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OVERVIEW
DO A 0 F 7 3 1 4
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CONSOLIDATED AUDIT CELL SERVICE
DATES: TIME: PLACE:
MARCH 24, 25, 1992 7:30 A.M. - 3:30 P.M. DOW CONFERENCE CENTER (RELIANCE) CELL SERVICE CONFERENCE ROOM
AGENDA CONSOLIDATED AUDIT
TUESDAY, MARCH 24 7:30 - 9:30
9:30 - 10:30
10:30 - 10:45
10:45 - 11:30
11:30 - 12:00
>2:00 -
3:30
PLANT PRESENTATION-DOW CONF. CENTER (RELIANCE) (SEE SEPARATE DETAILED GUIDELINE) CELL SERVICE BLOCK TOUR ELECTICAL 5 * POINT AUDIT SUMMARY LOSS PREVENTION/FIRE AUDIT LUNCH (CELL SERVICE) OCCUPATIONAL HEALTH AUDIT
WEDNESDAY, MARCH 25
8:30 - 10:00
H.M.T.R.
10:00 - 11:00
REACTIVE CHEMICAL AUDIT
11:00 - 11:30
SAFETY/SECURITY AUDIT
11:30 - 12:00
LUNCH (CELL SERVICES)
12:00 - 3:00
SAFETY/SECURITY AUDIT (CON'T)
EMPLOYEE INTERVIEW SUMMARY MAJOR MANAGER/SECTION MANGER
EMPLOYEE SURVEY SUMMARY SAFETY SUPERINTENDENT
SAFETY SUPERINTENDENT/SAFETY DEPT. HOUSEKEEPING INSPECTION
3/10/92
D0 A
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CONSOLIDATED AUDIT CELL SERVICE
DATE: TIME: PLACE:
TUESDAY, MARCH 24, 1992 7:30 A.M. - 9:30 P.M. DOW CONFERENCE CENTER (RELIANCE)
AGENDA PLANT PRESENTATION/DISCUSSION/TOUR
I. PROCESS AND UNIT OPERATIONS
`PROCESS FLOW SHEETS `CRITICAL INSTRUMENT DEVICES AND FUNCTIONS `PLOT PLAN LAYOUT
II. ORGANIZATION
ill. REVIEW OF PLANT/DEPARTMENT POLICIES/ PROCEDURES AND COMMUNCATIONS
IV. REVIEW OF TRAINING AND RETRAINING PROGRAMS
V. REVIEW OF SIGNIFICANT INCIDENTS/MAJOR CONCERNS
`SAFETY - OSHA RECORDABLE DATA LAST 3 YEARS MEDICAL - MEDICAL VISIT DATA LAST 3 YEARS
VI. PLANT/DEPARTMENT INDOCTRINATION
VII. PLANT GENERAL TOUR `PROJECTS AREAS OF CONCERN `MAINTENANCE SHOPS MOTOR CONTROL CENTERS EATING FACILITIES LABS
PLANT TOUR GUIDES:
SAFETY/SECURITY/OCCUPATIONAL HEALTH/REACTIVE CHEMICALS
LOSS PREVENTION/HMTR
45 MINUTES
10 MINUTES 20 MINUTES 10 MINUTES 15 MINUTES 20 MINUTES 60 MINUTES
DEAN WALTERS JOHN LEWIS
3/10/92
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PROCESS DESCRIPTION
GENERAL:
The Cell Service plant Is primarily a disassembly/ reclamation/ assembly operation involving the handling, shipping, receiving of parts and asbestos. Few reactive or flammable chemicals are involved.
CHLORINE CELL:
The cell is composed of three basic parts: The anode, cathode, and frame. The Dow cell has vertical anodes made of titanium expanded metal coated with ruthenium oxide and steel screen or punched plate cathodes supporting a deposited asbestos diaphragm. The frame is cast from polymer concrete. Cells are placed on skid beams juxtaposed and clamped together with tie rods to form a series. Covers are placed over the series.
In operation a brine level is maintained in the cover. Direct current is introduced into the series. The chlorine ion is oxidized at the anode to form chlorine gas which rises to the top of the cover. The sodium ion joins the hydoxyl ion as it migrates to the cathode. The diaphragm inhibits hydroxyl ion back migration and hypochlorite formation. Hydrogen forms on the cathode. The catholyte, composed of NaCL, NAOH and water, mixed with H2 gas, over flows out the top sides of the cell. The cell effluent flows down into a header below the cell. The hydrogen rises into a header above the cell.
PROCESS DESAUDIT.D0C:3/13/92:LLM
no a CONFTDFNTTAl
PRODUCED FOR THE ASBESTOS DATABASE
DATE: J?-/
MASTER No. 4 Z/OSS V&.
DOW CONFIDENTIAL
1
*DOW CONFIDENTIAL*
HYDROGEN Header
COVER
CATHODE BAC' SCREEN FRAME COPPER CLIP CONNECTOR CATHODE POC (BOLTED TO BACKSCRE ANODE POCKE (WELDED TO BACKBOAR ANODE BACKBO
CELL EFFLUENT HEADER SKID BEAM
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PRODUCED FOR THE ASBESTOS DATABASE
DATE:
__________
MASTER No. 4?/Of5
CELL FRAME:
Cell Service receives used cells, places them in a soak pit to keep the diaphragm soft so it can be easily separated and thereafter be washed from the cathode. The cell is removed from the soak pit, placed on a conveyor line and moved for disassembly and assembly access. The cathode is removed from the frame and placed in a soak pit. The frame and anode assembly is manually washed and the anode removed. If the frame is not suitable for future service with minor repairs, it is sent to landfill, otherwise it is cleaned, repaired and fitted with a suitable anode and cathode. New, replacement frames are shipped from Dow, Russellville, Arkansas.
CATHODE/DIAPHRAGM:
ASBESTOS REMOVAL:
The cathode is placed in a washer in which high
pressure water blasts deposited asbestos from the
cathode. The wash water is supplied by a 12-stage
well-injection type pump driven by a 1000 HP gas
turbine. The asbestos/water is clarified, filtered and
the water is recycled through the washer. Asbestos
from the clarifier bottom is concentrated on a vacuum
belt filter, collected and landfilled.
Overflow
asbestos containing water from all processes,
including slab drainage are pumped through a filter to
waste treating.
Few used cathodes are suitable for rediaphragming. New cathodes and cathode parts are supplied by Russellville.
ASBESTOS HANDLING:
Louisiana Division is the only Dow site in the U.S.A. handling dry asbestos fibers. Suitable protective equipment, procedures and monitoring is used.
DO A 070371 OONFTDFNTTAl
PROCESS DESAUDIT.DOC:3/4/92:LLM
DOW CONFIDENTIAL
2
Palleted, wrapped or boxed sacks of asbestos are received in enclosed trailers. The material is off loaded and stored in a controlled access room in Block 26 warehouse. Pallets are moved to Cell Service storage/handling as needed.
A manually operated baglifter assists in handling
bags. Bags are placed on a conveyor which feeds an
enclosed automatic debagging machine. The debagged
asbestos falls through a lump breaker and into either
of two agitated vessels where it is mixed with water.
The storage/handling room, lab, and equipment are
vented through a HEPA-OSHA approved, high
efficiency-filter.
A particle detector continuously
monitors the filter blower discharge and is tied into
an alarm/shutdown circuit.
Filter differential
pressure monitoring and documented filter inspections
are also measures taken to maintain a safe
environment.
ASBESTOS PULP SLURRY:
Asbestos/water slurry is supplied to LAD and Texas chlorine plants for treatment of operating cells diaphragms. The two LAD chlorine plants own 1000 gallon portable trailers which are filled as needed. Two Dow owned tank trailers transport slurry to Texas. A lighted, access platform with a ramp and a safety harness monorail provides safe access to the top of the tank trailer.
DIAPHRAGM DEPOSITING/BAKING:
The asbestos diaphragm is deposited on the perforated steel cathode pockets and back screen by immersing the cathode assembly in a slurry of refined asbestos fibers and drawing a vacuum on the diaphragm.
PRODUCED FOR THE ASBESTOS DATABASf
DATE:
92
MASTER No. 4-'3/0S'5
PROCESS DESAUDIT.DOC:3/13/92:LLM
DOW CONFIDENTIAL
3
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The drawing slurry contains Kynar, a fluorine polymer. The drawn cathode is placed in an oven where moisture is removed and the Kynar is sintered. The drying medium is hot exhaust gas discharged from a gas turbine which drives a generator.
After baking, inspection etc. the cathode is placed in the cell frame.
ANODE:
Anodes requiring repair, generally to the backboard, are sent to Russellville. Prior to the shipment these anodes are machine washed in the same washer used to wash cathodes (above). However, lower pressure recycled water is used. Anodes in bad repair are salvaged, not landfilled, because of the metal value.
Anodes not requiring repair are removed for gasket replacement and inspection and cleaning of the frame and anode seal surfaces.
CELL STORAGE/SHIPPING:
Completed cells are stored in Blocks 26, 35, and 56 covered storage areas. Cell shipped off site are
wrapped, loaded onto open trailers, lashed and tarped.
TRAILER ACCESS STATION:
A lighted, access platform with a ramp and safety harness monorail has been installed to provide safe access to trailers for loading and unloading operations such as blocking, lashing, tarping.
PROCESS DESAUDIT.DOC:3/4/92:LLM
DOW CONFIDENTIAL
DO A 070300 OONFTDFNT TAl
4
CRITICAL INSTRUMENTS
SUMMARY: There are 49 critical instruments including vibration monitors. The instruments protect rotating equipment; gas turbines (3), one twin-screw air compressor and one 12-stage centrifugal pump. Two instruments guard against the discharge of asbestos particles to the atmosphere. There is no process control computer.
STRENGTHS: Testing is up to date and documented.
OPPORTUNITIES FOR IMPROVEMENTS: P&ID's and written emergency procedures should be upgraded/provided in accordance with LP 15,4.
L.PREVAUDIT.D0C:3/13/92:LLM
DO A 077329. OONFTDFNTT Al
PRODUCED FOR THE ASBESTOS DATABASE
DATE:
92
___________
MASTER No. 4 3/<?S3~
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SUMMARY
1. A PARTS HANDLING OPERATION
NO PROCESS REACTIONS
OPERATIONS UPSETS HAVE NO IMMEDIATE UPSTREAM OR DOWNSTREAM IMPACT
SMALL VOLUME OF FLAMMABLES INVOLVED
2. SMALL OPERATION, EXPERIENCED PEOPLE
10 DOW PEOPLE, 18 CONTRACT PEOPLE WORKING ON SAME SHIFT
ONE-ON-ONE COMMUNICATION PREDOMINATES
3. SIGNIFICANT POINTS
ONLY DOW PLANT IN THE U.S. HANDLING DRY ASBESTOS
ROUTINE HANDLING OF 3-4 TON CHLORINE CELLS
MORE LABOR INTENSIVE, LESS CAPITAL
INTENSIVE THAN CHEMICAL PROCESSING OPERATIONS
Do a 077335 CONFTDFNTTAl
LLM:3/1 3/92
PRODUCED FOR THE ASBESTOS DATABASE
DATE: 3-/3-9Z- sy
MASTER No. #3 / OST