Document 2qO0Q68zwnkvqDO08rQDrZVkr

MUDWii MISSISSIPPI SIMP AMD OVKSUILIYY STUDY VOS 4 DECEMBER 1990 mmmmm wmmmm mm VAB.0001108430 4 Table of Contents 4 HAZOP REPORT VOLUME Legal Notice............................................................................................................i 1.0 Scope...............................................................................................................................1-1 2.0 Methodology.............................................................................................................2-1 2.1 Team Members....................................................................................................3-4 2.2 Documents made available . ...........................................................3-6 2.3 Criticality evaluation .........................................................................3-8 3.0 Mitigation...............................................................................................................4-1 3.1 Mitigation Summary ... ....................................................................... 4.0 P&IDs...............................................................................................................................5-1 APPENDIX A. Study Data Report by Criticality Rank.......................................A-l I Wl VAB.0001108431 4 VISTA COMPANY CONFIDENTIAL Aberdeen Chemical Plant Section 1.0 Scope Vista Chemical Company operates a nominal capacity 455 million pound per year PVC plant located in Aberdeen, Mississippi. The plant manufactures PVC resins by polymerizing VCM in batch reactors. As a part of the process, some non-condensible material containing small amounts of VCM is produced. The material must be incinerated to convert the VCM to HC1 and other environmentally innocuous byproducts. The current incinerators are being replaced because they are becoming mechanically unsound. The Incinerator Replacement Project is the subject of this HAZOP study. nf p ' I: * K T . VAB.0001108432 i - n > J -r i , ! ' 'l t I-1 7--.': 1 I : .v 'L-: d bi* I. ! - U i > Jdrr -u'- section 2.1 Team Members 1-1 The HAZOP study team assembled to identify potential hazard or operability problems should be composed of a multiple disciplined team with the sufficient technical expertise to answer most guide word deviation questions without resorting to further expertise. The HAZOP study team meetings were held at the VISTA Aberdeen Chemical plant site in Aberdeen, Mississippi. All team members conducting the HAZOP study are employees of VISTA from the Aberdeen plant. They are as follows: Attendee Expertise/Responsibi1ity Rendell Newton* Jim White* Steve Kilgore* Joe Shackleford* Don Johnson* Mike Kane* Process Engineering Representative Project Engineer Maintenance Advisor I & E Advisor Operations Advisor Trainer/Facilitator * = full time # = part time Section 2*2 Documents made available Prior to the start of the HAZOP, the necessary reference documentation needs to be assembled and made available for use and reference during the HAZOP team study. A meaningful HAZOP study cannot be conducted without the required documentation to review. Assembly of the documentation optimizes the chance for a successful HAZOP. INCINERATOR P&ID - February, 1981 . r F'lr n I| u-*f n 'll'. 1*11-. i l' iq -By-i.- -fff r-i-1- 1 tt " T l - i ? n- ' -1. >, t ...............! I + r" k : y-.Hiti'I ,k t ^ ,1-| VAB.0001108433 4 p<i--*> - - -1 -I 2--1 section 2.3 Criticality evaluation During the initial stage of the HAZOPs, the team should develop a criticality rating and a probability rating for preparation of a hazard ranking matrix. This is to allow screening of identified hazards by prioritization and sorting to focus subsequent corrective action on the significant identified hazards; eliminating the insignificant or trivial hazards from any further consideration. To this end, a hazard rating index and a risk ranking matrix was developed in the HAZOP team review as follows: HAZARD RATING INDEX Criticality Rating I Maj or An incident which may result in a possible lost time injury, or a reportable VCM release, or major damage or production loss greater than $1,000,000 An incident which may result in a restricted work case, or a VCM release, or severe damage or production loss between $50,000 and $1,000,000 An incident which may result in a recordable injury, or moderate damage or production loss between $10,000 and $50,000 IV Slight Loss of containment of small amounts of flammable material which may result in slight damage or production loss less than $10,000 Frequency Rating A Frequent Expected to occur frequently in the life of a single plant, i.e., may occur more frequently than once per year B Probable Expected to occur in the life of a single plant, i.e., may occur between 1 and 100 years C Occasional Could occur in the life of a single plant but expected to occur once in the life of multiple plants, i.e., may occur between 100 and 10,000 D Remote Unlikely to occur in the life of multiple plants, i.e., may occur less frequently than once per 10,000 years qi-n i. 'i. J pi- ,L_| -i. . i--1* . - - .1 L11 h- -- -j-:-->tb- VAB.0001108434 - .............. -ik- i i n-i : +-W * H ? -rr..i -.i.r- s'." -"<1 -i-fj. q n -if .i-xri 3 -v-ri 1.71 i-|h "s r rr Brir-mq-v. f-r iiMI - -iHLEi '-k- ^ -h ----- 2-2 RISK RANKING MATRIX Frequency ABC I c R II I T I c A L III I T Y IV D A The risk ranking codes assigned to each grid of the risk ranking matrix are as follows: Risk Ranking 1 Unacceptable Mitigation planning should be completed within six months using engineering and/or administrative controls to reduce the risk ranking to a 3 or less. 2 Undesirable Mitigation planning should be completed within twelve months using engineering and/or administrative controls to reduce the risk ranking to a 3 or less. 3 Acceptable with controls Should be verified that procedures or controls are in place 4 Acceptable as No mitigation action required i. p. r* . . . r |. V ...................... J j'- ' A i fl- Id 'H" ............... " ' ! i. T r rr| ,, -4 | if*>- VAB.0001108435 - 11 ' f1- H? inl.JH#-'!-! pf -'m, - jp'-i h -k: > ! li^-1 2-3 4>-n-i4f,H VAB.0001108436 I"1- Ha`fflrr * -J?*- - li'frfri" *- II "in !-*. -'^n .W>il-- * r>: I- I- 'i-.ifc -*M*'vi--,l SECTION 3.0 MITIGATION SECTION 3.1 MITIGATION SUMMARY ITEMS WITH A CRITICAL RANK OF 1 Risk Code I-A No references cited. Risk Code I--B One reference cited. Risk Code II-A ITEMS WITH A CRITICAL RANK OF 2 Risk Code I-C No references cited. Risk Code II-B Three references cited. Risk Code III--A Two references cited. ...................................... 3-1 %l I IF" 'T 4 * i vji IF VAB.0001108437 1 J ! i rn F I. flt p- .!?> J* T' I - Tm -d SECTION 3.2 MITIGATION SHEETS SUMMARY OF CRITICAL IDENTIFIED HAZARDS Page 1 : I--B PROCESS WATER TREATMENT SYSTEM CRITICAL RANK: 1, UNACCEPTABLE MAJOR CONSEQUENCE PROBABLE OCCURRENCE MUST BE IMPROVED DEVIATION: HIGH COMBUSTIBLES EQUIPMENT NUMBER: LINE SEGMENT 6 EQUIPMENT DESCRIPTION: AIR TO INCINERATOR CAUSE: VCM GAS RELEASE CONSEQUENCE: FLASHBACK INTO BLOWER DISCHARGE SUGGESTED MITIGATION: SRO DESIGN OF BLOWER SYSTEM RESOLUTION: COMMENTS: HI.' 'I J1-- i; 11 -p- -`Of ' ........................................... ji. . HI. . * 1- .11 .I -I - < "I *: "' Hr*:! * : i Hd' r" |P " I!'1 A- f-1- <mi r1 ' 'r I 1 ' it it -I-V" TM MrH|H' T-' VAB.0001108438 *n !- l|fc'll11 r-' SUMMARY OF CRITICAL IDENTIFIED HAZARDS Page 2 PROCESS WATER TREATMENT SYSTEM CRITICAL RANK: 1, UNACCEPTABLE SEVERE CONSEQUENCE PROBABLE OCCURRENCE MUST BE IMPROVED DEVIATION: INCREASED TEMPERATURE : II-B EQUIPMENT NUMBER: COMBUSTION CHAMBER EQUIPMENT DESCRIPTION: CAUSE: OVERFIRING CONSEQUENCE: DAMAGE TO REFRACTORY SUGGESTED MITIGATION: SRO REFRACTORY TEMPERATURE RATING RESOLUTION: .bip iM. -q. -idf I*' 1 . I' I . .1 PI d-d yii i i i-'ii ii --iiti I ip P.lH * '-IWT1 t I-" klh-i- hi-: I I-1! 'f. Ii Jl- VAB.0001108439 :k,- hlh I HsiiHiJ : i i s ! rr Hku ii rt . rl . 11---t i-.,rpi' i: r- p i.nr-HHiij -r h SUMMARY OF CRITICAL IDENTIFIED HAZARDS Page 3 : II-B :h . l: huj-ii- :~ui h. j. : .................... l >1 -f- 1 n Tq w r. ic" - r * t i- PbtIi !!- i-t.'-m *r VAB.0001108440 -j ; H -i- |-r* 7-.|- - H,, h r -S------ ' i1J, irq-fl >H 7-lf I- (PH ! ^ H 1.--"INS p n-"--ilrs'-H'(l hTH"-r-Tr-", I **11 - . *r >" :p '*-f IV SUMMARY OF CRITICAL IDENTIFIED HAZARDS Page 4 : II-B w | -i " J -W - . i ' -J . .j; -CiT I -rW :1V U't T ' I H*- -V f I- - 31-- J | ; r j|i> . ; l j r v -I,-.. . |. bpi -J - " J i ^ i 4. m -w1, ia ..................... 1I h al hlIJ'U *i VAB.0001108441 <i-%r ,w' j ' j-ti, h: -n h * f ii t. -IT V*-'j- t -C- -i h P vHii.IL MUM... :p F- ' l .1- i j d i i:. -T- cq n . .jk i je j!i .+ c:k:mi jr i i pi i m > ii 4)4 V HU V '4 14 4 4'J'lk. ' I I jm^ 'J- h ' k- Ljk.-I.LI : I '. J.. . I IL* SUMMARY OF CRITICAL IDENTIFIED HAZARDS Page 5 : PROCESS WATER TREATMENT SYSTEM CRITICAL RANK: 2, UNDESIRABLE - SHOULD BE IMPROVED = MODERATE CONSEQUENCE = FREQUENT OCCURRENCE DEVIATION: REDUCED FLOW & EQUIPMENT NUMBER: LINE SEGMENT 8 EQUIPMENT DESCRIPTION: WATER TO SCRUBBER CAUSE: PARTIAL PLUG OF LINE, NOZZLE, OR ORIFICE, VALVE PINCHED CONSEQUENCE: POSSIBLE OVERHEAT AND DAMAGE, HCL EMISSIONS SUGGESTED MITIGATION: SRO OTP AND INTERLOCKS RESOLUTION: COMMENTS: H , i -I . VAB.0001108442 ' ' ! T -fitfE H -.-r-.P ^ T- Vh _ .. </. 1 l- i > ,l,jr |vj cm: r ' -T* Mr y > i * r 'ii W ,jrd I i- v ih SUMMARY OF CRITICAL IDENTIFIED HAZARDS Page 6 : III-A 4 s. 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LU tXi Ui UJ Er C-i tn t3 UJ tn LU kp-4 ___J o i-- Ld LU -- CO y UI LX LU PC* (Tj ^^1 tx u CJ.i Cfj Ui CO Ui --* CP 1-- LX LU L<r 3 OCJ QC LU A QCj ft-- 3^ LU f LC9 LU cc tJ t_ri CZJ LU i< --1 Cd LU ft-- <x 3 CO LU Cl UJ CCI CO izn tt ti to CD LU cn UJ str H-- CC Ut K<E 3 CO f-- SPLU U LU Oil m or UP cn CO Ui cn UJ * ___i CZi I-- a LU P-- <x. oe --rAr L*n!inJ* Um^-Im ai i 7Mr' LJ L-i _ r i L -->1 i ii iLl O ex LU CO tLJ -TP LJ LU a c#: Left CD x: <i_ u x <- 1 Z Ui Zi oc UJ OJ y~ CC LU CO zc "iCJ> LU T LJ L-> LU UI u C3 cn CMC UJ OD rr- Ui Oi XT rr LJ i__1 LJ 3EUi "i o ztr Ll ~y LU erv ex LU oa Tf~ TT LJ ex LU CX4 hX LJ in LJ CJ jX UJ LU ~~d '--i C=1 d ex CeT. LU LU CQ 0=1 >_ cX <L IE rr LJ o zc LJ ZI LU xo a m LJ jMLLU ex LL LU UI OCj cn 3d 3C: <C <L mm LJ Li 3: X LJ r ji z JiLU LU UJ I-? C3 ers I L I1 4 I VAB.0001108456 r ii i r si t 1 ... j. CJI cx U.. ~4--* --- U un a Or a Tfl ip D LC O --i." UJ nj -- y -t* ui to*--* m M c_> cu CC fci >' n _Q jc' crt rX OJ o. 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M U It II II II 11 1L ll tf PI II M 11 It 1 -i i; 11 It ll ll If ll ll 11 kl kl H Ll H Ik >- -*4 * ft) LJ **4 Ul c a1 OJ *-4 u LU Lu II It 11 II It ll 11 11 11 II 11 11 OJ un *p a fr- o H 11 II Ik h C_J *> w d LU LU c n to m 2E* <L Cu Ld C__l M-J Cd IZI f~ <x a: LU LL Jk'"' uu t- a UJ 4cA^Wt| o LU a. 1 d tn p d i IX oc Uul ca 3C <X LU --rC~J 35 LU C3 CL LU (Q f- a: ir: L-J 7T- CJi UJ T^i C31 t VAB.0001108457 To: HAZOP Team <tnChael R. Kane 9inir lZOP) will be December 11 and rs are asked to aX2sK\ 0v SUtt 7;30 - 7:35 am It* * (UXL<^ 7:35 - 7:45 am 7:45 - 8:15 am 8:15 8:45 am i 8:45 - 9:15 am vcrw\ C^Vvw> kr ^A-U dA4ft^(/u/b^ x'(s C**\ rt\j x'jL N 9:30 - 9:45 am LW 9:45 - 10:15 am jL 10:15 10:45 am LiL 10:30 11:30 am ^ y^A/. j.T, 12:00 - 2:00 pm ALL 2:15 4:00 pm VAB.0001108458 ACT AHM ALT ATMOS A2-1 A13-1 BLDR BPCV CHK CV DM EX FL FCV F/O H20 HAZAN HAZOP ID INSUL KOH LG LK LS MAINT MALF MATL MAX MIN VISTA CHEMICAL COMPANY CONFIDENTIAL Aberdeen Chemical Plant List of Abbreviations Actuated Accurately Hazardous Materials Alternate Atmosphere Piping spec Piping spec Bleeder Back Pressure Control Valve Check Control valve Drum Exchange Filter Flow control valve Fail open Water Hazard Analysis Hazard & Operability Study Identification Insulation Potassium hydroxide Level gage Leak Level switch Maintenance Malfunction Material Maximum Minimum A VAB.0001108459 * '1 W-*' -- Hi T-r f-ff : 'I#*' '-pr. j h r VISTA COMPANY CONFIDENTIAL Aberdeen Chemical Plant List of Abbreviations MOC MOD MSDS MV NAP NORM NC NO OTP PAR P&ID PG PIC PM PREP PRESS PROD PRV PSIG REC REG REV RO RV SPEC SRO STD TEMP TG TRANS VAC VCM Material of Construction Module Material Safety Data Sheet Manually operated valve Not a problem Normal Normally closed Normally open Operator Training & Procedures Partially Piping & Instrumentation Diagram Pressure Gage Pressure Indicating Controller Preventive maintenance Preparation Pressure Production Pressure Relief Valve Pounds per square inch gage Recommend Regulator Revision Restriction orifice Relief Valve Specification Suggested review of Standard Temperature Temperature gauge Transmitter Vacuum Vinyl Chloride Monomer . 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"O 0 3 o> o Oc 0 CO 3 o> co c E c 2 Q. o E o c O CO a CO <D o CO CD X CO O CO . 3 o CO 3 o co o CO CO CD co o OC O CO c E co O) CO 0 C Q. 0) EzCO: "0 o $ CO co CD o TD CO CD Q. c o 0 CD CO jQ CO cr o o 0 o 0 O) CO 10 C n D)*3 co CO CO c O O)* 2o 3 E CO "O 0 oc o o 25o 255 CO o aj a> ca SI a. 0 a) o CO o0 CO D C 3 CVI 00 SI 0 o Q. 0 c o Oo O <5 CO 0 0 "D 0 Q. 0 O O <0 Mi i -I- Hf W- - . 'i - " f + I' I F VAB.0001108464