Document N2xr80xQKVbL7mYw2zLVLk9kw

UNION CARBIDE CORPORATION p. o. box 471, texas CITY, TEXAS 77SSO HEALTH & ENVIRONMENTAL AFFAIRS June 13, 1985 ,* Mr. Herb Williams, Regional Director Texas Air Control Board, Reg. 7 5555 West Loop, Suite 300 Bellaire, TX 77401 * Subject: Report of Emergency Air Emission, Vinyl Chloride Release, June 10, 1985, Solution Vinyl Resins Process, Tank Car Unloading Rack, Tank Car Valve and Piping Malfunction______ Dear Mr. Williams: The attachments to this cover letter describe the emergency that resulted in the release of approximately 1300 pounds of vinyl chloride monomer on Monday, June 10, 1985 at 0930 hours. A TACB Long Form for Rule 7 Major Upsets is included along with a copy of the Department Head's accident investigation report. This release occurred at our tank car unloading rack in the plant as a consequence of pipe fitters attempting to repair a leaking fitting on the transfer piping on the tank car dome prior to unloading the car. In addition to the above documents, also included are: Standard Operating Procedure for Unloading Vinyl Chloride Tank Cars. Schematic Drawing of the Tank Car Dome piping connections. VCM ambient air monitoring locations and results by Industrial Hygiene Lab. Plant plot plan showing unloading rack location. Mr- Herb Williams June 13, 1985 Page 2 Remedial action to prevent recurrence is listed on the last page of the Accident Investigation Report, along with a photograph of the dome after the leak was stopped- Personnel exposure to this release was very low as indicated by the Industrial Hygiene monitoring samples in the immediate downwind vicinity of the tank car. If any further information is desired, please contact me. Yours^yery truly. JFE:IR:VinChlor Attachments Cc: Emergency Response Branch EPA , Region 6, Dallas Dr. Ed Ibert, GCACD, La Marque Bcc: 0. H- Cunningham/R. C. Wise - T. T. Do C. L. Dudnick - 500 M. E. Eisenhour L. B. Feldcamp - Baker & Botts S. J. Footer/F. S. Provenzano J. B. Leverton K. E. Martin/A. P. Yalcinkaya R. A. Mendez (Letter only) S. M. Norwood/D. R. Hall J.' F- Erdmann, P.E. /Envir. Protection Coordinator (409) 948-5126 ucc 050649 TEXAS AIR CONTROL BOARD (TACB) REPORT FORM FOR NOTIFICATION REQUIREMENTS FOR MAJOR UPSET (RULE 7), PLANNED MAINTENANCE (RULE 8), START UP OR SHUTDOWN MSSL Account No. Region VII <This line for State use only) Company Name Union Carbide Corporationi Solvents and Coating Materials Division Plant Location Texas City. Galveston County. TI____________________________________ _ P.0. Box U71 or Mailing Address 3301-5th Avenue Southcity Texas City State n .Zip. 77590 Owner, Operator or Responsible Management F-S "Foley" Proveniano; Plant Manager Telephone Number U09-9b5-7illl _____________ _______ Nature of Unit or Process Affected land Other Processes Affected, if any) Vinyl Chloride tank car unloading rack. 4th Ave and D St., Texas City Plant. Inclusive Dates if for Shutdown and Start-up Monday, June 10, 1985 Time and Expected Duration of Excessive Emissions 0930 to 0950, 20 minutes Reason or Cause. Maintenance Q Major Upset J7J Test Q Explanation In the course of connecting the piping for unloading Vinyl Chloride from tank car PPGX-9070, pipe fitters were working to repair a leaky fitting when the liquid discharge valve was inadvertently bumped a partial turn to allow VCM vapors to escape from the piping they were working on. (Which had not been closed up yet) _________ I Level of Emissions (give basis for estimate): Physical and Chemical Composition. Rate, Concentration, and Duration Tank car full of Vinyl Chloride (25,000 gal) normal specs, no reaction, fire or explosion involved. Loss of VCM (by reweiqhing tank car and comparing to received weight) was approx. 1300 pounds. (Wind direction S to SSE, 5 to 7 mph, temperature 82F). Measures (to be) Taken to Minimize Quantity and Duration of Emissions Water Spray put On tank to prevent possible vapor cloud ignition. Toxic gas alarm and fire alarm were both activated. Fire truck and emergency response personnel responded Perimeter amhient. air levels of VCM-- checked, nearby building occupants evacuated. Two men put on protective suits and fresh air masks to go in and shut the partially opened valve, and stop the flow. Total time: 20 min. __ Measures (to be) Taken to Prevent Recurrence (Jf not determined yet, give date when measures will be submitted) See attached Accident Investigation Report. Procedural changes to prevent valve opening by accident -- keep tank car dome closed when working on external piping. Seal weld the piping components where possible to minimize development of piping leaks. Date, Time, and Means of Notification (letter, telephone, etc) | National Response Center i wwtitacxofflMeiScBXMXXX Juno 10. 'flFS. 1114 hrs.. phone tn Petty Off. M. Brvan hv ,1. F. Frdmann TACB Regional office_.J.une 10,'flS. 1106 hrs. phone to Mr. Cliff Farnum. bv J. F. Erdmann CB Local Program ^une TO, '85, 1122 hrs, phone to Ms. Phyllis Gilliland, by J. F. Erdmann Date June 13, 1985 Forra sent tot TACB-Austln TACB-Region 7 Signed Oalroston Coifity Air Control X J- F. Erdmann, P.E. U.S. E.P.A< -Dallas 7-- Envlr. Prot. Coord. Rational Response Center ____ ucc 05065t UNION CARBIDE CORPORATION CHEN ICA IS AND PLASTICS DIVISION 6ACCIDENT INVESTIGATION REPORT" Please route and review as shnwn. Oept. Hd (s) 1. S. M. Norwood Signify w mi r II/A hy initialing nr atlanh rnmments Mgrs, Dept S i FP or H t EP Depts 3. R. A. Mendez 5- F. G_ Phtnney 2. 4. 6. Accident Report # :__ 0249_____ Loss Description: Pollution/Air Accountable Denar tment: OCAR Solution Vinyl ResMopidingV. Tk. Car Rack pate ol Accident- 6/10/85 ; G3 0 Q3 QPotential Accident Classification: Actual Accident Classification: __ Probability Recurrence: Remote __ Q] Loe m Moderate [TJ High H EIGIB m Loss Analysis 4* B. J + C. i -t- 0. s A. $ 300 Material Loss (J Loss/Unit x # Units )( in lbs; eaIs; e Product Mixup (Rerun, Devaluation,etc.) * Equipment Dange (J to Replace/Repair) Business Interruption (J V-M Loss) + E. s + F. t 4,000 Med./Comp. Constant Productivity Loss (Est. Manhours x S/Manhour) and/or Cleanup Costs Oo ro Wl Total Loss DETAILED REPORT Accident Summary A vinyl chloride leak occurred on Tank Car PPGX-9070 while it was on the southeast spot of the VCM Tank Car Rack. Investigation Tank car PPGX-9070 was connected to the unloading hoses on 6/9/85. The nitrogen pressure test on 6/10/85 (Midn. Shift) showed a minor leak. The Day Shift Operator on 6/10/85 re tested the unloading hoses toidentify a leak in the pipe threads above the hammer coup ling. The Chief Operator was notified of the leak & Pipefitters were requested to repair the leak. The Pipefitter removed the hammer coupling, taped the pipe threads, & re assembled the coupling. The pipe threads still leaked due to the apparent wear of the pipe nipple. The nitrogen hose to the pipe nipple was removed & the nitrogen hose end was broken off in this process. The Pipefitters left for coffee break. The Pipefitters & the Operator returned after coffee break to replace the pipe nipple & the nitrogen hose. The Pipefitters were attemptingto remove the pipe nipple from the end of the host when a VC1 leak started. VCl leaked through thehand valve on the tank car & out through the hammer union which had been loosened., to remove the pipe nipple. The toxic gas alarm #623 was turned in at 9:35 a.m. and the fire spray system was actuated. The Fire Squad arrived & provided additional water spray protection. The Fire Squad personnel entered the area with protective clothing & closed the hand valve on the tank car which was open less than 1/4 turn. ucc (continued on attached page) Q50S51 CT- 20?3B J Investigation (continued) Additional Facts: 1* There was no VC1 leak during the coffee break nor anytime prior to the reported leak. The hammer union had been loose for several minutes including the coffee break without any VC1 leakage. 2. There was a 24-inch pipe wrench inside the wheel of the leaking hand valve. The end of the pipe wrench was placed down between the valve wheel spokes. --- 3* VCl area monitors read a maximum of 5.1 ppm during the incident. Peremeter monitors set by the Industrial Hygiene Department showed up to 7 ppm VCM approx. 100 yards downwind of the leak during the incident. 4. The loss of VCl was 1300 lbs per the tank car weigh tickets before after the incident. Chairperson: Members: ACCIDENT //20249 INVESTIGATION TEAM S. M. Norwood R. A. Mendez J. E. Tipton M. Williams J. Foreman D. L. Berringer M. E. Durdin H. Terrell W. E. Alford, Jr. Y. Cantu D. R. Hall D. B. Rygaard R. J. Bocek J. R. Rex M. E. Eisenhour J. D. Summers A. P. Yalcinkaya K. E. Martin J. F. Erdmann Dept. Head Ass't. Pit. Mgr. Pipefitter Leadman Pipefitter Pipefitter Maint. Superv. Maint. Area Superv. Shift Prod. Superv. Chief Operator Operator Group Leader Day Prod. Supervs. Prod. Engr. Day Prod. Supervs. Sr. Staff Engr. Safety Engr. Industrial Hygiene Industrial Hygiene Environmental Protection ucc 050652