Document Gy66qxvno2evK4VnYYr1QagY

( Texas City, Texas Company April 9> cc: J. V. Waggoner R. T. Clark E. M. Jones frit. M. Keating P. D. Montgomery/ G. L. Wofford D. R. Goodfellow H. D. Woodmansee 1959 J. C. Boles P. W. Kent J. W. Porte Nina Hadden/G. L. Roberts S La Hunter TO: Pile Ref: My call report 4/8/58 Sub j: VISIT TO DIAMOND ALKALI COMPANY DEER PARK., TEXAS VINYL CHLORIDE MONOMER In the referenee call report I stated that Diamond had always found our Vinyl Chloride Monomer to have a slower reaction rate than competitors 1 or their own VCM. This was an error. I should have stated that they had always found our VCM to have a slightly faster reaction rate. The recent complaints from Great American plastics Co. and General Tire Company have been to the effect that our VCM reacts more slowly. This conflicting information means that either our material is better than some monomers on the market and worse than others or that the rate of reaction of VCM cannot be expected to have the same reaction characteristics in any one customer's process relative to another customer's process. DMB:rf D. M. Brown C8Y 1111869 RSV0031170 MONSANTO CHEMICAL G^.JANY Locations Texas City, Texas Date : November 3, 1959 Subject : ProceBB Hazard Committee Report Safety Board To J. S. Putnam Early in 1999 a complete and maBBive report was prepared showing the status of the varlouB Items llBted by the Process Hazard Committee. Many of theBe items have been completed or otherwise disposed of and this letter is a summary of the present btatus. Each general operating supervisor was contacted concerning his particular group of items and present status was determined. The items on the attached list are grouped into six categories: 1. ThoBe completed. 2. Those which supervision considers nonh&zardous. 3. Those which supervision considers non-Justi fiable for hazard correction. 4. Those for which a continuous program or schedule is now in existence. / 5. , Those not done. V 6./ Those that are in active progress toward -- correction. I consider the first four of the above categories to be "completed" items because either the work has actually been completed or is not going to be done, or is of such a nature that it requires continuous vigilance and will not reach a status of being completed. It is suggested that, if another such comprehensive Pro cess Hazard Report is to be prepared, the items in these four catagoriea be dropped from that future report and only the items in categories five end six be included. CLG:lt Attachment C. L. Gilmore SC 16667 RSV0031171 I. THOSE COMPLETED Item Ho. Description 5 Fire protection for south tank farm. 18 Portable pumpB without re lief valves protecting auction and discharge. 25 Air purge failure on non-explosion proof analytical Instruments can create explo sion. 27 Fire Water Supply 28 Inadequate fire protection at propane storage. 36 Loss of all refrigeration engines at same time. 45- Alkylation liquor (AL)- water separator. 46 Reaction mixture separator ' 5257 58 59 63 67 71 73 76 78 79 80 HC1 feed control Vacuum operation Salt water failure Area Control valves Age of unit Hydrogen flare system Introduction of organic impuritieB Converter Flame-out Soot Filters Polymer in Compressor Compressor House -Water entrainment into compression SC 16668 RSV0031172 Item Mo. 82 84 96 99 101 102 106 107 110 111 114 116 121 125 128 132 133 136 137 138 139 140 141 TTACHMENT PAGE 2 Description Vacuum Columns (18D7 and 8) Acetylene Distribution System Acid Scrubber (1904) Rerunning off-specification HCN HCN Storage Bypassing Control Valves Reaction Inhibitors Proposed Catalyst System Reactor Spiking Waste Organic Surge Tank (20T16) HCN Vaporizer EDC reactor (2371) 1) TJJpset can relieve Cl2 to main VCM flare (C2H2 present main flare). C0H2 Separator (22S3) 1) Vessel relieves through RD to atmosphere. Cracking separator (22S1) coke plugging makeB KV undependable VCM storage (22T9)-Insufficient level gauges. CE column (22D8) Corrosive service. Refrigeration turbine (22DP1) Acid unit (department 21) deteriorating. Comnunications -- One phone in control room. C2H4 and CgHg communication easily interrupted. VCM compressor (22C2) - No RV on positive dis placement compressor Possible cross connection with sanitary water to contaminate drinking HgO. Reactor (26ri) maintenance decontamination pro blem. SC ^6669 RSV0031173 Item No. 149 154 162 166 167 170 171 173 181 183 190 191 192 193 194 195 196 197 198 207 208 209 211 216 ATTACHME. PAGE 3 DescriptIon TBA Tank Cars CO Concentration In Area Product Separator (41S17) Peroxide Storage Product Separator (41S17) Proposed use of chilled water In department 41. Building Evacuation Styrene tar feed line General Electric Turbineb Styrene Rack, organics In soil. PreBBure Cells RPU Little RPU Pilot Plant - EKA Pilot Plant - Cyanurlc Chloride Pilot Plant - Oxidative Chlorination Pilot Plant - General High pressure testing Low pressure testing Car and Loading Grounding Operational procedures and Training not Ready. HCN Shipping Piping Around 20P134 SC Pressurizing TD2 and 7D3 16670 RSV0031174 ATTACHMENT PAGE 4 Item No. 217 218 219 220 221 222 226 228 229 230 Description Department 5 vent system Department 7 vent Bystem Department 8 common vents 16K1 has no relief valve Department 16 expansion contemplates methanol brine system. Oxygen Compressor Fire Drainage Ethylene In Cooling Tower Low pressure Polyethylene Pilot Plant Oxidative Chlorination, 1/29/58 II NON-HAZARDOUS 2 Use of plant air system for respiratory masks 4 Out-of-date flow sheets 6 Inavailability of nitrogen for purge purposes during oxygen plant shutdowns 10 Flame arrestors 14 Reciprocating engine protectivedevices. 30 Flammable mixture can occur In quenchers during decoking 34 Spill and fire at liquid ethylene storage tank spreading widely because of no fire wall. 37 Emergency disposition of butane In case of tank rupture. 38 Valves In acetylene system contain copper bearing alloys, which can produce oopper-acetylide which is spontaneously explosive. SC 16671 RSV0031175 Item No. 43 44 46 49 50 51 55 70 72 81 83 86 87 88 90 93 108 109 113 117 118 126 ATTACHMENT PACE 5 Description Unable to purge acetylene lines during emergencies. Ethylene feed pressure control Temperature control on alkylators Pressure relief of alkylators Ethylene feed control Alkylated liquor line from orifice washers to separator Reaction mixture scrubber Vent System Air Intake (for plant air) Excess nitrogen In Oxygen Off-gas flare system Oxygen Analyzers Product Acetylene Column (l8D5) Adsorber (l8Dl) Oas Holder Reactor Interlock Spent Catalyst AN Storage AN Storage Light EndB Column Surge Tank (20T10) Reactor Relief SC Cycle Gas System CgHg driers (22A1) 1) Possible to inject CgHg into hot (275*0) uirjr' iMid by human error 2) Possible to send CgHg mixed with NO to boiler house through human error. 16672 RSV0031176 Item Ho. 127 131 142 146 147 148 163 164 165 179 185 187 202 224 ATTAGH^_JT PAGE 6 Description Reaction off-gas flare haB standard type flame arrestor but must burn some CgHg VCM storage (22T4). Three rundowns in single tank wall. Explosive mixture In flare due to Og andCj>H^ low conversion. Lima Slaker TBA Product Column (25D1) TBA Storage Xylol Handling Experimental superpressure line. Recycle Gas Waste gas line from department 18 LPO Truck Rack - Fire Hazard. Empty Transport Containers Contain Explosive Mixtures. Chlorine Barge Unloading Single means of access or exit from the cold boxeB. III NO JUSTIFICATION J3 Rupture of compressor discharge line can cause fire and spill. 66 Salt Water failure 77 Recycle Qas Control 94 Reactor Cone 97 HCN Stripper SC 16673 RSV0031177 ATTACHMENT PAGE 7 Item No. 103 115 l6l 172 175 177 183 186 Description Unit Cyanide Vent Acetylene System Compressor House Oilfield boilers Expansion joints in steam distribution syBtem. G&b shut-off valve LPO Truck Rack --Fire Hazard VCM and Chlorine Tank Car Rack Near Residences. Iff CONTINUOUS 3 Identification of material in piping by color code. 7 Unauthorized personnel entering operating areas. 9 Railroad cars dispatched to railroad shops in contaminated condition. 11 Priority of expansions vs. existing plant engineer ing and research work. 12 Field Communications 18 Routine inspection of turbine over-speeds not followed. 17 Routine relief valve inspection not followed. 20 Minimum Job training of Operators 23 Equipment is being operated at above design conditions. 24 CauBtic piping 29 Wystemie poisoning of personnel by lead oxide in lead pot area. SC 16674 RSV0031178 Item No. 31 32 42 53 54 60 62 65 95 104 105 123 130 134 156 160 1?4 176 178 182 184 189 199 200 ATTACHMENT FACS 8 Description Failure of reciprocating engine parte due to old age. Pyrophoric polymer la made in 1D3 stripper. Sparks from Dept. 1 and 10 flare can start fires on ground and on near-by wooden build ings. Plnely divided aluminum Off-gas water scrubbing towers Condition of piping In department 5-7 Storage tank polymerisations Main condenser HCN absorber (19D5) "Buddy" System Area Sump 23T5 vapor space explosive Cracker condenser (22E4) tube leaks to CTV side Air In organic columns on shutdown Methanol Storage. Tank Blanketing. Area Spill Alarm Mixed gas control Emergency air cospressors 16675 Control valve servicing Chlorine distribution Acid loading lines in poor condition. Dock and Bay Area Fire Protection In adequate . Shop testing and repair Qas cylinder handling RSV003U79 AT CEMENT PACE 9 Item No. 201 203 204 214 223 Description Drum Handling Acetaldehyde Tank Car Loading HCN Tank Car Loading Explosive mixture In tanks and towers Oxygen Line Labeling In Pipe Racks V NOT PONE Item No. 16 Description Comments Routine inspection of turbine over- Action on this Item speeds not followed. not decided on nor justification developed. 61 Runaway polymerizations 64 Relief System Status unknown Hazard exist, but re peated studies Indicate excessive cost to correct 68 Salt Water Failure Hazard exist, but re peated studies Indicate excessive cost to correct 91 TeBt Ignitor 92 Main Flare No comments Entrainment exists, no change on procedure yet. 112 Acetylene Feed Control Engineering study to be made. Research work completed. 119 Acetylene Compressor No action as yet. 120 Acetylene Stripper No action as yet. 129 Quench tank (22T18) HV dis charges to atmosphere on west Engineering study re quired, no priority. side of distillation structure. 143 Plant Sewers 144 Reactor SC 16676 Sewer model unsuccessful a) Completed b)Not done RSV0031180 at chment PAGE 10 Item Mo, Description 144 Continued 145 IBY-HCN Mix Tank 150 Hydrolyzer 158 Relief Venting 205 M7A Concentration In20E44 212 Alkylation liquor (AL) - water separator 232 Fire Water Supply Comments cl Hot Done d| Not done e) Not done Ho Action Ho Action Originally considered no hazard, but with expansion,needs re evaluating. Ho test as yet Ho comments VI ACTIVE 1 Use of Sanitary water for pro Completion date cess purposes. January 1, i960 8 Fire Alarm System System has been changed and an operable better system being Investigated . 13 Momentary fuel gas failures cauBe a) Completed explosions in direct fired vessels. b) No Justification cl No hazard d) Active Responsibility of Utilities Section. 19 Operating and Design Manu&lB out of Date. Manuals in various de grees of coiqpleteness. Continuous Item once brought up to date. 21 Expansion of units produces Various plant expansions underBlzed relief valves. now In progress. 16677 RSV0031181 Item No. 26 35 56 69 74 75 85 89 98 100 122 124 135 ATTACHMKK PAGE 11 Description pipe racks Use of drummed methanol creates sources cf fire while drum Is open Benzene column, 4D1 Air Intake (for Oxygen Plant) Converter Stacks Soot Higher Acetylene Stripper (18D4) HH3 Storage Polymerization control by add Inhibition Waste streams Off-Oas System Chlorine Storage EDC-RoO separator (22S7)j HgO saturated with organics goes to sewer. Comments Signs are being re quested and Installed. Will be installed. Engineering study required. Tech Services has com pleted study, report and evaluation In pro* gress. Engineering Study Long term study - Progress Now testing analyzer Valves exist on vertical tank, HVs plan similar for horizontal tank. Inhibitor system completed. Polymerization hazards under study. Evaluation in progress In department 24. RV In early i960. Chromatograph Instrument Is under study. 1 Not Justifiable 2 Completed 2j Aetlve Continuous Another tank to be Installed. SC 16678 RSV0031182 Item No. 151 152 153 155 157 159 168 169 180 188 210 213 215 225 227 ATTACHMT ? PAGE 12 Description Hydrogenation Ohlt Linde Unit Waste Gas Line Waste Gas Header Compressor House High Pressure Piping Polyethylene Storage Polyethylene Dust Instrument Air Old Seatraln Tanks in Poor Repair Acetaldehyde Rundown Tanks Reaction Mixture separator Sulfur pots Vacuum Trip on Feed Gas Com pressors (31C5) Catalyst Spill SC Comments a PAFE Approved b PAFE Approved c Completed a Continuous b( Active c, Active Awaiting approval Awaiting approval Awaiting approval Considered no personal hazard probable, however, test program in progress. Study In Progress Study in Progress 30 lb. System study. Tanks being sold Research Study In Pro gress. Engineering Study in Progress. Target Date November 1959 Part of expansion work 1) Research work dis continued. 2} Completed 3) Active. Approval requested Requires fire training. Grounds and testing pro gram will become active soon. 16679 RSV0031181 Item Ho. 231 ATTA' "'ENT PAGE 13 Description General Problem of transmlsslon system seems to Indicate a thorough safety study Is needed. Comments Engineering study SC 16680 RSV0031184