Document Rjjbkn4QLOKdGJK9jB4nLeR7X

Conoco Chemicals Company Conoco Inc. P. O. Box 91. New Highway 25 Aberdeen. Mississippi 39730 (601) 369-8111 A PVC PLANT SAFETY AND HEALTH MANUAL ABEPDEEN, MS SUBJECT: Fire Prevention Plan EFFECTIVE DATE: March 18, 1983 PREPARED BY: A - W- APPROVED BY: Safety Director Manager References: CFR 1910, Subpart L-Fire Protection, 1910,134 Purpose: The potential for personal injury and property damage in operating plants that handle flammable and toxic materials can be serious if the hazards are not properly controlled. Conscientious operation of our plant and adherence to sound operating practices are the only consistent methods that can be used to control these hazards. This plan is therefore being Issued to: 1. Minimize the potential for fires and related emergencies through positive housekeeping and control of flammable materials and ignition sources. 2. Insure that all fire protection systems operate properly by routine testing and maintenance of critical systems. FIRE PREVENTION PLAN Fire related losses which can occur in industries like ours are particularly 8evere. Due to the nature of the materials which are routinely handled in our Plant (primarily VCM, natural gas, propane, and other hydrocarbon raw materials find fuels), operating personnel must exercise preventive control of hazards vhich can lead to fires. of the materials used to make PVC and its compounds are flammable or com estible. Table I, below, is a list of commonly used materials which are flammable or combustible and can be fire hazards if not properly controlled, majority of these materials are supplied as finely divided dusts and in cases are capable of causing an explosion if dust accumulations are ^^|oved to form an ignitable cloud. Section 1.230 Page 1 FIRE PREVENTION PLAN PAGE 2 ABD00095546 A TABLE I VINYL DEPARTMENT Flammable Combustible PVC Initiators (Oxidizer) Gasoline Natural Gas/Propane Vinyl Chloride Monomer Alpha Methyl Styrene (AMS) Odorless Mineral Spirits (OMS) Bubble Breaker Cardboard Diesel Fuel 2-Ethyl Hexaldehyde (CTA) Glycerine Methocel Paper Bags Hydroquinone COMPOUND DEPARTMENT Flammable Gasoline c * i Combustible Antimony Trioxide 4310 R-l Violet Expoxidized Soybean Oil Oncor 75RA Paper Bags Cyasorb UV-531 Diabasic Lead Stearate Ferro ThermOCheck 1827 Synpron 1438 Hostalube XL 165 Wax Lubricants (polyethylene, petroleum) "Mark** Compounds Mineral Oil Bisphenol A Cardboard Boxes Color Concentrates Lead Stabilizers R-4067 (Interstab) Hal-Lub-D Hystrene 5016 l I A It A C C a: pt "r Co Di AC' Am An: Ga. Hy( Section 1.230 Page 2 Agi Amt Anar c c BET Car Con g Die ADDQ00P55d7 FIRE PREVENTION PLAN PAGE 3 DRV BLEND DEPARTMENT Flammable Gasoline Combustible "Acryloid" Products Acrawax "Advastab" Products Advawax Calcium Stearate Cardboard Boxes Diesel Fuel "Mark" Products Paper Bags Thermolite 101, 175 Wax Lubricants (polyethylene, petroleum) PLASTICIZER DEPARTMENT Flammable Gasoline Combustible Alcohols Phthalic Anhydride "Darco" Carbon Black Cardboard Boxes Diesel Fuel Bisphenol A Paper Bags Sulfonic Acid Catalyst (liquid) (Scott Air Pak and turnout gear required for fire fighting) MAINTENANCE DEPARTMENT Acetylene Amercor Mark III Anhydrous Ammonia Gasoline Hydrogen Gas Flammable Natural Gas Propane Paints and Thinners Sulfuric Acid (generates hydrogen gas) Combustible Agitene (regular, super) Amerzene 35 Ammonium Nitrate (highly dangerous if mixed with oils) BETZ Kl-2 Cardboard Boxes Conoco lube oils and greases Diesel Fuel Mitee Thread Cutting Oil Neutrameen NA-7 Polysperse Plus Slimicide C-31 Slimicide C-68 UCON Lubricants and heat transfer fluids Section 1.230 Page 3 FIRE PREVENTION PLAN PAGE 4 ABD00095548 LABORATORY DEPARTMENT A Numerous flammable and combustible liquids and solids are stored and used in small quantities in this department. Many of the above noted chemicals classified as combustible are used routinely and are not commonly thought to be fire hazards due to the very high tempera tures required to ignite them. We must always remember that elevated process ing temperatures can cause a material that is classified as a combustible at normal storage temperatures to be reclassified as a flammable material. Special precautions are outlined in the Safety Control Permit System Procedure which will govern all hot work operations in areas where flammable or combusti ble materials are used or stored. Hot work in the vinyl and propane processing area should be allowed only when there is no other reasonable method. Fire protection and control systems used in the plant range from simple hand held fire extinguishers to sophisticated water spray deluge systems. This * equipment is routinely checked by Safety and/or Electrical and Instrument Per- sonnel to insure that it operates properly when needed. The Safety Director is ' responsible to see that fire protection systems are maintained in an operational* condition. ; Supervisory personnel plant-wide are responsible for controlling fuel source 3 hazards through conscientious operation and the Safety Control Permit System. Smoking will be permitted only in areas of the plant specifically identified J for that purpose. Fire protection rules in the Safety Rule Book will be strict!! adhered to. J Table II, below, is a listing of fire protection equipment which is available g for used in the event of a fire related emergency. S TABLE II A$. ( FIRE FIGHTING EQUIPMENT Equipment Areas Of Coverage Diesel Driven Fire Pumps For Water Supply (4-2000 GPM, 100 psig units - north pump house) (2-2000 GPM, 130 psig units - south pump house) Areas processing vinyl chloride monomer and propane fuel. Process Water System Plasticizer, compound, and warehouse buildings sprlnfcj ler systems Deluge Spray Systems Vinyl reactors and tank farm. 3 Fire Monitors (Fixed) Vinyl reactor, VCM and propane tank farm, VCM incinerators. Section 1.230* Page 4 ABD00095540 FIRE PREVENTION PLAN PAGE 5 TABLE II (Continued) Equipment Areas Of Coverage Fire Monitors (portable) Emergency equipment station, initiator storage freezers. Dry Chemical Wheeled Fire Extinguishers New reactor module, old reactor module, south compound cooling tower. Dry Chemical Hand Portable Fire Extinguishers Various locations plant-wide. Hose Houses and Fire Hydrants Fire Turnout Clothing (hats, coats, boots & gloves) Various locations plant-wide. Available for use plant-wide, stored in the Emergency Equip ment Station. Extra Handline Fire Hoses, Nozzles, and gated wyes Selected hose houses in vinyl areas. Extra Fire Hose (3*-inch hose with 2^-inch couplings) Hose reel cart in Emergency Equipment Station. Scott Air Paks Various locations plant-wide. Additional Firefighting Nozzles and related equipment Available for use plant-wide, stored in the Emergency Equip ment Station. CO^ (Carbon Dioxide) Fire Extinguishers Laboratory and Motor Control Centers. Halon 1211 Fire Extinguishers HOUSEKEEPING Behind vinyl control panel and in telephone switching room. Along with the proper control of flammable and combustible materials, main tenance of high housekeeping standards is critically important. The proper disposal of trash from the various plant operations will minimize the accumula tion of combustible materials and thereby reduce the potential for fire. The following is a list of basic housekeeping requirements for fire prevention purposes: Section 1,230 Page 5 FIRE PREVENTION PLAN PAGE 6 ABD00095550 A HOUSEKEEPING - (Continued) 1. Ordinary hazard materials such as floor sweepings, paper bags, used filters, rags, and other miscellaneous discarded items shall be placed in dumpsters which are routinely dumped into the central trash compac tor. 2. Initiator bottle disposal shall be done in accordance with current Vinyl Department procedures. Disposal of initiators which cannot be used in our operations shall be done under supervision of the Safety Department and Process Engineering. 3. Inventories of empty drums in the various operating areas shall be kept to a minimum. All empty steel drums shall be taken to the drum storage area east of the API Separator. Empty fiber drums should be placed in the large open top trash containers located south of the plasticizer building. 4. Cleanup and disposal of dust type materials which have been contami nated with substances hazardous to health, such as lead, shall be done with vacuum cleaning methods. 5. Housekeeping requirements for operations which involve hot work are specified in the Safety Control Permit System Procedure. 6. Motor control center areas (breaker rooms) shall be maintained free < and clear of discarded materials and shall not be used as storage i areas. Whenever breaker panels are located in storage areas, a clear ^ access lane of at least 36 inches from the front of the breaker panel shall be maintained. * 7. Containers of laboratory solvents and reagents, once empty, shall be disposed of as ordinary hazards (see paragraph 1). Waste chemicals * shall be disposed of in accordance with approved waste disposal proce-J dures. FIRE PROTECTION SYSTEM MAINTENANCE The fire protection systems and equipment used in the plant undergo routine1 testing and maintenance. The Safety Director is responsible to see that aV systems are operational and that routine testing is accomplished. Also, he responsible to see that repair work on systems and equipment is accomplished a timely basis whenever problems are discovered. Table III below specifie testing requirements and frequencies for the various systems and equipment. Section 1.230 Page 6 FIRE PREVENTION PLAN PAGE 7 ABD00095551 TABLE III FIRE PROTECTION SYSTEM AND EQUIPMENT MAINTENANCE System/Equipment Frequency Checkout Requirements Fire Pumps Weekly 1) All engines start on pressure drop and sequence. 2) Battery and charger condition. 3) Engine operating temperature. 4) Engine oil pressure. 5) Engine hours. 6) Fuel levels. 7) Flowing and static pressure. 8) Engine RPM Semi Annual 1) Flow studies. 2) Verify engine RPM with tachometer. 3) Cooling system flush and charge with fresh coolant (annual). 4) Verify thermostat operation. Deluge Systems Weekly (Reactors & Tank Farm) Monthly 1) Flow gas over gas detector field sensors on gas detection system check for system release. 2) Proper operation of deluge valvestrip and reset. 1) Systems drain freely. 2) No breaks in deluge piping systems. Quarterly 1) Check flowing pressure on each system. VCM Storage Sphere Weekly 1) Remote and local control operation of actuated valve (pit). 2) Nozzle orientation directed at bottom half of sphere. Stationary Fire Monitor Semi- Nozzles Annual 1) Free operation of valve. 2) Flush until water is clear. 3) Nozzle free of debris. Sprinkler Systems Annual 1) Flow test at inspector check point. 2) All systems protected by antifreeze solution if wet, Post Indicator Block Valves and Other Fire System Valves In Each Weekly 1) Check to insure that firewater supply valves to unit deluge valves are open and locked. 2) Verify all thermostatic release air line valves are open and locked. Section 1.230 Page 7 A FIRE PREVENTION PLAN PAGE 8 System/Equipment Post Indicator Block Valves and Other Fire System Valves In Each Unit Fire Hose Fire Extinguishers (Hydrostatic) Emergency Alarm Smoke Detection System CO2 Fire Extinguishing System - Lab Chemical Storage Room ABD00095552 TABLE III FIRE PROTECTION SYSTEM AND EQUIPMENT MAINTENANCE Frequency Checkout Requirements Quarterly 1) Check to insure that all underground supply line block valves are open and locked. Annual 1) Hydrostatic pressure test of at least 200 psig main tained for at least 15 seconds. 2) Hose shall not leak or jacket threads break. 3) Dried and reinstalled in hose house, or rack, pre connected to hydrant or supply valve. Five or Twelve Years 1) Done under contract with licensed cylinder hydro static test contractor. Weekly 1) Test alarm tones (vapor, fire, evacuation, weather) one per week on rotating sixteen week cycle. 2) Test all clear tone after each test. Semi Annual 1) Check voltages, detectors and alarm signal devices for proper operation. 2) Check supervisory cir cuitry. Semi Annual 1) Weigh CC>2 supply bottles, refill as needed. 2) Check actuating mechanisa for proper operation. 3) Check pre-alarm for opera tion and audibility. 4) Assure that all piping nections are secure and that there are no system leaks. Section 1Page 8