Document MMKzoyj0ex8GoKvz6a9pooeQ9

V Interoffice Communication To : C. R. Miller From : S. J. Vincent Date : May 6 , 1981 Subject : PLANT POWER FAILURE ON APRIL 30, The Aberdeen Plant experienced a total power failure on April 30, 1981. The power outage began at approximately 1:^0 p.m. and lasted an estimated 16 minutes until 1:56 p.m. The sequence of events concerning the power outage were (a) that a momentary power loss occurred at 1:1+0 p.m., (b) a few seconds later total power was lost, (c) at an estimated seven minutes later the power was momentarily restored and then lost again, and then (d) total power re sumption occurred at approximately 1:56 p.m. During this entire incident, there were no VCM releases or relief valve discharges. In addition, no employees suffered any injuries or were exposed to any VCM. The only known direct product loss was from a resin silo. The Aberdeen Electrical Department was contacted relative to supplying the basic cause of this power outage. The reason given was that TVA was at the Chesnut Street substation performing their "routine switching". The Electric Department indicates that no prior notification was given to them that TVA was performing this routine switching or that TVA was even in town. It has been our understanding that TVA was to contact the Aberdeen Electric Department who would in turn inform us that switching was to occur. During this power outage the plant was totally without power. The emergency power backup for our telephones did not function properly so we were without any telephone communications. The battery backup for the vinyl communications radios was in service, so radio communications were possible. All plant equipment was down during this outage. The status of the major pieces of equipment follows: Area Old module Reactors Equipment D-300 Product 5385 Status This reactor was being chem washed. D-1+00 5385 N.0. was added, This reactor had just completed polymerization. D-500 5385 N.0. was added. This reactor was in polymerization DTH 000083038 C. R. Miller Plant Power Failure on April 30, 1981 May 6, 1981 Page 2 Area Equipment D-600 Product 5385 CRD Reactors D-7U1 5^25 D-7^2 5^25 Dryers Compound D-7^3 D-7^U #1 #2 #k #5 #6 #7 #8 FCM Banbury 5305 5^25 5385 5385 5385 5^25 5305 5385 5385 36861 Nat. 38611 Nat. Dry Blend Plasticizer Orbitran R1 R2 R3 r4 RP-100 DIDP DIDP DOP 610P Status This reactor was waiting to be recovered. N.O. was added. This reactor was in polymerization N.O. was added. This reactor was in polymerization. Charging had just started. N.O. was added. Running - did not set-up. Batch had just dumped and blender bucket had not yet dumped. DTH 000083039 C. R. Miller Plant Power Failure on April 30, 1981 May 6, 1981 Page 3 A total of 10 N.O. cylinders were used in the old module and 18 N.O. cylinders were used in the CRD area. The deluge system did operate for both reactor areas. During the power failure response was very good and positive from all employees and contractors. One of the most critical needs to develop was the need for air pressure in the vinyl reactors. A concerted effort was begun about five minutes into the power failure to secure several portable air compressors (lubricated). A tie-in point was located at #9 air compressor so that air pressure could be restored to the vinyl reactors. While in the process of moving air compressors (lubricated) and then securing the necessary connections, the power was restored and the plant air compressors were immediately placed back in service. Upon restoration of power, all equipment was returned to service. The status of the equipment after startup was as follows: Area Equipment Product Hours Lost Comment s Old Module Reactors D-300 5385 1.0 Noisy gearbox. D-l+00 5385 1.0 Slow seal response. D-500 D-600 5385 5385 5 1,0 CRD Reactors D-7^1 RVCM (llhrs.) 5385 (1 batch) 5^25 (remainder) 35-0 Seal failure. D-7U2 5385 (3 batches) 17.0 5^25 (remainder) D-71+3 5385 (3 batches) 26.0 5305 (remainder) One gritty batch. Has not been processed yet. D-71+4 5385 (3 batches) 15.0 5^25 (remainder) DTH 000083040 C. R. Miller Plant Power Failure on April 30 , 1981 May 6, 1981 Page 4 Area Dryers Compound Equipment #1 if2 ifh a5 a6 ai as FCM Product 5385 5385 5385 (Alt.) 5425 (Alt.) 5385 (Alt.) 5l*25 (alt. 5305 (Alt.) 5385 (Alt.) 5385 5385 36861 Nat. Dry Blend Plasticizer Laboratory Utilities Banbury Orbitran R1 R2 ' R3 Rl* GC Computer Air Compressors Boiler #1 Boiler #2 38611 Nat. RP-100 DIDP DIDP DOP 610P NA Air Steam Steam Boiler #3 Steam Hours Lost 6.5 i*.o 1*.5 Comment s 8.5 7.0 3.0 3.0 1.2 FCM did not set-up. Added steam and it responded after initial high AMP readings. 0.5 * 0.5 Orbitran was reset. 0.5 0.5 0.5 0.5 3.0 Restoring program. 0.3 0.3 0.3 During the evening of l*/30 boiler tripped Lost an estimated ll*.0 hours since this. 0.3 DTH 000083041 C. R. Miller Plant Power Failure on April 30, 1981 May 6, 1981 Page 5 In the old reactor area all of the large reactor seals appear to have held. The D-300 gearbox is still noisy. In the new module, the large reactor seals on D-7^2 and D-7^3 rebounded immediately and continue to run. Problems were present with D-74l and D-744 seals. After 30 minutes D-744 seal reseated and continues to run well. D-74l seal was unable to respond and had to be changed ($2500 est.) D-74l seal change complicated the operation of the CRD area. A high level of RVCM built up in the storage tanks so recovery could not be performed on any of the other three reactors until D-74l was returned to service. Upon completion of the seal change D-74l was used as an RVCM receiver. The dryers suffered extensive downtime due primarily to plugged slurry transfer lines. The following are the major product losses: Area Quantity of Direct Loss Lost Production Compound 1,000 pounds 8,000 pounds Reactors Resin Silos (1) 3,000 pounds 505,000 pounds - (l) All material made beside the one 743 batch can be upgraded. There does not appear to be a quality problem resulting from the use of N.O. (2) Calculation based on hours lost. The following recommendations are made as a result of this power outage. A. A determination needs to be made as to why the emergency generator did not provide the emergency backup power to the telephone system. This problem needs to be corrected. B. Investigate the feasibility and cost of providing emergency power to the gaitronics. C. Determine if the proposed diesel driven air compressor installation can be expedited as a separate item. D. Verify that the DOP seal flush system in the CRD area is functional including the back-up system. This system should be returned to service at the earliest possible opportunity. E. Schedule another meeting with TVA to express our concern about their "routine switching". c: CLM, PEM, JRM, RDJ, RAF, AHS DTH 000083042