Document VGqVnKDz7doGoe46EwJVBLG84

I. AROCLOR DEPARTMENT BIENNIAL SAFETY AUDIT November 11, 1970 Division - Organic Location ~ Anniston, Alabama Department Reviewed * Aroclor Status of Reviewed Facilities - The Aroclor Department came on stream in 1928 producing only Liquid Aroclors. Since that time several major expansions have been completed to increase Liquid Aroclor capacity and to produce Solid Aroclors. The Aroclor Department also encompasses facilities to prepare blends of the aforementioned products. Products Produced Aroclor 1221 1232 1242 1248 1254 1260 Aroclor 1268 5432 5442 5460 5060 Hontars Aroclor Blends HC1 Audit Committee Hal Brazelton - Maintenance Supervisor - Aroclor Area Tom Lawrence - Plant Safety Supervisor Tom Lackey - Aroclor Department Foreman Gerald Miller * Aroclor Department Supervisor Distribution G. L. Jessee H. E. Schulte J. C. Landwehr J. L. Corder T. W. Lawrence V. R. Haupt Director Safety & Property Protection Audit Team Members 0008903 TOWOLDMONOQ48125 II. LOSS EXPOSURE 2. Aroclor, Department (Liquid) 826.08 Losb Exposure Fire and explosion in chlorinators Property Value 111 $ 1.900.000 ______ Dally Business Interruption Value *= 143 M #/day @ $ .114 PL _ $ 603 >500 $ 16,300 Assumptions: 1. Days to repair " 60 2. Salvage Value 507. 3. Explosion/Fire Factor E2/F4 * .33 Loss Estimate: Property Damage (1-0.3)(1,900,000) Business Interruption (60)(16,300) Possible 850.000 978.000 x .33 Probable 280,000 323,000 1,828,000 603,500 Comments: Equipment Protection: Relief Valves Rupture Discs Shutdown Systems Temperature Alarms & Controls Pressure Alarms & Controls Fire Protection: Yard Hydrants ~ Hand and cart extinguishers - Plant Engines Aroclor, Department (Solid) 826.17 Loss Exposure * Fire and explosion chlorinator area Property Value $ 2.000,000 Dally Business Interruption Value 86,500 #/day @ $ PL $ .1075 = 514.000 $ 9.300 Assumptions: 1. Days to repair 60 2. Salvage value * 50% 3. Explosion/Fire Factor E2/F4 * .33 Loss Estimate: Property Damage ** (1*0.5)(2,000,000) * Business Interruption * (60)($9,300) Possible x .33 1,000,000 558.000 Probable 330.000 184.000 Comments: 1,558,000 514,000 Equipment Protection: Relief Valves Rupture Discs Shutdown Systems Temperature Alarms and Controls Pressure Alarms and Controls Fire Protection: Yard Hydrants - Hand and cart extinguishers - Plant Engines 0008904 TOWOLDMONOQ48126 Ill* STATUS OF UNRESOLVED HAZARDS 1. Description: Complete upgrading of low voltage control panel in Motor Control Center Responsibility: Maintenance Status: Work underway 95% complete Target Date: 4/15/71 Check Date: 4/15/71 3. 2. Description: Safe technique to remove Montar 5 from Aroclor Stills No. 4 and No. 5 Responsibility: TSD - Maintenance Status: In TSD backlog. Design package to be transmitted 4th Quarter 1971. Engineering Cost $3.6 M - Cost of System $10 M - $150 M Target Date: 12/1/71 Check Date: 10/1/71 3. Description: Process Control to assure circulation of Solid Aroclor through coll in external direct fired furnace. No. 4 Still Responsibility: TSD - Maintenance Status: TSD currently recommends Ramapo Flow Meter as installed on CEA 2080 construction of No. 5 Still. Total cost estimated at $5 M. Experience with Ramapo Meter System is unsatisfactory. TSD to continue investigation and repair. Target Date: 9/1/71 Check Date: 5/1/71 4. Description: Capture hot sprays from relief vents on Liquid chlorinatorspotential personnel burn hazard Responsibility: TSD - Maintenance Status: In TSD backlog. Concepts presented in 1970 to eliminate this hazard were rejected based on operational difficulties, added safety problems and cost. This item has been placed on permanent hold by Production effective 10/1/70. 00a'05 TOWOLDMONOQ48127 HAZARDS UNCOVERED BY THIS REVIEW 4 1. Description: Biphenyl charge tank was protected with Protect-o-seal closures as part of an earlier accident investigation. The top of this tank is subject to severe corrosion and Vapors escape through holes where the tank has failed. Responsibility: Production - Maintenance Status: TSD report in March 1970, "recommending carbon steel top and Insulation and/or tracing to maintain temperature above dew point", will be done. Maintenance to replace tank top in 2nd Quarter 1971 at cost of $3 M. Target Date: 6/1/71 Check Date: 3/1/71 2. Description: Protect operator from nozzle on 1st stage No. 5 still jet. Still jet start-up places operator in hazardous position if 1st stage nozzle is cracked or broken. Responsibility: (1) TSD, (2) Maintenance Status: TSD to provide design by 7/1/71 Maintenance to construct and install by 8/1/71 Cost $1 M. Target Date: 8/1/71 Check Date: 5/1/71 3. Description: Main 2300 V feeder to Aroclor motor control center now enters department in a fire hazard area and is not pro tected from accidental personnel contact. Responsibility: (1) TSD, (2) Maintenance Status: TSD recommended on 2/5/71 that the feeder be encased in a non-conducting material such as Corroclux or Transite. Maintenance will fabricate and install in 3rd Quarter 1971 Estimated cost $1 M to $7 M. Target Date: 9/15/71 Check Date: 8/1/71 0008906 TOWOLDMONOQ48128 HAZARDS UNCOVERED BY THIS REVIEW (Contd.) 5 4. Description: HC1 off-gas lines from Solids chlorlnators are routinely operated near the chlorine-steel reaction temperature. High temperature alarms on chlorlnators No. 9, 10, 11 would prevent loss of off-gas lines and off-gas coolers. Responsibility: (1) TSD, (2) Maintenance Status: TSD will provide design by 3rd Quarter 1971. Maintenance will Install in 4th Quarter. Cost estimated $1.5 M. Target Date: 12/15/71 Check Date: 11/1/71 5. Description: The Aroclor Motor Control Center is not fused on the low voltage side of the 2300 -- 440 V transformer. Major shorts in the area must be relieved at the main sub-station. This system requires a long time factor to stop power to the control center. Equipment loss can be significantly reduced by fusing on the 440 V busses of the center. Responsibility: (1) TSD, (2) Maintenance Status: The TSD recommendation that bolt-in fuses be Installed will be completed in April 1971. Estimated Cost $1.4 M. Target Date: 5/1/71 Check Date: 4/15/71 6. Description: Several locations were observed where safety equipment would most likely be inaccessible in the event of emergeacies. Responsibility: Production Status: All safety equipment locations will be reviewed and re located to achieve maximum accessibility in case of emergencies. Complete by 5/1/71 - Cost $300. Target Date: 5/1/71 Check Date: 4/15/71 7, Description: Concrete curtain wall on West side Bldg. 27, 3rd level, is cracked and could easily fall into work area below. Responsibility: Maintenance Status: The curtain wall serves no purpose and the concrete portion can be taken down leaving the steel roof supports. This work can be completed by 10/1/71, Cost $4 M. Target Date: Check Date: 0008907 TOWOLDMONOQ48129 6. IV. HAZARDS UHCOVERED BY THIS REVIEW (Contd.) 8. Description: Grating on catwalk around top level of No. 5 still furnace was not secured to foundation. Presents tripping hazard. Responsibility: (1) Maintenance, (2) Production Status: MRO No. 23401 issued on 3/28/71 to complete work by 4/15/71 Cost $300. Target Date: 4/15/71 Check Date: 4/15/71 9. Description: Design change on #9 Chlorinator cooler has left a hole in the floor on 3rd level Aroclor Department. This hole is barracaded but should be filled permanently. Responsibility: (1) Maintenance, (2) Production Status: MRO No. 25402 issued 3/28/71 to install grating. Target Date: 4/15/71 Check Date: 4/15/71 10. Description: The South Plant storm sewer runs from the Benzene unloading area under Aroclor and the organic warehouse. A Benzene spill into the unloading area sewer would pose an explosion hazard down stream. Responsibility: (1) TSD, (2) Production, (3) Maintenance Status: No concrete recommendations for action can be obtained at present. Several ideas have been brought forward, however, all potential solutions to date are not acceptable Therefore, in April 1971, a review meeting to discuss this problem will be held. Pending this review meeting, action to resolve the hazard will be published. OOOd1*08 TOWOLDMONOQ48130