attendance Plant: Ut aj ^ - Date: ?//0 __________________ Session: n A-c 7~/<JCl\ eTM, la)s 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.. 12. 13. 14. 15. 16. 17. 1 8. 19. 20. HW/cmk 7/9 1 Plant/Department \Zl^j / Z~ l/t. ) 1-- Functional Area /^6-ZP Slrj#.___ /hutr^ -%* /U2> dJtPP&u^-L C<z/> Ctsufc'/i c o n f id e n t ia l ________________________ Occ+jfc /kalM/&o<.<C AuJpJ ______ ____________________________ _____ (Jcyl 7T__________ ___________ /^t_________________ ______ :i_____ ::_______ ~'g yr_]//y^y X'______ _________________________ o /T'pc. Pzntjn Svhjiof it __________ _______ _______ :______ ___ J /M i> -Or\r&a I'J^lAu t H~ ^7tW)____ V go w (C0tOi REACTIVE CHEMICAL REVIEW CESS_ \/l kJ V L HLDING to Lo I LOUISIANA DIVISION REACTIVE CHEMICAL REVIEW CHECKLIST REVIEW DATE PRESENTER q | IQ \ 3 I ADMINISTRATIVE ^Review sghe4uled through 389-1601 Mini or (Full)review (Circle one)____^ -- Type of review - New Super., (2y&aiy Process change, Project (Circle one) 10 copies of Review package (copyof slides) sent to .. 7 days prior to review s/' Safety Superintendent and Environmental Superintendent invited to review V" r&d contact, process engineer, Tech Center contact etc., invited to review ^Appropriate supervision invited to review DATA Appropriate interpretation of data Screening tests complete Reactive Chem Global database searched Calculated thermodynamic data y/Physical Properties ___Literature data ___ Unusual properties ^ 11 CHEMISTRY v/ Ecruations for each reaction (side and main) comparison of Calculated vs. Measured heats of reaction ______Reactivity matrix (inter-reactivity of all process materials) Impurities SYSTEM Pressure relief system design Process conditions (temp, press.) _____Quantities ^Critical instruments ^Materials of Construction ____Equipment size REDACTED MISC. v-* Recommendation from last review y/ Tech Center input History of related R.c. incidents yx-F&E Index complete ^Waste storage and disposal ______Training activities j/^Worst case scenarios/lines of defense determined Discussions with Safety Superintendent, R.C. Personnel or other resources R&S149819 PACKAGE COMPLETENESS _____Statement of purpose yY'Summary of major reactive chemicals concerns Process chemistry--include kinetic and thermodynamic data (Measured vs. calculated) afWWP ) figut, eoUea^D otl oyy fcAr/T#z ___^Physical property summary for all chemicals handled (Boiling point, vapor /pressure, flammable limits, flash point, auto ignition temperature, _____Materials Handling- Include how the Plant receives, identifies, stores handles and disposes of materials. d&v&ftds /'l Simplified Process Flow Sheet - include control schemes, monitoring and relief devices, points where there is reactive chem data, equipment size and location, process conditions and quantities. ______Summary table of Reactive Chemical data - include raw materials, intermediates, products, by-products and wastes. Reactive Chemical concerns for each step - include concerns for each step in the process and worst case scenarios and calculations. Cover the steps, taken to prevent an incident, or lines of defense, (see attachment A) One copy of actual Reactive Chemicals Report (i.e. ARC traces) at meeting. Vinyl II Reactive Chemicals Review Chemical Data Concerns Recommendations from Last Review Self Evaluation Questionnaire COMPOUND Dow Confidential 23-JUL-91 VINYL II PLANT TABLE OF PHYSICAL PROPERTIES BOIL POINT (DEG C) VAPOR PRESS (ATM) FLAMMABILITY IN AIR (V/VZ IN AIR) FLASH POINT (DEG C) " AUTO IGNITION (DEG C) - 252.7 - 195.8 - 191.5 - 183.0 - 161.6 - 102.4 - 85.0 - 84.0 - 78.5 - 48.0 - 24.2 - 4.4 8.0 12.2 16.0 31.7 39.8 48.0 59.4 60.5 61.0 74.1 76.8 80.0 83.5 87.0 97.8 100.0 109.0 114.0 121.0 140.0 146.0 275.0 301.0 993.0 1021.7 1134.6 998.4 949.9 406.3 69.7 47.1 48.1 63.5 11.4 5.7 2.8 1.6 1.4 3.9 0.8 0.6 0:4 0.3 0.3 0.2 0.1 0.1 0.1 0.1 0.1 0.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 4.0 - 75.0 -- 12.0 - 75.0 _ 5.0 - 15.0 3.0 - 34.0 2.5 - 80.0 2.0 - 11.1 8.1 - 17.4 2.0 - 11.5 _ 3.6 - 14.8 3.6 - 33.0 5.6 - 11.4 8.1 - 17.4 5.6 - 12.8 4.0 - 20.0 5.6 - 12.8 8.0 - 10.5 - 1.3 - 7.1 6.2 - 15.9 8.0 - 10.5 _ - _ 0.5 - 6.2 1.2 - 3.3 * * * - 136.1 580 k 650 k 460 - 136.1 k - 17.8 * * ^543 * 335 k -455 - 45.0 * * * - 78.0 556 k * 519 472 - 28.0 * k -20.0 * 570 556 k * k * * -11.1 13.0 * * * k * * 537 * 498 413 410 * k * k * * * 124.0 305.0 * k k * >1000F >1030F k R &S149821 REDACTED CONFIDENTIAL 23-JUL-91 NOTES FOR REACTIVE CHEMICALS CONSOLIDATED AUDIT REACTIVE CHEMICALS DATA THE RINGED-BINDER THAT CONTAINS PERTANENT REACTIVE CHEMICALS INFORMATION ON VINYL CHLORIDE/ETHYLENE DICHLORIDE PROCESSES HAS BEEN EXAMINED. THE MOST RECENT ARTICLES/REPORTS IN THIS FOLDER ARE DATED 1982 OR EARLIER. VE WILL HAVE TO GO THROUGH THE "GUIDELINES FOR UPDATING REACTIVE CHEMICAL DATA". I HAVE PERFORMED A SEARCH OF THE REACTIVE CHEMICALS DATA BASE ON VINYW . CHLORIDE, ETHYLENE DICHLORIDE AND HYDROGEN CHLORIDE. ALTHOUGH THIS DATA BASE IS NOT COMPLETE, MANY ARTICLES WERE FOUND IN THE 1980-1990 TIME FRAME WHICH SHOULD BE REVIEWED AND POSSIBLY INCLUDED IN THE MANUAL. IS THERE AN AUDIT PROGRAM IN PLACE AT THE VINYL II PLANT TO PERIODICALLY REVIEW AND/OR UPDATE THE INFORMATION IN THE BINDER? THE RETENTION PERIOD FOR ARTICLES IN THIS BINDER SHOULD ALSO BE TAKEN INTO CONSIDERATION. SHOULD MSDS SHEETS BE INCLUDED IN THIS MANUAL OR DO WE HAVE A HAZARDOUS COMMUNICATIONS MANUAL IN PLACE AT THE PLANT DEDICATED FOR THIS PURPOSE? ALL "KNOWN" COMPOUNDS WHICH ARE HANDLED AT THE PLANT SHOULD HAVE MSDS SHEETS AVAILABLE, AS WELL AS PHYSICAL PROPERTY AND THERMODYNAMIC DATA. OTHER COMMENTS: I THINK VE OUGHT TO POINT OUT THE FACT THAT VE HAVE A WEAKNESS IN THIS AREA BUT VE ARE COMMITTED TO SPENDING THE APPROPRIATE TIME TO MAINTAIN GOOD REACTIVE CHEMICALS RECORDS. THEY ARE INTERESTED IN US REALIZING OUR WEAKNESSES. WE COULD SHOW THEM A COPY OF A PAGE OF OUR DATA BASE SEARCH TO STRENGTHEN THE COMMITTMENT ISSUE. (I'M SURE THAT NOT MANY PLANTS WILL DO THIS). -k-k`k-k'k'k'k'k'k'k'k'k'k'k'k'k+ck'k`k`k`k`k-k-k'k'k'k'k'k'k'k'k'k'k'k`k`k'kik'k'k'kic'kitity)<'k'k`k`k`k'ki<`k`k'k'k`k'k J g Z t* fcJ q ? Sd O H O JPCT3) tO CNPOD> FURNACE F-101 HEATING REQUIREMENTS MEASURED VERSUS THEORETICAL PERFORMANCE F-101 OPERATION (29-JUN-91): 1 MEASURED RESULTS: THEORETICAL RESULTS: FURNACE EFFICIENCY: Dow Confidential 29-JUL-91 O o 2 L2-*-J 2 H > # w n $ o 33 sa3 CO OroD CO VINYL n EDC CRACKING CHEMISTRY Major Secondary Reactions Minor Secondary Products 9/3/91 AER Dow Confidential 101^UP1A011l3/R00QA4IB/A/ABB/RQR/CR//CBB/D//RRQS/ED/QS l1l1I10l/1006A590A/AAAB/B/mmB//SS 111 Am iu a/b/s 114AR/BR n11s7 AA/mB 112 Am 123 A/B in Am 12S ARmR r1122a76 AaA//mBb 113209AAmm/S 131 A/B/S 132 Am 133 Ams iMAmm 149 A/B/S 151 Am IS2A/B 156 A/B 161 A 163 A1/6B91111111/66666A6O69994299/DBAHLNAJE//////mmmMKEGCV//FD/G/H 116699OP//US 111117767713902 AAAAR//mm/BBT -LOCATION o-ioi WKM ISOLATION VALVES D-102 FURNACE TAILPIPES C-100 E-106. C-ttl E-120 E-121 C-120 E-121 T-120 C-130 D- KB WKM C-140 B-142 E-143 E-165 T-160S VCM TRANSFER P-161 SUCTION P-162 SUCTION T-160S T-I6CTS D-160 E-164 D-16S D-130 T-130 D-112 VCM PUMP SUCTION N2HEADER E-143TO T-120 TANKCAR LOAD HDR. SPHERE PUMP SUCTION OCCIDENTAL TRANSFER P-180 SUCTION T-162 SUCTION T-162 FILL E-169 DOCK RECIR. irHtC AT LEVEE 12- HIC AT LEVEE 6- EBV AT LEVEE 12* AT LEVEE D-181 E-169C3H6 E-I81C3H6 METER PROVING Page I snnrmn 193 400 19S 212 ISO 2S0 IS9 250 r. ISO ISO 120 22S 400 IBS 2S0 230 250 2J 250 230 230 25 25 100 250 50 ISO 125 150 250 260 250 250 250 210 250 250 250 250 250 250 250 250 . 250 150 275 250 250 sssens'su IVLLM/KIUK03 PSV# 174 Am 175 A/B 205 Amc 211 Am 212 A/B 215 Am V 216A/B 216 C/D 217 Am 220/221 230 235 A/B 250 Am 251 Am 252 Am 300 Am 302 Am 304 Am 3ii Am 315 Am 320 LOA/LOB/LOD 320 LOC 325 Am 332 Am 334 Am 335 Am 336 Am 176 Am 350 Amm 350 KA2/KA3/KA4 410 Am 420 Am 421 A/B/C/D 502 Am 531A/B/C 541 Am VINYL II PSV GUIDE LOCATION METER PROVING BLK43UNE D-200 C-111 C-212 D-260 P-216 A/B V-260A V-260B 02TOpLOCK S-230 P-21SA/B C-250 R-2S0 HEAT RECOVERY D-300 90# STEAM D-310 D-320 E-325 P-322 K-320 SEAL OIL S-325 E-332 D-330 E-331 E-332-2 D-541 TO SOLVENTS D-3S0 K-350 THROX T-420 THROX D-63B D-S3I D-541 SEli. 250 250 195 150 150 75 200 250 250 260 44 m 50 285 ISO 250 140 100 300 175 366 45 230 250 300 250 250 250 150 140 300 50 300 205 150 75 Page 2 DISTILLATION REACTIVE CHEMICALS CHLORINATION OF RECYCLE EDC: A. 5 B. SIDE REACTION (UNDESIRED): 9S86HS$U G31DVG3H l DOW CONFIDENTIAI b I( iviiMaauMOD DJH 9/2/91 R201 8c 202 (cont'd) RT 9/3/91 J, V t * O o 2 MO 2 H > r W w a n> S o S323 03 C-fOa CD no R-201 AND 202 MAIN REACTION SECONDARY REACTIONS V /* CONFIDENTIAL REDACTED R&s m 982s T 9/.''/<y] WASH COLUMNS C-203 & C-204 REACTIONS 3T 9/3/91 2 P3 z H > O P5 c u C/3 to fOCoC ECOLOGY AREA CHEMICAL REACTIONS COMBUSTION REACTIONS: SCRUBBER REACTIONS: JRB 9/3/91 0S86W S5d aaxovaan iviiNaaiaNOD VCM Area Concerns Concern: Coke Cycle Length Improvements: CCI4 levels reduced to 1300 ppm resulting in 6-9 month cycles Cracking rate Mod6 control on all six furnaces Opportunities: Relocate CCI4 addition point, control improvements Decoke shot recycle (disposal cost savings) VCM Area Concerns Concerns: Valve Reliability in Furnace Area Improvements: WKM valve trials Opportunities: Replace unreliable valves during 1992 shutdown src:8/91 VCM Area Concerns Concern: Coke Induced Control Valve Sticking Improvements: Slower coke formation due to CCI4 reductions Mod5 control Opportunities: Define appropriate stroking frequencies and implement a PM program src:8/91 VCM Area Concerns Concern: Furnace Temperature/ Cracking Control Improvements: Redundant instrumentation (ex. tail pipe temp.) Mod5 Control Fuel to EDC Feed Ratio control src:9/92 VCM Area Concerns Concern: Corrosion/ Erosion Problem Areas Improvements: Manurite furnace coils (radiant) Coil thickness checks performed during decokes Decoke sandjet runs minimized Monel stems on quench loop ball valves & isolation valves Alloy piping in critical high wear areas in quench loop Opportunities: Painting in furnace area Evolve to Manurite 900D coils VCM Area Concerns Concern: Seal Leaks Improvements: Seal failure monitoring has helped identify some root failure causes Training on installation, operation and maintenance of seals Seal selections better suited to process application Opportunities: Evaluate canned/mag-drive pumps Continue failure analysis src:8/91 VCM Area Concerns Concern: Tarpot Column (C-270) Fouling Improvements: 02 Analyzers Pressure testing maintenance Opportunities: Clean/inspect column and associated equipment during 1992 shutdown Install equipment to remove solids srC:8/91 VCM Area Concerns Concern: Secondary Chloroprene Removal Column (C-255) Fouling Improvements: Reboiler replaced with 2 larger ones Opportunities: Cleaning 3Q91 Mod5 Control Aspen simulation to identify optimum operating conditions src:8/91 OXY-EDC Concerns Concern: Catalyst Activity & Deterioration Improvements: Recharge R-201 during 2Q91 Opportunities: Recharge R-202 in 1992 Continued R&D assistance to evaluate new catalyst Communicate with Ft. Saskatchewan on catalyst performance problems $rc:8/91 VCM Area Concerns Concern: Tube leaks on VCM finishing column overhead condenser E-140 Improvements: Study to determine cause of failures Plugged much of suspected high risk zone New exchanger engineered Opportunities: Replace during 1992 shutdown Study to identify control improvements to minimize column upsets src:8/91 GO O Other VCM Area Improvements RE-120C Heat Recovery in service Dual Tank Bottoms- EDC tanks T-260, 261, T-230 F-106 VCM Furnace started up P-100 EDC Furnace Feed Pumps Rewheeled C-111 Quench Tarpot replaced- higher pressure rating - put on Mod5 control Replaced D-531 CI2 pot and header- higher pressure rating & electric tracing Installed higher efficiency trays in C-120 VCM/HCI Splitter (bottom half) New seats to minimize coke buildup in Neles / quench loop ball valves CO analyzers on VCM furnaces & F-110 along with 02 control 3-Way valve at E-143 to prevent contamination of VCM spheres Mods control on dowtherm furnace F-110 src:8/91 OXY-EDC Area Concerns Concern: Ethylene Quality Consistency Improvements: PM and improved reliability of incoming ethylene analyzer Cross plant ethylene quality team & cross plant operator visits Measures in Place: % Ethylene controlled in reactor recycle Incoming ethylene analysis with alarming for methane & ethane Lower 02 flammability limit determinations - R&D Opportunities: Mod5 Control Poly C vent feed to R-202 Evaluate isobutane levels in Poly A recycle src:8/91