Document B5kwqnEyMXkgkzgDMVJNz4B5w
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CONFIDENTIAL? Subject to Protective Order of 14th Judicial District Court
WRITTEN BY: "PULLEM* OAT
APPROVED BY: DERIVATIVE'S AREA SUPERVISORS
DATE: 6/22/88
icHwCK i ACTION STEPS (Capital letters) and Comments (Small letters)
|
This SOP is written to develop a uniform procedure
throughout Derivatives to ensure that the appropriate steps
are taken prior to removing from service or bypassing an
^varmTMnStTUment' r shut down system automatic valve.
- ls
W1^ Provlde an effective way of communicating the
status.of these instruments to others and making sure that
the necessary steps are taken to correct the problem. This
procedure is intended to apply to all pressure, temperature
-low, xevel, analyser, etc. associated control valves.
instrumentation and the
This SOP is considered to be each unit's minimum standard. Each unit reserves the right to require a higher level of
reliability if it is deemed necessary by the unit supervision.
1. IF AN ALARM, INSTRUMENT, OR SHUT DOWN SYSTEM MALFUNCTIONS, THI OPERATOR'S FIRST RESPONSE SHOULD BE AN ATTEMPT TO FIX IT.
In every circumstance, the first response should be a reasonable effort toward correcting the cause of the problem. Operating without alarms, instrumentation, or shu
down system valves introduces a level of ri3k that is not
desirable.
2. CHECK TO MAKE CERTAIN WHAT PRIORITY THE ALARM OR INSTRUMENTATION FALLS INTO:
Check the list of alarms attached m the unit SOP manual to
determine what the priority of the alarm is.
The priority
system to be used is as follows:
Priority
~ Critical instruments whose failure would eithe:
cause or fail to inform of situations causing accidental
fire, explosion, uncontrolled release of dangerous
materials, reportable environmental releases, or major
property or production loss. These alarms include those
which have been mandated by outside agencies (RCRA, EPA,
DEQ, Consent Decree), also Operations Review Committee
(ORC) reliability alarms, and alarms deemed critical by
operations supervision. All of these alarms are on the
prooftesting schedule.
Priority 2 - Critical instruments whose failure could eithe;
cause or fail to inform of serious conditions involving
recordable environmental releases, property or productio:
losses, or other non-life threatening situations. These
are slightly lower priority alarms which are also on the
prooftesting schedule.
Priority 3. - All other alarms, which are not on the
prooftesting schedule.
SL 008778
SL 008779
tOMJ-lUtiN'i'iAL:
Subject to Protective Order
of 14th Judicial District Court
/--O.
M No. 91-1145 Note: Operations will treat priority 1 and 2 alarms m
identical fashion. The only reason that these are
differentiated is for the sake of the prooftesting
program.
an
IF THE ALARM IS PRIORITY 1 OR 2. GO TO STEP #5. IS PRIORITY 3, GO TO STEP #3.
IF THE ALARM
3. R_ESPONSE TO PRIORITY 3 ALARMS. THE LEAD OPERATOR SHOULD FOLLOW ESTABLISHED UNIT PROCEDURES AND HIS KNOWLEDGE OF THE UNIT TO EVALUATE EACH SITUATION AND MAKE A DECISION AS TO WHETHER THE INSTRUMENT CAN BE BYPASSED OR NOT.
If there is any doubt about this choice, supervision should be consulted. These alarms and instrumentation are not considered critical under normal conditions.
4. THE LEAD OPERATOR SHOULD IMPLEMENT THE OUT-OF-SERVICE PROCEDURE FOR PRIORITY 3 ALARMS.
This will include taking immediate action to initiate repairs. This means that at least a note in the mamtenanc logbook must be made to initiate repairs to orevent the problem from being forgotten.
STOP HERE FOR PRIORITY 3 ALARMS.
5. RESPONSE TO PRIORITY 1 OR 2 ALARMS. RCRA, EPA, CONSENT A)
DECREE. OR CRITICAL ALARMS, INSTRUMENTATION OR SHUT DOWN TMV
SYSTEM AUTOMATIC VALVES. NOTIFY YOUR LEAD OPERATOR OF THE SITUATION.
No one except the unit lead operator or supervisor has the authority to approve taking an alarm out of service.
6. THE LEAD OPERATOR WILL DECIDE IF IT IS SAFE TO TAKE THE
INSTRUMENT OUT OF SERVICE. IF IT IS SAFE TO DO SO, THE LEAD OPERATOR WILL COMPLETE AN "OUT-OF-SERVICE" TAG AND MOUNT IT C THE CONTROL PANEL. HE WILL ALSO MAKE NOTE IN THE OPERATIONS LOGBOOK TO EXPLAIN THE DETAILS OF WHAT HAS BEEN DONE AND WHY IT WAS NECESSARY. IF, IN THE LEAD OPERATOR'S OPINION, IT IS NOT SAFE TO DO SO, SUPERVISION SHOULD BE CONSULTED.
The out-of-service tag is intended to be a communications tool for notifying other people that Priority 1 or 2 alarms are out of service. These tags should be affixed to the instrument on the control panel or, if this is not possible in another prominent place on the control panel. These out of-service tags will remain on the board until the situatio is corrected.
There are circumstances during routine operations when ssoomme
'of these alarms or valves need to be taken out of service
for short periods of time to perform short term routine
on the system. Some examples of this include the following 11) Pulling alarm cards at EDC I to look for a "mystery alarm .
(2) Taking alarms out of service on the computer at VCM
II long enough to identify them on the CRT display.
/7
VONb Subiecfe to Protective Order
14th Judicial District Cour*
S' 3
3). When a$&plr a4or' and log book Instrument man go
out.Sl.de to look at a abut down system valve that is
sticking.
(4). When OHC analyzers are bypassed for preventive
maintenance work.
Under these and other similar circumstances it would not
normally be worth the effort to complete an out-of-service
tag. For these short-term situations it will be acceptable
practice for the alarm, instrument, or control valve to be
taken out of service provided that both of the following
criteria are met:
1) The lead operator is informed of the situation and
gives approval.
2) The operator gives undivided attention to this
problem.
If both of these cannot be met, then the out-of-service tag
must be used regardless of the length of time required for
the work to be done.
The out-of-service tags are not a substitute for performing maintenance. The out-of-service tags serve only to communicate the 3tatus of instruments m need of repair.
8. TAKE IMMEDIATE ACTION TO INITIATE REPAIRS ON THE OUT-OF
SERVICE INSTRUMENT.
After a priority 1 or 2 alarm, instrument, or control valve has been properly taken out-of-service or bypassed, it should not be forgotten about. On day shift this may requir redirecting the maintenance logbook priorities, or notifyin supervision so an "Emergency'* work order can be written. 0 the back shifts and during holidays, this may mean notifyin the shift supervisor and getting shift mechanics or calling out mechanics so that the repairs can be made m a timely fashion. In either case it is strongly recommended that repairs be started a3 soon as practical.
Ordering "Hut-of-.Service" tags, These tag3 are set up m
our reproduction department with a form number (59A-6) so that day shift operators can reorder these by telephone.
, 9.
WHEN THE REPAIRS ARE SUCCESSFULLY COMPLETED AND THE ALARM, INSTRUMENT, OR CONTROL VALVE IS PUT BACK INTO SERVICE, THE LEAD OPERATOR WILL REMOVE THE OUT-OF-SERVICE TAG FROM THE BOARD, TAPE IT INTO THE LOGBOOK, AND COMPLETE THE BOTTOM SECTION OF THE OUT-OF-SERVICE TAG.
SL 008780
,10.
A "WEEKLY OUT-OF-SERVICE TAGGING CHECKLIST" WILL BE COMPLETE BY EACH UNIT ON MONDAY MORNING GRAVEYARD SHIFT TO CONFIRM THAT THE PANEL ALARMS AND LIGHTS ARE IN WORKING ORDER AND THAT ALL OF THE OUT-OF-SERVICE ALARMS, INSTRUMENTATION, AND CONTROL VALVES HAVE BEEN PROPERLY TAGGED ACCORDING TO THIS SOP. THESE CHECKLISTS WILL BE MAILED TO THE DERIVATIVES ENVIRONMENTAL FOREMAN EACH WEEK FOR RECORDKEEPING AND AUDITING.
The objective of the weekly checklist is to routinely take an inventory of the out-of-service tagging which has been done and to correct all tagging deficiencies on the spot.
S-y
/7 Each individual unit will make up a detailed checklist whic:
will be entitled "We kly Out-of-Service Tagging Checklist".
During this weekly inventory, the audible and visual ala^^s should be proven to be in working order. A check of alflcf
the out-of-service tags on the panel will be made to insure that they all have been done correctly. Also a cross-check in the field will be made to insure that no bypassed SDS automatic valve has been overlooked. All tagging discrepancies which are found should be corrected on the
spot by following 3tep #11 below.
11.
12.
IF A PROBLEM IS IDENTIFIED DURING THE WEEKLY CHECKLIST WHICH HAS NOT BEEN PROPERLY "OUT-OF-SERVICE" TAGGED * THE DEFICIENCY MUST BE CORRECTED IMMEDIATELY. RETURN TO STEP #1 ABOVE AND FOLLOW THIS SOP TO INSURE THAT EACH ITEM IS PROPERLY OUT-OF-SERVICE TAGGED.
THESE CHECKLISTS WILL BE REVIEWED BY THE UNIT SUPERVISORS AN! AREA SUPERVISOR, INITIALLED, AND MAILED WEEKLY TO THE DERIVATIVES ENVIRONMENTAL FOREMAN.
feL 008781
CONFIDENTIAL:
1
Subject to Protective Order Of 14th Judicial District C urfc '
N . 91-1145
cCWI PENTJfAI.f
SbP !?
SL 008782 Jfibject to Piat&t't.ive Carder
4th Judicial District Court
-------WO-- -tii jt* ALARM, INSTRUMENT, CONTROL VALVE ,PANEL CHECK NOT OK (CK BOTH)
PRI
IF
ALARM TEST CIRCUIT, ETC. DESCRIPTION
OK TAGGED RPRS.INITI
1. LOW CHLORINE GAS PRESSURE
62
1
2.#1 COOLING TOWER PUMP
86
1
3.#2 COOLING TOWER PUMP
85
1
4. DSA CHLORINE ALARM
72
1
5. #3 COOLING TOWER PUMP
84
1
6. #4 COOLING TOWER PUMP
83
1
7. #4 COOLING TOWER BASIN LEVEL
59
1
8. #3 COOLING TOWER BASIN LEVEL
58
1
9. #5 COOLING TOWER PUMP
82
1
10. ETHYLENE TO PLANT H/L PRESS
57
1
11. #6 COOLING TOWER PUMP
81
1
12. #1 COOLING TOWER FAN #1
80
1
13. #1 COOLING TOWER PH H/L
-55
1
14. AIR PRESS LOW
67
1
15. #1 COOLING TOWER FAN #2
79
1
IS. #2 COOLING TOWER FAN #1
78
1
17. #2 COOLING TOWER FAN #2 18. #1 480 VOLT SYSTEM GROUND
77 52
*
1 1
19. #3 COOLING TOWER FAN #1
76
1
20. #3 COOLING TOWER FAN #2
75
1
21. #1 EDC DAY TANK H/L
45
1
22. #2 BOTTOMS STORAGE H/L
45
1
23. #3 EDC DAY TANK H/L
42
1
24. #4 BOTTOMS STORAGE H/L
48
1
25. #5 EDC DAY TANK H/L
46
1
26. #6 EDC DAY TANK H/L
43
1
27. TETRA AND SHIPPING PUMP 2S. EDC TRANSFER PUMP
47 41
1 1
so S' n
SL 008783
ALARM. INSTRUMENT, CONTROL VALVE,PANEL ALARM TEST CIRCUIT, ETC. DESCRIPTION
CHECK 1
IF OK
NOT OK TAGGED
/>-C (CK. BOTH) PR I I
RPRS.INITI
29. EMERGENCY POWER LAE
13
1
30. EDC EMERGENCY POWER TRANSFER
12
1
31. CONTROL ROOM BLOWER
11
1
32. AREA B 250# STEAM
18 -
1
33. #1 EDC CONDENSATE PUMP
21
1
34. #2 EDC CONDENSATE PUMP
21
1
35. #5 LIFT STATION LEVEL
23
1
36. LOW EDC FLOW TO TRI II
24
1
37. #7 EDC DAY TANK H/L 38. #8 EDC DAY TANK H/L
4 3
1 -1
39. CRUDE EDC TRANSFER PUMP
27
40. feu.
42. SHELL ETHYLENE PRESS HIGH
43. SHELL ETHYLENE PRESS LDW
44. OCCIDENTAL ETHYLENE PRESS HIGH
45. ORANGE ETHYLENE PRESS HIGH
46. ORANGE ETHYLENE TEMPERATURE LOW
47. ORANGE ETHYLENE TEMPERATURE HIGH
48. OCCIDENTAL ETHYLENE TEMP. HIGH
49. ANTI AIR SD SYSTEM BYPASS
50. MILLION GAL.TANK TRANSFER PUMP
51. OCCIDENTAL ETHYLENE TEMP. LOW
52. ANTI-AIR SHUTDOWN ACTUATED
J3. HIGH OXYGEN IN CHLORINE GAS
'^4. EDC PLANT VENT GAS TO INC.HIGH PRS.
CONFIDENTIAD* Ruh^pf i-o Protective Order of 14th Judicial Distru t Court
__________________________________ MfX.
-
1 1 1 1 1 1 1 1
X
1 1 1
SJS*/7
SL 008784
W*
ALARM. INSTRUMENT, CONTROL VALVE.PANEL
ALARM TEST CIRCUIT, ETC. DESCRIPTION
i- *.,, protective Order
Judicial ni'trict Cour
No. 91-1 US
_/
CHECK IF OK
NOT OK <CK BOTH) PRI TAGGED RPRS.INITI
55. CHLORINE GAS PRESS #1 PLANT
62
1
56. #1 CHLORINE SURGE DRUM PRESS H/L
105
1
57. ETHYLENE PRESS TO #1 PLANT H/L
57
1
58. CHLORINE FLOW TO #1 REACTOR H/L
107
1
59. NORTH CHLORINE VAPORIZER TEMP H/L
109
1
60. SOUTH CHLORINE VAPORIZER TEMP H/L
108
1
61. CHLORINE GAS TEMP. TO #1 REACTOR
110
1
62. #1 REACTOR HIGH PRESSURE
103
1
63. ETHYLENE FLOW TO #1 REACTOR H/L
100
1
64. #1 CHLORINE SURGE DRUM BOTTOM TEMP. 99
1
65. #1 REACTOR LEVEL H/L
97 98
1
66. #1 REACTOR GAS SEPERATOR LEVEL H/L 94 F67. #1 STRIPPER GAS SEPERATOR LEVEL H/L 93
1 1
68. STRIPPER REFLUX PUMPS #1 STRIPPER
1
69. #1 STRIPPER STEAM FLOW
91
1
70. #1 PLANT EDC CRUDE TANK H/L
90
1
71. LIQUID CL2 TO #1 PLANT H/L PRESS.
61
1
72. CHLORINE GAS TO #1 PLANT TEMP.
60
1
73. STEAM PRESS TO CHLORINE VAPORIZERS 70
1
74. STEAM TEMP.TO CHLORINE VAPORIZERS
69
1
75. #1 REFRIGERATION UNIT
56
1
76. STEAM FLOW TO CL2 VAP 1&2 H/L
68
1
77. #1 EDC TRANSFORMER TEMPERATURE
54
2
78. #2 RECIR.PUMP #1 REACTOR kf9. #3 RECIR.PUMP #1 REACTOR 80. #4 RECIR.PUMP #1 REACTOR
65 64 63
i i i
81. HIGH C2H4 TO CL2 RATIO #1 REACTOR
i
82. LOW C2H4 TO CL2 RATIO #1 REACTOR
i
CONFIDENT! Ai.:
S/>S /?
Qi nnA7QC
oL uUo/05
#Bt>ject to Protective Order
^4th Judicial district Courfc,
1r
ALARM. INSTRUMENT, CONTROL VALVE.PANEL
CHECK NOT OK (CK BOTH)
PR I
b ALARM TEST CIRCUIT, ETC. DESCRIPTION
IF OK tagged RF'RS. INITI
on 04
CO
TRIP INITI. CL2 VAP. SHUTDOWN SYS
1
84. #1 REACTOR LOW LEVEL MODICOM
1
CO
#1 REACTOR HIGH PRESS MODICOM
1
86 #1 EDC PLANT VENT TRIP
1
87. #1 EDC PLT.HI6H VENT FLOW TO INCI.
1
88. LOW ETHYLENE ANALYZER A #1 REACTOR
1
89. LOW ETHYLENE ANALYZER B #1 REACTOR
1
90. HIGH OXYGEN #1 REACTOR VENT
1
91. LOW ETHYLENE ANALYZER A #3 REACTOR
1
92. LOW ETHYLENE ANALYZER B #3 REACTOR
1
93. - HIGH OXYGEN #3 REACTOR VENT ANAL.A
1
r4' HIGH OXYGEN #3 REACTOR VENT ANAL.B F95. ETHYLENE PRESS TO #1 PLANT
96. #2 CL2 SURGE DRUM TEMPERATURE
106 40
1 1 1
97. CHLORINE FLOW TO #3 REACTOR H/L
34
1
98. ETHYLENE FLOW TO #3 REACTOR H/L 99. #3 EDC REACTOR PRESSURE H/L
35 31
1 1
100. #3 EDC REACTOR LEVEL H/L
T `m` A.
1
101. #3 EDC REACTOR LEVEL H/L REDUNDANT
1
102. #3 EDC RX GAS SEPERATOR LEVEL H/L 29
1
103. #2 EDC STRIPPER FEED PUMPS
30
1
104. # EDC STRIP. GAS SEP. LEVEL H/L 105. #2 EDC STRIPPER REFLUX PUMPS
25 26
1
106. #3 EDC RX CRUDE TANK LEVEL H/L ^107. #2 EDC ST FEED PUMPS
108. #3 LIFT STATION LEVEL 109. EDC DOPP KETTLE AGITATOR 110. #2 EDC REFRIGRATION UNIT
27 28 16 15 14
1 1 1 1 1
m
// CONFIDENTIAL:
nno7ftC SL UUo/OD
Subject to Protective Order 14th Judicial District Court
r-- , DATE:
LNSYF ljMENT r
CGWTKOL
VALVE , PANEL.
No. 91*1145
CHECK r M1 -ti1..i1 t1 1. ,,M.i. , rp
_ ` - ,'l .i.j) i- ,,. ------^
M TEST CIRCUIT, ETC. DESCRIPTION
OK A '.1" tZ. U i_' H DC b s. NIT I |
L. Jl .1- a EDO pORF ! ET7 LE HI OH LEVEL
1 1 "7 EDO DOFF KETTLE HIOH PRESSURE
j } ^ " t .4,
EEC STILL "FHPPRh H `PE H/l, '-DP jt; j j F'VFi H 1
..V a/ '2 0 i=:
.
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w-^ C ' / i . . \~t f [
1 i. '5 ,, ....
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,:c p. HltH PREEB MOC T.EC;-. '
1"' 1 , Vp LDC " X !i [CH TEMP- MODI CON
P3 -NAL . LOUl i I ARP I ER OmS PRESS.
1,16 = h, 2 :-':..ANF' HI Oh '-'ENT PLUM ' 0 .NCEN, i " T EDC RECOVERY ST'ILL PRESS
"T
EDC RECOVERY STILL BINS TEMP H/L
; '>? . EDC RECOVERY STILL LEVEL h-L
S3
CTO. -Tl PEHCTOR CRUDE pumps
oq
I'M., EDC EEC. 3T REFLUX TANK LEVEL H L
.32. EDC RECOVERY STILL REFLUX PUMPS
49
133. CT MOTOR rMP ALARMS PUMPS i - 6
1.34. CT MOTOR AMP ALARMS PUMPS 7 ~ 3
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