Document 65YbYyzZv88DowQj9xZDBJO6d

VINYLS area s.o.p. TEXAS CITY PLANT UCAR SOLUTION VINYLS COMPLEX TOTAL AREA ___ ______ NO. 2 t( Revised) ! PAGE: Cover Sheet | EFFECTIVE: March 15, 1981 SUBJECT: Vinyl Chloride Exposure Protection This S.O.P. is a Revision of two S.O.P.'s combined; S.O.P. No. 2 three pages issued August 23, 19TS and S.O.P. No. 2~6 issued January 16, 1979, eight pages for Bldgs. 113 and 117. Please take those two S.O.P.'s from your Manual and insert this new Revised S.O.P. No. 2 for TOTAL AREA, effective March 15, 1981. It contains the following: A. POLICY B. MONITORING EQUIPMENT C. LEAK DETECTION D. RESPIRATORY EQUIPMENT E. EMERGENCY ucc 048491 VINYLS AREA S.O.P. TIvXAS CITYJ'IJVNT lICAlt S01.UTION VINYl-H COMPJ.EX Bldgs. 115 & 117 NO. 2 r PAGE: EFFECTIVE: SUBJECT: | | ! S.O.P. No. 26 is combined in TOTAL AREA, S.O.P. No. 2 (Revise effective March 15, 1981, pages 1 through 11. t ucc 048492 VINYLS AREA S.O.P. TEXAS CITY PLANT BUSINESS UCAR SOLUTION VINYI.S COMPfcEX- TOTAL AREA NO. 2 (Revised) t PAGE: 1 of 11 EFFECTIVE: March 15, 1981 SUBJECT: vinyl Chloride Exposure Protection A. POLICY 1. UCC Policy is to fully comply with the OSHA Regulation for Ex posure to VC1 (1910.1017) reference letter by D.L. Engle dated 3/1/76 to all employees, Texas City Plant* 2. The OSHA standard for VCl requires that no employee may b ex posed to VCl in concentrations greater than 1) 1 ppm averaged over any 8-hr period, 2) 5 ppm averaged over any period exceedi: 15 minutes, & 3) may not be exposed by direct contact with ligu VCl (1910.1017c). 3. At any time the allowable levels are exceeded in an area, personnel working in the area must wear respiratory protection and rain suits if required. 4. All Visitors to the Regulated Area will register at Bldg. 114 Control Room. The Regulated Area is shown on an attached plot. 5. All Operations & Maintenance personnel regularly assigned to the Regulated Area will be registured on Rosters kept by the Chief Operators & Leadmen. The Contract Division will keep Rosters oj contract personnel entering the area. The UCAR Vinyls Staff Roster will be maintained by the Vinyls Secretary. These Rostc: (Logsheets) must be forwarded to Bldg. 197 on a regular basis for filing. 6. The Regulated Area will be monitored by three continuous vapor fraction analyzers (VPA's) with sample points scattered through out the area. B. MONITORING EQUIPMENT 1. Continuous Vapor Fraction Analyzer (VFA) Two continuous vapor fraction analyzers are currently in servici in the Unit and located in Bldg. 115. A third unit will be addi during 1981. Each analyzer consecutively analyzes sample point: requiring 40 minutes to compltc a scan (2 minutes/point). The analyzer is designed to analyze for VCl only. Results are UCC 048493 VINYLS AREA S.O.P. TEXAS CITY PLANT UNIQN '] BUSINESS "*2*1 CONFIDENTS. UCAIt SOLUTION VINYLS COMP TOTAL AREA NO. 2 (Revised) PAGE:2 of 11 EFFECTIVE:March 15, 1981 SUBJECT: Vinyl Chloride Exposure Protection recorded on a strip chart and stored in a micro-computer for further processing. After each 20 point cycle, the stored info mation is printed out showing VC1 concentrations for each of 19 sample points. The 20th point is a 10 ppm calibration point. The first analyzer covers Tank Area 1, Bldgs. 115 & 117. The second analyzer covers Bldgs. 121, 122, & 114. The location of the sample points arc shown in the attached lists. The third analyzer will be located at Bldg. 113 and cover Bldg. 119 and the VC1 Tank Car Unloading Rack. Calibration samples are taken every 40 minutes. Whenever the calibration samples read out of the specified range (i 1 ppm), the analyzer must be reported to Maintenance for repair. The Bldg. 115 Operator & Bldg. 113 Operator when VFA is install* are responsible for monitoring the VFA, re^UXaiir| maintenance for repairs if required, ordering & replacing the printout sheets, and removal of completed sheets each Monday Day Shift. The completed sheets should be placed in the DPS's box with oth< charts. A file is maintained at Bldg. 115 for filing the VFA printout sheets. 2. Portable Organic Vapor Analyzer (OVA) Portable OVA units (Century) are currently available at Bldg. 1. for pin pointing leaks in the unit. One unit will also be located at Bldg. 113. The analyzers can be used to measure tot. organic vapors, or specifically for VC1. The analyzer is accurate to 1 ppm. C. LEAK DETECTION 1. Vinyl Chloride Leak (Defined) A leak, other than one that can be detected by sight, sound, or smell, is defined as a single reading of 10 ppm or greater, or two consecutive readings of 5 ppm or greater on the VFA. ucc 048494 VINYLS AREA S.O.P. TEXAS CITY PLANT UCAR SOLUTION VINYLS CO UNION *U$tN*$5 iCARBlOt I cmimm TOTAL Aim NO. 2 t(Revised) PAGE: 3 of 11 EFFECTIVE: March 15, 1981 SUBJECT: Vinyl Chloride Exposure Protection 2. Leak Detection Procedure (North Area) a. The Bldg. 115 Operator is responsible for monitoring the continuous analyzer (VFA) printouts and determine if there is a leak as previously defined. b. The North Area Chief Operator must be notified immediately when a leak is indicated. Other personnel in the affected area must also be notified immediately over the public address (PA) system. c. The Chief Operator, or the Operator if delegated, will dete mine the source of the leak using the portable organic analyzer (OVA). The Operator searching for the leak must wear respiratory protection (MSA Pack). It must be assumed that he will be exposed to levels higher than the permissib exposure limits when the source of the leak is discovered. d. When the source has been determined, corrective action must begin immediately to stop the leak. If maintenance is re quired to repair the leak, the request should have a high priority, normally 24 unless the leak is very large or a vapor cloud release, then 1A. Maintenance personnel repair ing the leak must also wear respiratory protection (MSA PacJ and rain suits if danger of exposure to liquid. e. Non-essential personnel shall be withdrawn from the area of the leak. Personnel required to remain in an affected area are required to wear respiratory protection when spending 15+ minutes in an area where the latest reading is 5 ppm, or anytime the individuals 8-hr TWA is forecast to be over 1 ppm. f. If, for any reason, repairs cannot be made immediately, the area must be isolated until the leak is fixed and VFA monitor indicates a return to normal conditions (<t 1 ppm). UCC 048495 VINYLS AREA S.O.P. TEXAS CITY PLANT UNION| BUSINESS comowm UCAR SOLUTION VINYLS COXTITOT TOTAL AREA____________________ NO. 2 t(Revis d) PAGE: 4 'of 11 EFFECTIVE: March 15, 1981 SUBJECT: Vinyl Chloride Exposure Protection g. The Chief Operator or Bldg. 115 Operator will notify personnel in the area over the PA system when the VC1 level is back to normal. h. All leaks, as defined, must be recorded on the forms pro vided (copy attached) with a description of the action take to eliminate the leak. The completed form should be routed to the SPS, DPS, and Vinyls Dept. Head. 3. Leak Investigation Procedure (Bldg. 113 Area) a. The Bldg. 113 Operator is responsible for monitoring the VF> printouts and determine if there is a leak as previously defined. b. The Bldg. 113 Chief Operator must be notified immediately, . well as any other personnel in the affected area, when a leak is indicated. c. Other steps of procedure same as procedure for North Area and as listed abovo. 4. Routine Check For Leaks A weekly check will be conducted to find small leaks in the are. The Bldg. 116 Operator and the Bldg. 113 Chief Operator will be responsible for conducting the checks for their areas each Saturday on Day Shift. Areas to be checked using the OVA inclu< North Area (Bldg. 116 Operator) a. Autoclave steam pumps b. Autoclave safety relief devices & manual vents c. Centrifugal pumps in the Stripping Unit d. Reciprocating (steam) pumps in the Stripping Unit e. The second & third levels of the Stripping Unit f. Safety relief devices in the Stripping Unit UCC 048496 VINYLS AREA S.O.P. TEXAS CITY PLANT UCAR SOLUTION VINYLS COMPLEX TOTAL AREA NO. 2 (^Revised) PAGE:5 of 11 EFFECTIVE:March 15, 1981 SUBJECT: Vinyl Chloride Exposure Protection 9. The compressors (unloaders and packing) h. Centrifugal pumps in Tank Area 1 i. Reciprocating pumps in Tank Area 1 j. The second level of Tank Area 1 k. Safety relief devices in Tank Area 1 l. Scrubber vent to atmosphere in Stripping Unit. VC1 Tank Car Rack (Bldg. 113 Chief Operator) a. First level - transfer pump b. Second level - four hookup spots. Building 119 (Bldg. 113 Chief Operator) a. First level - compressor, reflux pump, cycle tank, knockout pot b. Second level - condenser c. Third level - stripper feed motor valve Tank Area 4 (Bldg. 113 Chief Operator) a. Transfer pump b. Acetone purge pump All leaks discovered should be recorded on the forms provided -andfiled at the Chief Operator's desk at Bldg. 115 and Bldg. 113. Action should be taken to eliminate any leaks as soon as practical. UCC 048497 VINYLS AREA S.O.P. TEXAS CITY PLANT UCAR SOLUTION VINYLS COMPLEX TOTAL AREA NO. 2 (Revised) PAGE: 6 of 11 EFFECTIVE: March 15. 1981 SUBJECT: Vinyl Chloride Exposure Protection D. RESPIRATORY EQUIPMENT 1. The approved respiratory equipment in the Unit for protection from expsoure to VC1 are 1) the MSA self-contained 30-minute air pack, and 2) the Breathing Air Systems. 2. One or more MSA air packs are located at each building in the vinyls area. A list is attached showing the number and locatio Each Operator should know the location of the respiratory quip ment in his/her working area. The MSA air pack contains a clea MSA mask and a full air bottle. Anytime an air pack is used, i must be reported to the Safety Dept. (Ext. 6027 or 5199) for refilling the bottle and cleaning the mask. 3. The Breathing Air System consists of a mask and hose connected to a cylinder of "breathing" air. Some buildings have cylinders connected to a manifold with several take-off points for hose use. Clean masks should be stored conveniently locate to each Breathing Air Station or in the Control Rooms. When a mask has been used, the Safety Dept, should be called (Ext. 6827 or 5199) and they will pick up the mask for cleaning Breathing Air. Systems are located at Bldgs. 113, 115, 116, 117, 122 and the VC1 Tank Car Rack. E. EMERGENCY A vinyl chloride emergency occurs when there is a massive VC1 release threatening a vapor cloud hazard. In this case, the Flammable Vapor Cloud Release S.O.P. (Vinyls Area S.O.P. No. 1) should be followed. UN/CN' I EUSiNCSS confidential ucc 048498 VINYLS AREA S.O.P. TEXAS CITY PLANT ... -^NTIAl UCAB SOLUTION VINYLS COMPLECT TOTAL AREA NO. 2 (Revised) PAGE: 7 of 11 EFFECTIVE: March 15. 1981 SUBJECT: Vinyl Chloride Exposure Protection The main steps of that procedure are as follows: 1. Actuate the deluge system for the affected area. 2. Evacuate the endangered area. 3. Activate the plant fire alarm and the toxic gas alarm. Locations of toxic gas alarm boxes: Box 612 - Pipe Rack east of Bldg. 117 Box 623 - Pipe Rack east of Bldg. 113 Box 632 - Pipe Rack northeast of Bldg. 120 4. Isolate the affected area, roping it off if possible. Do not allow ignition source near area. 5. Do not re-enter the area. Only Fire and Rescue Squad wearing proper protective equipment are allowed in the area. 6. Isolate the leak by remote valve or pumping arrangements, if possible. 7. All available water should be used to dispense the cloud and form a water curtain to prevent vapors from reaching an ignitioi source. Deluge, spray systems, monitor nozzles, and fire hoses should be used. 8. As a last resort, entry to the area shall be made from upwind by Fire/Rescue Squad especially trained to cope with vapor releases, wearing protective clothing and respiratory protectioi and under a prtoective water spray. An ignition should be anticipated at any time. 9. If a fire occurs, do not extinguish until the source of the fuel is shut off. A re-ignition could be more hazardous than the fire. UCC 048499 VINYLS AREA S.O.P. TEXAS CITY PLANT UNION t ?3!NES$ (fltfflfj CONFIDENTIAL UCAR SOLUTION VINYLS COMPLEX TOTAL AREA NO. 2 (Revised) PAGE: 8 of 11 EFFECTIVE: March 15. 1981 SUBJECT: Vinyl Chloride Exposure Protection Point No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LOCATION OF VINYL CHLORIDE CONTINUOUS SAMPLE POINTS - NORTH END Building Tank Area 1 Tank Area 1 Tank Area 1 Tank Area 1 Bldg. 117 Bldg. 117 Bldg. 117 Bldg. 117 Bldg. 117 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Bldg. 115 Calibration Point Level 1 1 1 1 1 1 2 3 1 1 1 1 1 1 1 1 1 3 3 1 Location North of 602 & 612 tanks North of 676 tank South of 615 tank South of 675 tank Middle of compressor room Control Room Middle of deck Middle of deck North of #2 Dilution tank North of B-8, 9 autoclaves South of B-7, 8 autoclaves South of B-9, 10 autoclaves Office Control Room Lab North of B-4, 5 autoclaves North of B-2, 3 autoclaves North of B-3, 4 autoclaves B-6 autoclave pump Calibration point ucc 048500 VINYLS AREA S.O.P. TEXAS CITY PLANT business CONFIDENTIAL UCAR SOLUTION VINYLS COMPLEX TOTAL AREA____________ NO. 2 (Revis d) PAGE: ft of 11 EFFECTIVE: March 15. 1981 SUBJECT: Vinyl Chloride Exposure Protection Point No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 LOCATION OF VINYL CHLORIDE CONTINUOUS SAMPLE POINTS - SOUTH END Building Level 121 121 121 121 121 121 121 121 121 Tank Area 2 122 122 122 122 122 122 121 114 114 115 1 1 1 2 2 2 3 3 3 1 1 2 1 1 2 3 2 1 1 1 Location Office - Bldg. 121 West end of building East end of building West end of No. 3 Bird chute Control Room East end by No. 4 wash tank Middle of atomizer room Center north wall of Bird room Middle of cyclone room Northeast of 13004 tank North of structure Between 013 and 031 North wall of gel tank room North wall of ionexer room Middle of floor Middle of floor Outside northeast corner of bldg. Office Control Room Calibration point - 10 ppm UCC 048501 VINYLS AREA S.O.P. TEXAS CITY PLANT UCAR SOLUTION VINYLS COMPLEX TOTAL AREA NO. 2 (Iffevis d) PAGE: 10 of 11 EFFECTIVE: March 15. 1981 VINYL CHLORIDE REGULATED AREA * 11 * VCL STO?*c, YANKS (ovr-ec. itevta' -< U) %oA \%\ 7^~raza "* 1 TM \D . - .. -t r\ 0) n \ l: u U8 | 1 >57 | AV. D ucc 048503