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VINYL CHLORIDE MONOMER fVOO
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``I Conoco Chemicals # * Aberdeen, MS Plant
January, 1975
DISTRIBUTION
B. W. ANDERSON
K. W. COUCH
R. D. GAMBLIN
L. W. KAMERY
N. *B. KETTERMAN
T. R. LOW
D. E. MICHELS
J, W. POWELL
*
F. J. SCOTT
R. W. SEYMOUR
J. E. STARK
F. M. WILLSON
J, T. WOQD
E. M. SMITH, Saddlebrook, NJ
R, G. WEISS, Ponca City, OK
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TABLE OF CONTENTS
I* DEFINITION OF A VCM EMERGENCY
II. PURPOSE OF THE PLAN
III. IV.
AREAS INVOLVED
4
IMMEDIATE ACTION TO BE TAKEN
A. VCM Release Inside A Reactor Building.
B. VCM Release In The Large Reactor Area. C; VCM Release From The Tank Farm Or VCM Tank Car D.* VCM Release From VCM Line, Receiver, Filter, Etc.
E. VCM Release From A Reactor Vent Stack.
P, Power Failure.
A V. DEPARTMENT ASSEMBLY LOCATIONS
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VI. COMPLETE PLANT EVACUATION
VII. . MEDICAL SURVEILLANCE
VIII. REPORT TO OSHA AREA DIRECTOR
IX. PLANT REPORTING
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X. PLANT DISASTER ORGANIZATION CHART
XI. DISASTER CALL LIST
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VAB.0001027579
VINYL CHLORIDE MONOMER
EMERGENCY PLAN
Conoco Chemicals Aberdeen, MS Plant
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X. DEFINITION OF A VCM EMERGENCY
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A VCM emergency is any unexpected massive release of Vinyl
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Chloride, such as the venting of a reactor through the vent
line or safety disc, breakage of a VCM line, release of
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liquid VCM in a building or area from a live reactor or
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VCM line or liquid discharge of VCM from a storage* tank
or tank car.
II. PURPOSE OF THE PLAN
A. Prepare personnel for VCM emergencies in order to insure
the health and safety of employees and the surrounding
*
community in the event of a VCM emergency. *
B. Minimize personnel exposure to VCM, property damage and
loss of material and provide for the resumption of normal
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opertions following a VCM emergency*.
III.
AREAS INVOLVED -
P
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VCM emergencies at the Aberdeen Plant may occur at the VCM
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Tank Farm, at a VCM tank car, along the VCM pipeline to the
Vinyl Reactor Areas and at each Vinyl Reactor Area. The VCM
emergency may expand to include other areas ot1 the entire *i
plant, depending on the extent of the VCM release and the
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weather conditions during the release
XV# IMMEDIATE ACTION TO BE TAKEN IN THE EVENT OF A VCM EMERGENCY
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Xn case of a massive Vinyl Chloride release, the following
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procedures should be followed in most cases. Each VCM
escape will be slightly different and a judgement' will
have to be made in each case. In most cases, the Vinyl m
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Reactor Shift Supervisor will make the first determination
of what actions are to be taken. The actions taken may
range from handling the VCM emergency with personnel present
at the time to full alert of the Plant Disaster Organization
Most cases will be handled in the following manner:
A. VCM Es cape In A Reactor Building
1 Evacuate All Personnel - The Charging Operator is to
J notify all utilities and other personnel of the emergency
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and be sure that they get out of the reactors and out of 1
the building. In the absence of the Charging Operator,
the Lead Operator is to be responsible for all personnel
getting out of the building. If the release is in V-ll,
the Recovery Operator is to notify the Large Reactor
personnel and they are to evacuate as if the escape
+
were in their area All operations personnel are to
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move away from the building and assemble at the East
end of the V-ll Dryer Room (outside Control Room),
Maintenance personnel who are in the affected area
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The correct respiratory protection must be worn during
evacuation.
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are to return to the Vinyl Maintenance Shop (Including
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Utility & Electrical - Instrument personnel). Contract
personnel are to return to the Contractor's Shop, West
of the Large Reactors. All other personnel are to return i
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to their areas, including personnel who are in the Vinyl
Area
vapor to get to his assembly area.
toward the VCM
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2. Set Off Deluge System - Do this while leaving the building
* 3.
(if possible) if the system has not started automatically.
a
Head Count - The Reactor Lead Operator or Dryer Supervisor
make
accounted for.(including Large Reactor Operators, if
applicable). The Vinyl Maintenance Supervisor is to make
*
a head count of his employees to be sure that ail are
accounted for. Hollis Martin and Jim White are to account
for all Contractor personnel,
4, Turn In The Emergency Alarm For Vapor Release - Dial 62
**
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for the Vapor Release Alarm and then dial 8 and announce
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over the Paging System the location and the nature of the
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problem. The alarm will alert the guard to stop traffic
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and alert other plant personnel of the emergency, so that
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All welding and hot work in the plant is to stop immediately
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when the Vapor Release Alarm is sounded.
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5* Shutdown Dryer Gas Burners - When the Vapor Release Alarm
. is sounded, the Dryer Lead Operator, Dryer Operator or
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Dryer Shift Supervisor is to intmedl shutdown buttom for the gas burners^oh"th'cT'V^iQ and V-ll Dryers (Reactor personnel may have already done this in the affected area, but the Dryer personnel must double-check. 6. Provide Medical &/C?r First Aid Treatment For Injured Personnel Standard First Aid procedures should be followed with the extent of treatment determined by the Shift Supervisor The Plant Nurse or the Laboratory First Aid Attendent should assist the Shift Supervisor with the First Aid If serious injury has occured, an ambulance should be called at once. Oxygen should be given to anyone who has been exposed to high VCM concentration. 7. Relocation Of Personnel - The Vinyl Reactor Shift Supervisor
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rmine
from the affected area what the emergency is. Alsot at this
time, he should determine the wind direction and, if necessary,
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relocate the assembly point to the concrete pad North of
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V-10. He may also spnd a messenger to another Reactor
Area or Areas to request them to evacuate to the Dryer
Control Room or V-10 Pad. If necessary, a messenger
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should be sent to the highway in front of the plant to
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stop traffic from entering the plant road. The Vinyl
Maintenance Supervisor should check the wind direction
and relocate his personnel at the Front Maintenance
Shop, if necessary. Jim White and Hollis Martin should
check the wind direction and relocate Contractor personnel I
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to the'Main Plant Gate, if necessary. If further evacuation
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is necessary, the Vinyl Reactor Shift Supervisor will again
sound the Vapor Release Alarm (dial 62) and (dial 8) and
announce
evacuation (including Compounding and other personnel
evacuation, if needed),
,8 Miscellaneous Action Steps - For a reactor bottom gasket * *
leak, vent the reactor to the atmosphere while leaving
the building, if possible.
*
blowdown
to the atmosphere while leaving the building, if possible
DO NOT BLOWDOWN A REACTOR IF UTILITIES ARE STILL IN THE
REACTORS.
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9 Re-Entering Building - A building or area that has a
higher concentration than 3,600 p.p.m. should be entered
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only to rescue a person or to prevent a greater hazard
from occurine. When the amount of VCM has been lowered.
normally 15-30 minutes, the Vinyl Reactor Shift Supervisor
and two other persons with Scott Air Paks, a century unit
and an Explosimeter should return to the building. Only
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one person should enter, while the others watch him from
the outside. Everyone must have a Scott Air Pak on. At
this time,- the person should stop the blowdown if the
make
that are necessary (i.e. take reactor off heat-up). He
should check the reactor to be sure- that all the pressure #
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has been released and if the reactor pressure is zero
VCM
(0. 1% VCM) in all affected areas, including lower levels,
and shut off the deluge system. Check the building for
VCM
If a reading above 25
p.p.m. is obtained, leave the building. Return after
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several minutes with a Scott Air Pak and check again
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until a reading of less than 25 p.p.ra. is obtained.
The building should then be ventilated for 10-15 minutes
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before re-entering by the operating personnel.
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10. Notification Of Plant Management - During the time the
personnel are waiting for the release to stop, the Vinyl
Dryer Shift Supervisor will call the Vinyl Reactor Operations
Supervisor and the Plant Safety Director to notify them of
the VCM emergency. The Operations Supervisor will notify
the Operations Superintendent, who in turn, notifies the
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Plant Superintendent. The Plant Superintendent is to
notify the Plant Manager.
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Depending on the nature of the emergency, certain members
of the Plant Management will come to the Plant. However,
the Vinyl Reactor Shift Supervisor believes the VCM
**
emergency to be extremely serious, he should notify the
Messenger (Resin Laboratory Technician) to start calling
in the Plant Disaster Organization (See Plant Emergency
Procedure for Disaster Organization, Job Descriptions,
etc,). Disaster Organization Chart.and Disaster Call
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1,181 arc found at the end of this Plan.
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11, Turn In The All Clear, When Appropriate - Dial 63. Alt
affected areas should be below 25 p.p.m. ceiling and no
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potential for additional releases existing before the
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All Clear is given.
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B. VCM Release In The Large Reactor Area
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1, Evacuate Personnel - The Senior Large Reactor Operator
Is to notify the Large Reactor Lead Operator by radio
(do not open the Control Room, as this may allow VCM
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. Into the Control Room) and then notify all personnel
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In the area of the emergency and to be sure that all
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personnel leave the area. The Junior Large Reactor
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Operator is to go"to V-ll and notify the Lead Operator
or any V-ll Reactor Operator of the emergency. V-ll
personnel are then to be evacuated as if the VCM release
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vere in V-ll. All Operations Personnel (except the
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Large Reactor Lead Operator) are to move away from the
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area and assemble at the V-ll Dryer Control Room.
Maintenance and Contract personnel are to evacuate the
Large'Reactor Area and V-ll the same as they would if the
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^-emergency were.a VCM release in a reactor building.
2. Set Off Deluge System - The Large Reactor Lead Operator
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is to set off the Deluge System using the button under
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the MSA Unit in the Control Room as soon as he is notified
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of the VCM release.
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3. Turn In The
Alarm For The Vapor Release - Large
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Reactor Operator is to dial 62 and then dial 8 and announce
over the paging system the location and the nature of the
problem,
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4. Head Count - The Senior Large Reactor Operator is to make
a tiAorl rftnnf and the V-ll Lead Ooerator is to make a head
count to be* sure that all operating personnel are accounted
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1 for. The Viny1 Maintenance Supervisor and Hollis Martin and
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Jim White are to account for the Maintenance and Contractor
personnel, respectively.
5 Shutdown Dryer Gas Burners - Same as Item A-5
'6* 7,
Re-location
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Re-entering
Of
Personnel
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Area - Same as
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Same as Item A-7.
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Item A-9.
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Notification Of Plant Management - Same as Item A-10
9. Turn In All Clear - Dial 63.
C. VCM Release From Tank Farm Or A VCM Tank Car
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X* Evacuate Personnel - The Yard Operator or other personnel
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observing a massive release of VCM from the VCM Tank Farm
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Area or a VCM Tank Car are to notify any other personnel
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in the area to evacuate and assemble in their other areas.
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2, Turn In The Emergency Alarm For Vapor Release - Dial 62 and
then dial 8 and report the location and the nature of the
VCM release. Then proceed to the V-ll Dryer Control Room.
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The Vinyl Reactor Shift Supervisor is to meet the person
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vho turned in the alarm at the Dryer Control Room.
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3 Determination Of Evacuation - The Vinyl Reactor Shift
Supervisor should determine from the person who turned
in the alarm what the nature of the emergency is. Also,
determine
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direct evacuation, as needed, by again sounding the Vapor
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Alarm
(dial 8) and announcing
the evacuation plan necessary
4 Head Count - Same as Item A-3
5 Shutdown Gas Burners - Same as Item A-5., ,,
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6 Provide Medical And/Or First Aid - Same as Item A-6,
7 Re-entering The Area - The Vinyl Shift Supervisor and two
other persons with Scott Air Paks, a Century OVA Meter and
" * an Explosimeter should re-enter the area to prevent further
*
release of VCM. When this is done, leave the area again,
until it is assumed that the area is clear Use a similar
*
procedure to Item A-9 before all personnel re-enter.
8, Notification Of Plant Management - Same as Item A-10, except
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that the Dryer Shift Supervisor is also to call the Warehouse
Operations Superintendent. 9. Turnon The All Clear - Dial 63
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D VCM Release From A VCM Line. Receiver, Filter, Etc.
1, The person observing the massive release of VCM is to notify
any other personnel in the immediate area to evacuate and
assemble in their designated arcasi 2, Turn In The Emergency Alarm For Vapor Release.- Dial 62 and
4.
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* * and then dial 8 and announce over the Paging System the
location and the nature of the release. Set off Deluge
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System, if applicable. Then proceed to the Dryer Control
Room .
The Vinyl Reactor Shift Supervisor is to meet the
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person at the Dryer .Control Room.
3. Determintaion Of Evacuation - If the release is located behind
the V-ll Building, the V-ll and the Large Reactor personnel are
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to evacuate. Remainder of this procedure is the same as Item
C-3.
4* Head Count - Same as Item A**3
5
5* Shutdown Gas Burners - Same as Item A-5.
6. Provide Medical And/Or First Aid Treatment - Same as Item
A-6.
7* Re-entering The Area - Same as Item C-7.
8. Notification Of Plant Management - Same as Item A-10
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9. Turn In The All Clear - Dial 63.
E VCM Release From A Reactor Vent Stack
.
* 1. Turn In The Emergency Alarm For Vapor Release - In the event
of a pending or existing release of VCM from a reactor rupture
* **
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disc, relief valve system or manual venting system, dial 62
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`then dial 8 and announce the location and the nature of the
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Vapor Release. The Guard will then stop traffic.
2* Shutdown Dryer Gas. Burners - Dryer personnel are to push the
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emergency shutdown^button for the gas burners and exhausters
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on the V-10 and V-ll Dryers immediately upon hearing the Vapo
Release Alarm, (beep - beep - beep) if reactor personnel have
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not already done this at the V-ll and V-12 stations.
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VAB.0001027589
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3. Evacuation Determination - The Vinyl* Reactor Shift Supervisor
is to check the wind direction and determine If any evacuation
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is necessary by Operations Personnel. Maintenance and Contractor
personnel should evacuate.to their assembly areas as soon as
the alarm has sounded. Further evacuation should be announced
Supervisor
alarm
and announcing (dial 8) the necessary evacuation
Head counts are to be taken at the assembly areas. ,
4 notification Of Plant Management - Same as Item A-10
5 Turn
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F Power Failure
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X. In the event of a power failure all reactor cooling water
supply and agitatrion will stop. Therefore, it is very Important to act quickly in order to keep the reactor venting
to a minimum during the power outage.
2. large Reactors - Inject \ gallon Alpha-Methyl Styrene into each
* reactor immediately, using nitrogen, and if the reaction runs
away, inject AMS again, as needed.
3, Small Reactors - Inject one pint 'AMS into each reactor
Immediately, starting with the reactions most nearly
.>..-;pomp 1 ee or reactions on which the pressure is the highest.
Inject Alpha-Methyl Styrene again, as necessary.
m
Additional help in preventing venting of the reactors will be
to close the empty reactors and use them and blowdown drums
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for extra expansion volume for reactors nearing venting
conditions
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4. Stop Traffic - Guard to stop traffic and prevent ail
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vi w^-av^3^^iaa~.parklng
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lot* Additional help should be sent to the highway
entrance and stop all except authorized personnel, see
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Disaster Plan. If venting of reactors begins, all cars
must be stopped.
4
5* Reactor Venting - The Vinyl Reactor Shift Supervisor is
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to follow the Procedure in E-l. E-2 & E-3. as much'as
+ possible, but send messengers to areas needed in place
of using the Vapor Release Alarm and the Paging System
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6. Notification Of Plant Management - Same as Item A-10.
V. DEPARTMENT ASSEMBLY LOCATIONS
1 The Vinyl Reactor Shift Supervisor will announce the needed
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evacuation over the Paging System or send a messenger to the
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needed areas, except by evacuation by procedure when the
alarm sounds.
A*
Vinyl Department
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1* Primary - East end of the V-ll Dryer Room outside the
Control Room.
2. Secondary - Concrete Pad North of V-10 Reactor Building,
.i Use if primary location is declared unsafe due to wind * * % ? direction or extent of VCM release.
B. Vinyl Maintcnnnce, Utility, Maintenance & Electrical/Industrial
People In The Vinyl Area
1* Primary - Vinyl Maintenance Shop.
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2. Secondary - Front Maintenance Shop. Use if primary location
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is declared unsafe due to wind direction or extent of VCM relea
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c. Contractors
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l. Primary - Contractors Shop.
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Secondary - Front Gate, Use if the wind direction extent of VCM release is declared unsafe. 4
D. Plasticizer
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1. Training Area or Hose Finishing Area, if required.
E. Compound
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1. Training Area or Hose Finishing Area, if required.
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F. Dry Blend
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1. Training Area or Hose Finishing Area, if required.
G. Maintenance
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I. Front Maintenance Shop.
H. Laboratory
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1. Transportation Trailer Area.
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I. Warehouse
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1. Shipping Warehouse, East Warehouse, if required.
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J. Engineering
1, Main Gate Area, if required.
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K. Yard
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1, Main Gate Area, if required.
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1. Main Gate Area, if required.
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M. Visitors
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1. Main Gate Area, if required. VI COMPLETE FLANT EVACUATION
If evacuation of the plant work site is .ordered, personnel
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Ye to be directed to the appropriate Disaster Exit(s). There
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A* Male Gate (North)
B. Shipping Yard Gate (East)
C# Railroad Gate South
Personnel leaving the plant work site during a disaster are retna
beyond the Disaster Exit and await further instructions
In the absence of instructions as to .where to go following a decision to evacuate the plant work site. Personnel are to use the nearest Disas.ter Exit and in no case are to go toward an endangered area, unless they are required to help cope with ,the emergency
VII MEDICAL SURVEILLANCE
VCM will be taken to the Company Doctor or to the Hospital Emergency Room, as soon as possible.
A statement of each employees suitability for continued exposure
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n.*to' VCM, including the use of protective equipment and respirators
shall be obtained from the examinimg physician promptly after
any examination. A copy of the physicians statement shall be
provided to each employee.
At the earliest possible time, after a VCM emergency, the Plant
fi
Safety Director will discuss the individual's VCM exposure with
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exposures
a Supervisory Personnel to determine estima
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He will then discuss the emergency with the
eal Personnel to determine what further med
surveillance is needed for each person.
VIII.
OSHA SAFETY DIRECTOR
Within twenty four (24) hours of any VCM emergency, the Plant
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Safety Director will report that emergency to the Area OSHA
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Safety Director. A written report with additional information
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and corrective action may be requested by the OSHA Safety
Director.
IX. PLANT REPORTING
The Plant Manager (1) Plant Superintendent (2) Ghief Process
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Engineer (3) will report the VCM emergency, within twenty
*i
four (24) hours to Saddlebrook Management (Manager Of
*
Manufacturing or General Manager) and Houston Safety. The
Vinyl Reactor Operations Superintendent will issue a report
on each VCM emergency as soon as possible, not to exceed
twenty four (24) hours. The report is to include names of
*
personnel involved in the emergency area.
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MANAGEMENT CROUP
Plant Manager
Plant Superintendent
DISASTER OFFICER orations Superintendent Of The Affected Area
MESSENGER .ab Technician
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ASSISTANT DISASTER OFFICER Chief Process Engineer
SAFETY DIRECTOR
SECURITY OFFICER Train ing Supervisor
4^. **
GUARDS
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FIRE CHIEF Reactor Shift Supervisor
hri-i*
/..; ::rr fire chief
t 1 T III Shift Supervisor
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MECHANICAL CHIEF Mechanical Superintendent
SUPPORT GROUP AllMaintenance <Sc Warehou
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Personnel
FIRST AID CHIEF & ASSISTANTS Chief Chemist
Laboratory Lead Technician
Compound Line I Technician
.^los'E- crew It A II
\ er - Line I/Line III Compounder
HOSE CREvJ
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Leader - Dryer Lead Operator
Automatic Bagger/Scrap Utility
Dry Blend Utility
Utility
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Utility
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Large Reactor Operator.,
Dryer Operator
.Dryer Utility
Dryer Utility
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FIF; 3RIG ME MECHANIC `Vinyl Area Shift Supervisor
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KIRK PUMP MECHANIC
Compound Area Shift Mechanic
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The messenger will call the people on the left s he cannot reach them. He should then call the person to the top right of the person that he cannot reach. They, in turn, will call the people Indicated to their right.
B. F. Hawkins (343-8832)
R. W. Seymour (369-6870)
D. F. Johnson (256-8279)
LuJ! Rrvan (343-8814)
B. J. Harrison (369-6344)
G. A. Morgan (369-2748)
Jerry Powell (369-4871)
Prank Willson (369-4628)
Nurse
Jerald Uptain (369-8109)
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Frantz
J. D. Horstman
K. W. Couch (369-6904)
R. D. Gamblin
(369-4693)
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F. J. Scott (369-4693)
R. W. Rve (369-4730)
C. W. Flvnn (369-6209)
*#
(963-2796) R. P. Beauregard (343-5184)
0. J. Knieht (256-7108)
*
J. K. Stark (369-4289)
(369-4926) J. D. Mays (369-4430)
Nonoycu11 (343-5595)
J. B. Heard (256-7326)
* 4 VAB.0001027596