Document Yjx3GJ0x77qK8jyvxDo3QpNwO
CAUSTIC 1 / CHLOR-ALKALI2 1997
REACTIVE CHEMICALS REVIEW CRITICAL INSTRUMENTS
no a 036691
conf T^FNTTAl
!
February 6, 1997
The Dow Chemical Company P 0. Box 150
Plaauemine. Louisiana 70765-0150
Gretchen LeBlanc Caustic / CA2 Plant
RE: Critical Instrument Program
The LAD Critical Instrument Program was reviewed and revised during 1996 to comply with the global standards as outlined in LPP 15.4. The new criteria focuses more on critical loops or systems rather than just the devices, and gives more clear-cut guidelines for designating these system as "critical". I have included an overview of the various levels in the program. The Instrument Central Support group worked with plant engineers to develop the list of critical loops for each block. Our goal with the new program is to functionally test the entire system, including any trips if possible.
New procedures have been written in order to accomplish this. Input from the block Instrument Specialist and area engineers were solicited in developing these procedures. Also GEMTS PM Modules have been entered to create work requests in the appropriate queues so that these tests are performed at the required frequency. We will also be reviewing the frequency of the tests based on past history and optimizing where possible.
Training for all Instrument and Analyzer personnel is taking place during January and February. This training will cover how to obtain and use the procedures, and how to appropriately document results.
For the Caustic and CA2 Plants:
All GEMTS PM modules have been created for the Crit Inst checks All procedures are complete and loaded into the Maint Op Disc System All personnel have been trained All P&ID drawings have been updated All physical devices have been identified in the field
Attached is a list of the critical systems for the Caustic and CA2 plants. This list indicates the PM Modules which identify the various systems, the individual instrument tags in each system and the consequence of system failure.
The GEMTS system will be used to keep the long-term performance history. Each procedure must be signed and dated when it is used and returned to the Central Instrument Support group. As managers of the Critical Instrument Program, we will make the appropriate GEMTS entries and retain the paper copy from the most recent check. The Central Support function will also monitor the overdue reports and notify the appropriate party if a check is overdue.
If you have any questions please do not hesitate to call.
I/A Central Support 6234
no ^ 036^94 CONF TQNTTfi,i
LPP 15.4 CRITICAL INSTRUMENT PROGRAM
RISK MATRIX
LEVEL 1 (Not normally classified as critical)
Minor injury as result of chemical exposure Environmental incident where contamination confined to site and recovery complete
in 1 year, or reportable to government agency Properly damage and/or business interruption >$50M and <$1MM Fire that is controlled by on-site personnel
LEVEL 2 (LAD Critical Instrument Program)
Day away from work case (DAWC) Incident resulting in local public being told to shelter indoors Environmental incident involving off-site cleanup or which could contaminate ground water Properly damage and/or business interruption >$!MM and <$50MM Fire that requires off site fire fighters to control
LEVEL 3 (LAD OS HA Process Safety Management Critical)
Fatality on or off site, injury resulting in hospitalization to member of public off site. Environmental incident resulting in cleanup off site or a fine Event leading to need to evacuate members of general public Properly damage and/or business interruption >$50MM and <$800MM Fire or explosion leading to properly damage off site
LEVEL 4 (Unacceptable risk must be reduced to level 3 or less)
Multiple fatalities on or off site Permanent environmental damage to an area >5 hectares of a natural habitat off site Properly damage and/or business interruption >$800 MM.
Crit Inst\matrix.doc D Mack 02/06/97
D0 A 036695 CONFIDENTIAL
LAO CRITICAL INSTRUMENT LIST
PM MODULE PT-1001
T-301_LEVEL PSL-3228
TAG*
PT-1001 LSH-3311 TSH-3314 PSL-3228
GRP ISO MO 150
IT-3651
IT-3651
UQ_CL2
PT-S2425 EV-S2400 EV-52402 EV-52405
D-227BTEMP
TT-2613A TT-2613B CV-2604
D-277A_TEMP
TT-2614A TT-2614B CV-2604
D-526 H2
AE-51310 AE-51311 AE-51312
At-161_02 CGD-CRIT-CHECKS
AT-6091 AT-6092 AT-6093 CV-6114 EV-6007 MC-601
CGD Clew Maintains Lisl
190 ISO 170 170 IA18
IA16 (All
DESCRIPTION Low Breathing Air to control room
T-301 high level switch P-302 gear low oil pressure
A-301 high amps Liquid transfer line EBVs
D-227 B temperature transmitter
D-227 A temperature liansmiller
High H2 inerts in D-526 tail gas
Ai-161 02 in H2 analyzer
Area Combustibte Monitors Analyzer House Monitors
CA2 PLANT
CONSEQUENCES OF FAILURE Loss of breathing air pressure Potential personnel injury Major equipment damage Major production loss
Potential undetected leak
Review Date: 1/97
LEVEL REQ FREQ GEMTS PROC DRAWING* FIELDS
2 N 6M Y
Y
N/A
Y
2 N 3M Y Y B1-305
Y
2 N 3M Y 2 N 3M Y
Y B1-304 Y 81-322
Y Y
3 N 1M Y
Y 61-502F
Y
Explosive potential (taffy pots) Explosive potential (tally pots)
Explosive potential
2 N 3M Y
Y B1-218C
Y
2 N 3M Y
Y B1-218C
Y
2 N 3M Y
Y B1-5513
Y
Explosive potential
Explosive potential Potential (or asohvxialion
2 N SD Y Y B1-604
Y
2 N 12M Y
Y
N/A
Y
C U. <r
n^
Oc C
Critlrtd ca2.idm
r-Te 1
DMack 2/6/97
LAD CRITICAL INSTRUMENT LIST
PM MODULE LSH-05600
TAG * LSH-05600
LSH-9013
LSK-9013
LSH-1537
LSH-1537
CGO-CRIT-CHECKS CGDCraw Maintains list
GRP HO HO HO IA11
DESCRIPTION D-205 HI LEVEL SWITCH
0-207 HI LEVEL SWITCH
T-204 HI LEVEL SWITCH COMBUSTIBLE GAS MONITORS ANALYZER HOUSE MONITORS
CAUSTIC PLANT
Review Date: 1/97
CONSEQUENCES OF FAILURE POTENTIAL PERSONNEL HAZARD POTENTIAL PERSONNEL HAZARD POTENTIAL PERSONNEL HAZARD
LEVEL REQ FREQ GEMTS PROC DRAWING* FIELD ID
2
N 6M
Y
Y BI-2056
Y
2
N 6M
Y
Y BI-2222
Y
2
N 6M
Y
Y BI-2032
Y
POTENTIAL FOR EXPLOSIVE MOCTURE 2 N 12M Y
Y
N/A
Y
caustic jets sheet 1
DMack
2/6/97
January 22,1997
The Dow Chemical Company P 0, Box ' 50
Plaouemme Louisiana
Gretchen LeBlanc Caustic / CA2 Plant
RE: Critical Instrument Program
The LAD Critical Instrument Program was reviewed and revised during 1996 to comply with the global standards as outlined in LPP 15.4. The new criteria focuses more on critical loops or systems rather than just the devices, and gives more clear-cut guidelines for designating these system as "critical". I have included an overview of the various levels in the program. The Instrument Central Support group worked with plant engineers to develop the list of critical loops for each block. Our goal with the new program is to functionally test the entire system, including any trips if possible.
New procedures have been written in order to accomplish this. Input from the block Instrument Specialist and area engineers were solicited in developing these procedures. Also GEMTS PM Modules have been entered to create work requests in the appropriate queues so that these tests are performed at the required frequency. We will also be reviewing the frequency of the tests based on past history and optimizing where possible.
Training for all Instrument and Analyzer personnel is taking place during January and February. This training will cover how to obtain and use the procedures, and how to appropriately document results.
For the Caustic and CA2 Plants:
All GEMTS PM modules have been created for the Crit Inst checks All procedures are complete and loaded into the Maint Op Disc System All personnel have been trained All P&ID drawings have been updated All physical devices have been identified in the field
Attached is a list of the critical systems for the Caustic and CA2 plants. This list indicates the PM Modules which identify the various systems, the individual instrument tags in each system and the consequence of system failure.
The GEMTS system will be used to keep the long-term performance history. Each procedure must be signed and dated when it is used and returned to the Central Instrument Support group, As managers of the Critical Instrument Program, we will make the appropriate GEMTS entries and retain the paper copy from the most recent check. The Central Support function will also monitor the overdue reports and notify the appropriate party if a check is overdue.
If you have any questions please do not hesitate to call.
[ I/A Central Support 6234
LPP 15.4 CRITICAL INSTRUMENT PROGRAM
RISK MATRIX
LEVEL 1 (Not normally classified as critical)
Minor injury as result of chemical exposure Environmental incident where contamination confined to site and recovery complete
in 1 year, or reportable to government agency Properly damage and/or business interruption >$50M and <$1MM Fire that is controlled by on-site personnel
LEVEL 2 (LAD Critical Instrument Program)
Day away from work case (DAWC) Incident resulting in local public being told to shelter indoors Environmental incident involving off-site cleanup or which could contaminate ground water Properly damage and/or business interruption >$!MM and <$50MM Fire that requires off site fire fighters to control
LEVEL 3 (LAD OSHA Process Safety Management Critical)
Fatality on or off site, injury resulting in hospitalization to member of public off site. Environmental incident resulting in cleanup off site or a fine Event leading to need to evacuate members of general public Properly damage and/or business interruption >$50MM and <$800MM Fire or explosion leading to properly damage off site
LEVEL 4 (Unacceptable risk must be reduced to level 3 or less)
Multiple fatalities on or off site Permanent environmental damage to an area >5 hectares of a natural habitat off site Properly damage and/or business interruption >$800 MM.
Crit Inst\matrix.doc D Mack 01/27/97
DO A 036699 CONFTDFNTTA!
LAD CRITICAL INSTRUMENT LIST
PM MODULE PT-1001 LSH-3311 PSL-3228
TAG*
PT-1001
LSH-3311 TSH-291 PSL-3228
GRP
HO ISO
IA-36S1
IA-3651
UQCL2 D-227BTEMP D-277A_TEMP
PT-52425 EV-52400 EV-52402 EV-52405
TT-2613A TT-2613B CV-2604
TT-2614A TT-2614B CV-2604
D-526 H2
AT-S1310 AT-51311 AT-S1312
AM61_02 CGD-CRIT-CHECKS
AT-6091 AT-6092 AT-6093 CV-6114 ^CV-6007 MC-601
CGO Crfiw Maintains Ltsl
190 180 170 170 IA18
1A16 IA11
DESCRIPTION Low Breathing Air to control room
T-301 high live) switch P-302 gear lew oil pressure
A-301 high amps Liquid transfer line EBV
D-227 B temperature transmitter
D-227 A temperature transmitter
High H2 inerts in D-526 tai gas
AI-161 02 in H2 analyzer
Area Combustible Monitors Analyzer House Monitors
CA2 PLANT
CONSEQUENCES OF FAILURE Loss of breathing air pressure Potential personnel injury Major equipment damage Major production toss
Potential undetected leak
Review Date: 1/97
LEVEL REQ FREQ GEMTS PROC DRAWING* FELD 10
2 N 6M V
Y
N/A
Y
2 N 3M Y Y B1-305
Y
2 N 3M Y Y B1-304
** N 3M
Y
Y
B1-322
Y Y
3 N 1M Y
Y B1-502F
Y
Explosive potential (taffy pots) Explosive potential (tally pots)
Explosive potential
2 N 3M Y
Y B1-218C
Y
2 N 3M Y
Y B1-218C
Y
2 N 3M Y
Y B1-S513
Y
Explosive potential
Explosive potential Potential for asphyxiation
2 N SD Y Y B1-604
Y
2 N 12M Y
Y
WA
Y
Oo
o^
^H 0u\) r* o^
o
Crillnst ca2.xls
DMack 1/27/97
I
.. t
LAD CRITICAL INSTRUMENT LIST
Bldgs 6 Grnd: Caustic Caustic Caustic
PM MODULE PT-1001 LSH-3311 PSL-3228 IA-3651
TAG* PT-1001 LSH-3311 TSH-291 PSL-3228
tA-3651
Liquefaction
UQ_CL2
Purification D-227BTEMP Purification 0-277ATEMP
PT-S2125 EV-52400 EV-52402 EV-S2405
TT-2613A TT-26138 CV-2604
TT-2614A TT-2614B CV-26M
Liquefaction
D-528 H2
Hydrogen Recovery
AM61_C2
Bldgs & Grnds CGO-CRIT-CHECKS
AT-51310 AT-S1311 AT-51312
AT-6091 AT-6092 AT-6093 CV-6114 ^CV-6007 MC-601
CGOCrew Maintains Usl
GRP MO SO 190 ISO 170 170 IA1S
IA16
1A11
DESCRIPTION Low Breathing Aar to control room
T-301 high Kvel switch P-302 gear low oi pressure
A-301 high amps Liquid transfer line EBV
D-227 B temperature transmiller
0-227 A temperature transmitter
High H2 inerts in D-S26 tal gas
At-161 02 in H2 analyzer
Area Combustible Monitors Analyzer House Monitors
CA2 PLANT
CONSEQUENCES OF FAILURE Loss of breathing air pressure Potential personnel injury Major equipment damage Major production loss
Potential undetected leak
Review Dale: 11*7
LEVEL REQ FREQ GEMTS PROC DRAWING* FIELD ID
2 N GM Y
Y
N/A
Y
2 N 3M V Y 81-305
2 N 3M y y B1-304
N 3M
y
Y
B1-322
Y Y V
3 N 1M y
y 81-502F
Y
Explosive potential (lady pots) Explosive potential (tally pots)
Explosive potential
2 N 3M y
V B1-21K
y
2 N 3M y
y B1-218C
y
2 N 3M Y
Y B1-S513
Y
Explosive potential
Explosive potential Potential for asDhvxialion
2 N SO y V B1-604
y
2 N 12M y
y
NiA
y
o oo
z'D wo H O' -* \!
O
Crillnsl cj2 xls
I) Muck
LAD CRITICAL INSTRUMENT LIST
PM MODULE LSH-05S00
TAG K LSH-05600
LSH-9013
LSH-9013
LSH-1537
LSH-1S37
CGD-CRIT-CHECKS
CGDCrew
Maintains list
GRP 140 HO HO
IA11
DESCRIPTION D-205 HI LEVEL SWITCH
D-207 HI LEVEL SWITCH
T-204 Hi LEVEL SWITCH COMBUSTIBLE GAS MONITORS ANALYZER HOUSE MONITORS
CAUSTIC PLANT
CONSEQUENCES OF FAILURE POTENTIAL PERSONNEL HAZARD POTENTIAL PERSONNEL HAZARD POTENTIAL PERSONNEL HAZARD
RevHw Date: 1W7
LEVEL REO FREQ GEMTS PROC DRAWING* RELD ID
2 N 6M Y
Y BI-20S6
Y
2 N GM Y
Y BI-2222
Y
2 N 6M Y
Y BL2032
Y
POTENTIAL FOR EXPLOSIVE MWTURE 2 N 3M Y
Y
NIA
Y
o 0o
%
1 a>
o o
Z U)
--f y. -i si
~a> vo
caustk.xts sheet 1
DMacfc 1/27/97
LAD CRITICAL INSTRUMENT LIST
Caustic
PM MODULE LSH-05600
TAG V LSH-05600
CaustIc Caust i c
LSH-9013 LSH-1537
LSH-9013 LSH-1537
Bldgs & Grnds CGD-CRIT-CHECKS
CGDCrew Maintains list
GRP MO MO MO IA11
DESCRIPTION D-205 HI LEVEL SWITCH
D-207 HI LEVEL SWITCH
T-JW HI LEVEL SWITCH COMBUSTIBLE GAS MONITORS ANALYZER HOUSE MONITORS
CAUSTIC PLANT
Review Me: 1197
CONSEQUENCES OF FAILURE POTENTIAL PERSONNEL HAZARO POTENTIAL PERSONNEL HAZARD POTENTIAL PERSONNEL HAZARD
LEVEL REQ FREQ GEMTS PROC DRAWINGS FIELD 10
2 N SM Y
Y Bt-2056
Y
2 N 6M Y
Y BL2222
Y
2 N 6M Y
Y BL2032
Y
POTENTIAL FOR EXPLOSIVE MDCTURE
2
N 3M
Y
Y
NIA
Y
caustic.ris sheet 1
DMaCfc V27S7
Caustic Critical Instruments
Description:
Tag:
Critical Inst. Level:
D-204 Hi Level Switch LSH-1537 2
LSH-1537 D-204 Hi Level Switch
Introduction Who is responsible
This procedure is used to provide a method of checking the functionality of LSH-1537. This is actually a differential pressure transmitter, calibrated such that a small amount of differential will result in a high level indication.
There is no trip associated with this device. It is an alarm only to warn personnel of a potential overflow of the caustic tank.
The following table lists the job roles and their duties:
Role Operations Operations Instrument Man
Responsibilities Process Isolation Inst. In and Out of Service Inst. Check and Maint.
Hazards/Warnings
Following is a list of hazards with associated precautions that should be taken before beginning this procedure. (Consider the areas of safety, toxicity, exposure, and environmental hazards. >0
Caustic
Hazard
Precaution Wear proper protective equipment
/
Safety equipment
The table below lists the safety equipment required to perform this procedure. If you do not have the required safety equipment, contact the Safety/Training Foreman.
Safety Equipment
Hard hat, safety glasses, goggles, rubber boots and hearing protection.
Respirator
Personal Personal
Location
Revised: 01/02/97 12:27 pm Printed: 01/27/97 02:31 pm
Dow Restricted
1 TOPLAN Group
OO A 036704
conftdpnttai
Caustic Critical Instruments
LSH-1537 D-204 Hi Level Switch
Lockout/Tagout requirement Waste disposal
Quality considerations Consequence of system failure:
Special tools
This procedure Does Not address a Lockout/Tagout issue.
none
This procedures DOES NOT affect the quality of our product. (If it does, explain how it does.)_______
Failure of this device to function properly could result in overfilling of D-204. Because the overflow tube occasionally plugs, personnel in the area could be contacted with hot caustic as the level continues to rise and spills over the tank.
Following is a list of special tools you will need to perform this procedure:
Volt/Amp Meter
Pump-up Kit
2 Way Radio
References/definitions While performing this procedure, refer to the following (documents, procedures, drawings, set points, ranges and trip points etc.):
Set Points, Ranges ,
Trip Points
Reference GEMTS for alarm point. There is no trip associated with this device.
Procedure
Follow the steps below to description.
Note: An asterisk (*) in the "Check" column indicates a critical item which requires initials.
Step 1 2 3 4 5 6 7
Action
Have operations block, bleed and tag transmitter
Get permit and sign Red Tag Master
Check with control room before proceeding
Connect volt meter to transmitter
Verify meter indicates transmitter is at zero
Using pump up kit, pressure up transmitter slowly to alarm point.
Verify high level alarm sounds in control room. Note pressure reading when alarm sounds. Verify that alarm point is correct.
Record alarm level:
% level
Check # * * * * * *
Revised: 01/02/97 12:27 pm Printed: 01/27/97 02:31 pm
Dow Restricted
2 TOPLAN Group
DO A 0367Q5
comp
T'DpMTTAi.
Caustic Critical Instruments
LSH-1537 D-204 Hi Level Switch
8 De-pressure and remove pump up kit.
*
9 Verify transmitter returned to zero.
*
10 Release red tag master and turn in safe work permit
*
11 Notify operations that test is complete. Sign and date below.
*
Create maintenance work order for any devices that need repair.
12 Test performed bv:
*
Date
WO Number
All devices performed as expected
YN
List any comments below:
Reviews
This document was last reviewed by the following individuals:
Name/Title
Date Reviewed
Ricky Lemelle / Technologist
12/96
Leroy Jefferson / Inst. Specialist
12/96
Document history
The following table documents the latest changes to this document. Procedures will be reviewed at least annually. Updates will be made as necessary and noted below.
Date 8/29/96
Created/Revised By Roger Sanford
New
Changes
Revised: 01/02/97 12:27 pm Printed: 01/27/97 02:31 pm
Dow Restricted
3 TOPLAN Group
00 A 036706 cONF.roFNrrAL
Caustic Critical Instruments
Description:
Tag:
Critical Inst Level:
D-205 High Level Switch LSH-05600 2
LSH-05600 D-205 Hi Level Switch
Introduction Who is responsible
This procedure is used to provide a method of checking the functionality of LSH-05600. This is actually a Rosemount differential pressure transmitter, calibrated such that a small amount of differential, will result in a high level indication.
There is no trip associated with this device. It is an alarm only to warn personnel of a potential overflow of the caustic tank.
The following table lists the job roles and their duties:
Role Operations Operations Instrument Man
Responsibilities Process Isolation Inst. In and Out of Service Inst. Check and Maint.
Hazards/Warnings
Following is a list of hazards with associated precautions that should be taken before beginning this procedure. (Consider the areas of safety, toxicity, exposure, and environmental hazards.)
Caustic
Hazard
Precaution Wear proper protective equipment
Safety equipment
The table below lists the safety equipment required to perform this procedure. If you do not have the required safety equipment, contact the Safety/Training Foreman.
Safety Equipment
Hard hat, safety glasses, monogoggles, rubber boots and hearing protection.
Respirator
Personal Personal
Location
Revised: 01/02/97 01:04 pm Printed: 01/27/97 02:29 pm
Dow Restricted
1 Dehbie Mack DO A 036707
CONFTDFNTTAl
Caustic Critical Instruments
LSH-05600 D-205 Hi Level Switch
Lockout/Tagout requirement
This procedure Poes Not address a Lockout/Tagout issue.
Waste disposal
none
Quality considerations
This procedures DOES NOT affect the quality of our product. (If it does, explain how
it does.)
_______________
Consequence of system failure:
Failure of this device to function properly could result in overfilling of D-205. Because the overflow tube occasionally plugs, personnel in the area could be contacted with hot caustic as the level continues to rise and spills over the tank.
Special tools
Following is a list of special tools you will need to perform this procedure:
Volt/Amp Meter
Pump-up Kit
2 Way Radio
References/definitions While performing this procedure, refer to the following (documents, procedures, drawings, set points, ranges and trip points etc.):
Set Points, Ranges ,
Trip Points
* Reference GEMTS for ranges and alarm points. There is no trip associated with this device.
Procedure
Follow the steps below to description.
Note: An asterisk (*) in the "Check" column indicates a critical item which requires initials.
Step 1 2 3 4 5 6
Action Have operations block, bleed and tag transmitter Get permit and sign Red Tag Master Check with control room before proceeding Connect volt meter to transmitter Verify meter indicates transmitter is at zero Using pump up kit, pressure up transmitter slowly to alarm point.
Check * * * * * *
Revised: 01/02/97 01:04 pm Printed: 01/27/97 02:29 pm
Dow Restricted
2 Debbie Mack
00 A 03A708 CONFIDENTIAL
Caustic Critical Instruments
LSH-05600 D-203 Hi Level Switch
7 Verily high level alarm sounds in control room. Note pressure reading when alarm sounds. Verify that alarm point is coned
Record trio level:
% level
8 De-pressure and remove pump up kit.
9 Verify transmitter returned to zero.
10 Release red tag master and turn in safe work permit
11 Notify operations that test is complete. Sign and date below. Create maintenance work order for any devices that need repair.
12 Test performed bv:
Date
WO Number
All devices performed as expected
YN
List any comments below:
* * * *
Reviews
This document was last reviewed by the following individuals:
Name/Title
Date Reviewed
Ricky Lemelle / Technologist
12/96
Leroy Jefferson / Inst. Specialist
12/96
Document history
The following table documents the latest changes to this document. Procedures will be reviewed at least annually. Updates will be made as necessary and noted below.
Date 8/28/96
Created/Revised By Roger Sanford
New
Changes
Revised: 01/02/97 01:04 pm Printed: 01/27/97 02:29 pm
Dow Restricted
Debbie Mack rONFrr, 0:56709 'ONFT^NTTAi
Caustic Critical Instruments
Description:
Tag:
Critical Inst. Level:
D-207 Hi Level Switch LSH-9013 2
LSH-9013 D-207 Hi Level Switch
Introduction Who is responsible
This procedure is used to provide a method of checking the functionality of the high level alarm on D-207.
There is no trip associated with this device. It is an alarm only to warn personnel of the potential overflow of the caustic tank.
The following table lists the job roles and their duties:
Role Operations Operations Instrument Technician
Responsibilities Process Isolation Inst. In and Out of Service Inst. Check and Maint.
Hazards/Warnings
Following is a list of hazards with associated precautions that should be taken before beginning this procedure. (Consider the areas of safety, toxicity, exposure, and environmental hazards.)
Caustic 110 VAC
Hazard
Precaution Wear proper protective equipment Check with meter before proceeding
Safety equipment
The table below lists the safety equipment required to perform this procedure. If you do not have the required safety equipment, contact the Safety/Training Foreman.
Safety Equipment
Hard hat, safety glasses, goggles, rubber boots and hearing protection.
Respirator
Personal Personal
Location
Revised: 01/02/97 12:28 pm Printed: 01/27/97 02:33 pm
Dow Restricted
1 TTTOT AW r?m..n
DO A 036710
CONFTDFNTTAL
Caustic Critical Instruments
LSH-9013 D-207 Hi Level Switch
Lockout/Tagout requirement
This procedure Does Not address a Lockout/Tagout issue.
Waste disprosal
none
Quality considerations
This procedures DOES NOT affect the quality of our product. (If it does, explain how
it does.)
___
Consequence of system failure:
Failure of this device to function properly could result in overfilling of D-207. Because the overflow tube occasionally plugs, personnel in the area could be contacted with hot caustic as the level continues to rise and spills over the tank.
Special tools
Following is a list of special tools you will need to perform this procedure:
Volt/Amp Meter
2 Way Radio
References/deflnitions While performing this procedure, refer to the following (documents, procedures, drawings, set points, ranges and trip points etc.):
Set Points, Ranges,
Trip Points
* There are no alarm or trip points associated with this system. The primary device is a level switch.
Procedu re
Follow the steps below to dese ript ion.
Note: An asterisk (*) in the "Check" column indicates a critical item which requires initials.
Step 1 2 3 4 5 6 7 8 9 10
Action Have operations prepare switch for test Get Permit and sign Red Tag Master Check with control room before proceeding Using volt meter, check switch to make sure it is safe for testing Lift alarm wire on switch. Verify alarm in the control room Replace wire Verify alarm cleared Release red tag master and turn in safe work permit Notify operations that test is complete. Sign and date below. Create maintenance work order for any devices that need repair.
Check * * * * * * * *
Revised: 01/02/97 12:28 pm Primed: 01/27/97 02:33 pm
Dow Restricted
2 TOPLAN Group
DO A 036711 CONFTDFNTTAL
Caustic Critical Instruments
LSH-9013 D-207 Hi Level Switch
Reviews
This document was last reviewed by the following individuals:
Name/Title
Date Reviewed
Ricky Lemelle / Technologist
12/96
Leroy Jefferson / Inst. Specialist
12/96
Document history
The following table documents the latest changes to this document. Procedures will be reviewed at least annually. Updates will be made as necessary and noted below.
Date 8/29/96
Created/Revised By Roger Sanford
New
Changes
Revised: 01/02/97 12:28 pm Printed: 01/27/97 02:33 pm
Dow Restricted
TOPLAv 00 ^
03^7 1?
lT T !
CA2 Critical Instruments and PM Instruments
CA2's Critical nstmment List
75433900 P&ID#
Breathing low# LSH-3311 PSL-3228 IA-3651
TT-2613A TT-2613B TT-2614A TT-2614B
Low breathing air to control room T-301 high level switch P-302 gear low oil pressure A-301 high amps Liq. transfer line EBV D-227 B temperature transmitter D-227 B temperature transmitter D-227 A temperature transmitter D-227 A temperature transmitter
7/30/96 --
IN
Mod ID. PSM Procd. Gemts Type Freq. P&ID#
NO 26 no drawins
C-AI-299
NO YES 140
13 B1-305
C-AI-153
NO YES 150
13 B1-304
C-AI-441 ???? NO YES 190
13 B1-322
E-DO-205 777? NO
180 4 B1-502F
E-AI-147
NO Yes 170
12 B1-218C
E-AI-157
NO Yes 170
12 B1-218C
E-AI-108
NO Yes 170
12 B1-218C
E-AI-108
NO Yes 170
12 B1-218C
AT-51310 AT-51311 AT-51312 AT-6091 AT-6092 AT-6093
ANALYZERS CRITICAL High H2 inerts in D-526 tail gas High H2 inerts in D-526 tail gas High H2 inerts in D-526 tail gas AI-161 02 in H2 analyzer AI-118 02 in H2 analyzer AI-108 02 in H2 analyzer
E-AI-206 E-AI-216 E-AI-226 B-AI-116 B-AI-118 | B-AI-108
NO YES IA18 NO YES IA18 NO YES IA18 NO YES IA16 NO YES IA16 NO YES IA16
4 B1-5513 4 B1-5513 4 B1-5513 4 B1-604 4 B1-604 4 B1-604
AT-8208 AT-8209 AT-8210 BLKCL2M ModbatsysA ModbatsysB ModbatsysC ModbatsysD ModbatsysE ModbatsysF Windsdm FT-8168 LAH2005 LT-2005 LT-2052-A LT-2052-B LT-2052-C LT-2052-D LT-2052-E LT-2052-F LT-2052-G LT-2052-H LT-2053-A LT-2053-B LT-2053-C LT-2053-D
| need to asign tag number to breathing air and p&id
|
PM LIST
D-810 TSS ph probes D-810 TSS ph probes D-810 TSS ph probes Chlorine block probes Mod 5 battery load check Mod 5 battery load check Mod 5 battery load check Mod 5 battery load check Mod 5 battery load check Mod 5 battery load check block wind sock & speed meters Outfall ditch flow (EPA) D-202 high level switch alarm D-202 level transmitter S-1 west level transmitter S-2 west level transmitter S-3 west level transmitter S-4 west level transmitter S-5 west level transmitter S-6 west level transmitter S-7 west level transmitter S-8 west level transmitter S-1 east level transmitter S-2 east level transmitter S-3 east level transmitter S-4 east level transmitter
1/8/96 Mod ID. PSM Proc
PM PM PM ENV PM PM PM 1
I PM PM PM ENV ENV ENV ENV PM PM PM PM PM PM PM PM PM PM PM PM
Gemt Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
ii
ii
____\_____;________ i
j
ii
TypeFreq. 120 ; 41
no . 4l
110 ! 4)
no 4|
190 ! 12| 190 12! 190 12 190 , 12 190 i 12 190 12 100 ! 12 130 | 4
140 : 140
140 140 ; 140 ? 140 ; 140 !
26 12 12 12 12 12 121
140 140 140 1 140 ; 140 .
12|
________
12| 121 12|
140 | 12| 140 12!
1/22/97 12:58 PM
Dow Confidential
\\LANT54\Chlor-Alkali\CA_Shared\ CA2 Critical lnstruments\Ca@crit DO A 036713 CONFIDENTIAL
CAU INST.XLS
CAUSTIC 1 CRITICAL AND PM INSTRUMENT LIST
FIELD TAG
DESCRIPTION
LSH-05600
D-205 high level switch
LSH-9013
D-207 high level switch
LSH-1537
T-204 high level switch
Pm/critical PSM
CRITICAL CRITICAL CRITICAL
Proc. Gemts Freq.
Type Equipment
Equipment Group
LS-82010 LS-82011 LS7168 LS7168A LSH-601B LSH-603B LSH-604B LSH-606B LSH-607B LSH-609B LSH-610B LSH-612B LT-1842 PH-6053 PH-6054 PH6057 PH7353A PHI1097 PH11689 PHI2418 PHI6051 PHI6055 PHI6056
Load station #1 tank car high Ivl Load station #2 tank car high Ivl T-245 high level alarm T-245 high high level alarm Tank car rack level switch on S-1 Tank car rack level switch on S-2 Tank car rack level switch on S-3 Tank car rack level switch on S-4 Tank car rack level switch on N-4 Tank car rack level switch on N-3 Tank car rack level switch on N-2 Tank car rack level switch on N-1 E-203 level trip transmitter Ph in the outfall canal Ph in the outfall canal Ph of the outfall canal Trench sump indication Ph in the RW out of HE-208 Ph in the RW out of CD-2Q4A T-11 ph transmitter Ph in hotwell by canal Ph in the outfall canal Ph in the outfall canal
PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM PM
yes yes
i
yes yes
i
no yes 26
no yes 26
yes yes
1
yes yes
1
yes yes yes yes yes yes yes yes yes yes yes yes
1 1 1 1 1 1
no yes 52
yes 4
yes 4
yes 4
yes 4
yes yes
4
yes 4
yes yes
4
yes 4
yes 4
yes 4
rosemt rosemt rosemt rosemt
yew rosemt rosemt
rosemt rosemt rosemt
140
140
140
140
140
140
140
140
140
140
140
140
140
no no 110 no no no no no 110 no
DO A 0 3 6 7 1 4 CONF ID FN TTA l
JBJ
1/21/972:16 PM
PAGE1
CAU INST.XLS
CAUSTIC 1 CRITICAL AND PM INSTRUMENT LIST
Type Equipment
FIELD TAG
PHI6061 PHI7024 PHT-7353 TSL-2411B TSL-2415B
DESCRIPTION
Ph west side of block Ph (w out of cooler & chillers etc Trench sump control PH ARU-2Q5 low temperature trip ARU-204 low temperature trip
Pm/critical PSM
PM PM PM PM PM
Proc.
no no
Gemts
yes yes yes yes yes
Freq.
4 4 4 52 52
Equipment
rosemt rosemt
yew
Group no no no
170
170
FT-1634 LT-1625 LT-1626 PT-1621 PT-1621A TT-1628 TT-50006 TT1628A
E-204 flowmeter E-204 level tran. (0-378" water) E-204 level tran. (0-378" water) E-204 pressure transmitter E-204 pressure transmitter E-204 inlet temperature trans. T-28 temperature transmitter P-204E discharge temperature
ISO ISO ISO ISO ISO ISO ISO ISO
yes yes yes yes yes yes no yes no yes yes yes yes yes yes yes
16 26 26 26 26 26 26 26
150 140 140 150 150 170 170 170
?o
Crr
JBJ
1/21/972:16 PM
PAGE2