Document 4a3MKVwwRzErzkkx6qR0n35Dp

FILE NAME: Reynolds Metals (RM) DATE: 1988 Nov 15 DOC#: RM033 DOCUMENT DESCRIPTION: Internal Inspection Results - Management Safety Tour Meeting MANAGEMENT SAFETY TOUR MEETING November 15, 988. * I PUUNIWS EXHIBIT RMC-23 AREAS INSPECTED: 1 & Z, 5 A 4 Digesters - ground level, 1 & 2 Digesters Upper levels, 5 & 4 Digesters - upper levels, 5 Digester A!I levels INSPECTION TEAMr Troy Burson, Jerry Ferguson, Tony Dunn, Dave Bachman, Merle Sfngleterry, Don Imig, Bob Bird, Darrel Harriman, Gilbert Myatt, Jack Barbee, Stan MI l!sap, B U I Bauman, Howard .Huggins 1 & 2, 5 & 3 Digesters - Ground Level 1 - Biggest problem is trying.to work in that steam, slurry, mud, whatever,, when we are trying to get ready for a digester outage, tomorrow- l don't see- anyway to do the work that we have planned because we cannot get ready for it. We cannot get in there to it. I don't think it will be cleaned up by then.. .1 don't have any people working in there. <T. Burson) 2- 1 & 2 overhead structures, #14 by the north end of #1 digester, by #1 biowoff pump there Is a 6* piece of pipe that is rusted into .on one end and can levered off about 20 ft. shaking In the breeze which needs to be taken down. 3. The city water stations hanging at the north end of #1 and on the south end of #1, no markings or color or anything else to note that they are fire stations. Might have a difficult time finding them and may be used for some other purpose. 4. Middle sump is rather explosive looking. (T. Dunn) 5- Biggest problem Is. the extreme steam condition of the middle sump. We hung a lot of hopes on the stack but obviously it is not going to work. We need to go back to the drawing board and engineer our way out of that. The basic problem is the types of bauxite we run. We have flow restrictions, pinched vapor valves, separator drains plugged. That Is the bottom line. How do we get around that? We don't know. We could shut the unit down * three times a month and still not control that situation so the next thing we need to do Is engineer our way out of it so we can handle the slurry and the steam through a separator or something. Obviously, what we have is undesirable and we should not have to live this way. <J. Ferguson) 6. On the south end of 1 A 2 there were quite a few hoses strung out across the sump; some were partially and some were completely submerged in that sumpIt would be a tripping hazard. 7. There were quite a few lights out around that sump area. All you could see out there were objects. 1 don't know if there is a fixture out there or not. You could see some fuzzy stuff, A big problem - fighting. 005140 Strong*riqaor booster pump has got- a temporary to oiler motor- Again, it Is hard "to get-to because the lines go by the area where steam *s flying everywhere; 1 don't like the way it is hooked up;*if should be protected .. better. , CO*. Bachman) The breaker panel itself Is not in the sump. It is down on the end but the route it goes is right by that area- - It is high and hard to get to- 1& 2 Digesters - Upper levels 1. Upper level hoses, scale, bolts laying around on top; housekeeping problem there 2. Don on flash tank level around 2-- T, saw some bolts, scaffold boards scatteredWith stack in center you cannot get past the temporary steam, capped on top, to do work on down the way. Cannot get up and down center stairways due to steam. Lots of miscellaneous items around but it is hard for me to criticize ' people leaving- a bolt behind or. scale behind when the guy cannot even see what he -is doing due to steam and mist and everything else*. Scrap is still there from building the stack but we cannot get to tt to clean it up.. I think we need to do something with that stack. We put a wooden cap on it Saturday and.it is blowing out the sides flow. Siding is coming loose. My opinion, is that we need to put.the f.loor in unless someone comes up with a better idea. This would at least keep the steam down low. If you don't disagree with that t plan to do that tomorrow during the outage. (D. Imig) 3. So much slurry and steam blowing on upper levels (coating your glasses and hitting your face before you could move) the place is-a hazard to be in There are housekeeping problems but why worry about that when you must worry about your eyes and face. Hoses are stretched across the walkway in several places. Extension cord and boards lying across-walkways and scaffold boards, in several places*. Another thing l noticed is* a.lot of insulation failing off pipes and laying- on grating. I donrt know what type of insulation there was but there*was* quite1* a bit of it around. Also, sawja lot of I-beams in the area, that are:.badly. ... - corroded. A lot of paint is missing off of them. (B. Bird) 4. Boards, bolts, scale and plastic is scattered; insulation problems; all 1 & 2 units. Regarding the digester outage tomorrow, Troy, if we see what'' * jobs you cannot work In preparation for the outage, we wilt just have to. seat the loops and get on with it.* We must have the digester outage. { feel the condition of #2 unit is contributing a lot to the mess and I am sure Jerry will agree. We are taking that unit down tomorrow. We will seal both loops so people can work on the #2 unit. Oon and f were together ookngat this stack. It S capped but the overlap of that material is causing the slurry to run out ail the way around it and we have got to do something with that. We need some engineering. It is one of the most serious problems we have had here. We need some help. We must keep on making production but we hav got to improve this situation. I am sure we will. We will make it safe for the outage tomorrow. (M. Singfeterry) - 2- 005141