Document Z8BVqR557Z7bNwY3QwdGQaQ5d

ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW 1/29/87 Review Item___________________________________________________________ Concerns__________________ Propane System - Tanks & Vaporizers y/0i) Electrical equipment not explosion proof & instr. revisions needed. 2) Material of construction of transfer pumps. ^'''3) Remote S/D capabilities Full port sight glass in unloading system. Catalyst Freezers Absence of leak detection system in sphere and boiler area. 6) Use of direct fired vaporizers as backup The direct fired vaporizers are for emer gency use only and appropriate safety re visions must be made before use. i^7) Guardposts protecting unloading station & pump pad. 1) Instrumentation PM needed 2) Back-up temp, indication. 3) Monitoring by operations. 4) Emergency plan does not exist for freezer failures. /5) Extended power outage. ..................-ii-i , i-i|i. nrj ti * i .:i f. * .f^ri j` :>* f-rjwmrt,.. ,5...,^. . I_-.-ii-rn, .- | -|u ` ' *1- ` ' II ffi *--1 '-.J {. `'v? " IT" 9- 'Mh .9 ' .".-w i' l 1 Action Completed/Planned 1) AFE written & approved. Estimated project completion is 5/1/87. (TFL) 2) Transfer pumps are ductile iron which are acceptable. 3) Class "A" design complete, to be AFE'd in 3rd Quarter Fiscal 1987 AFE Proj. 4) Eliminated sight glass but retained flow indication. (Gate w/external lever which rotates with gate.) (JME) . 5) Design complete. Installed and operational by 2/27/87 in sphere & boiler area. (TFL) 6) Having another natural gas sup plier will eliminate the need for the direct fired vaporizers. 7) Included in Class "A" design (Item 3). Will be installed by 2/15/87. (TFL) 1) Up to date except will start yearly control system P.M. & calibration (I-E supv) 2) Installed & operational in little freezers. (DWH) 3) A-operator log sheets have been revised and are being typed. 1/30/87. (DWH) 4) P. Engineering will investigate. Complete by 4/87 (MLN). 5) AFE approved. Started mechanical design in October, 1986. Installed & operational by 2/27/87. (REP) VAB.0001166956 Review Item Bleeder Valve Program Emergency/Disaster Plan Power Failure Procedures VCM Sphere/Unloading Area ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW 1/29/87 Concerns 1) Program not up-to-date 1) Plant Preparedness 2) Community Awareness 1) PM of AMS system valves and instrumentation 2) Emergency generator PM 3) Reactor T/P chart drives not on emergency power. 4) Fire pump run lights. 5) Instrument air pressure indicators not on emergency power 6) Reactor mechanical seal integrity j. 7) Emergency Equipment - Diesel supply. 8) Operator training on reactor mechanical seal power failure procedures. t^Y) Need to "mothball" bullets 2) PM on unloading compressor shutdown instrumentation (temp & pressure switches). 3) Compressor belt drive PM 4) Development of effective railcar chock * page 2 leted/Planned 1) Program is up-to-date but the sur veys are not. Plan & surveys up-to date by 3/87. (MLN) & 2) Plant emergency plan Revision is complete. Community Awareness plan in progress. (JVU) 1) PM determined adequate. See attached Preventive Maintenance sheet from 10/30/86 meeting. 2) Same as Number 1. 3) Estimated project completion (in stalled and operational) is 2/15/87. 4) Installed & operational. 5) Estimated project completion is 2/15/87. 6) Bladders in both reactor modules are installed and operational. 7) Class "A" design was issued in Sept. Installed & oper. by 4/87 (JGC). 8) Training is complete. (JME) 1) Vapor phase corrosion inhibitor has been injected to complete mothball plans. (TFL) 2) Annual PM and documentation of pressure and temp, switches is planned. See attached P.M. sheet from 10/30/86 meeting. 3) A monthly check of belt tightness will be made and documented. See attached P.M. sheet from 10/30/86 meeting. 4) Completed and implemented. VAB.0001166957 l1 **i h m: i h , ipj nimm - i. n.................................. * Wf!*- I PIMi ittupll H-- wnmi+w*- 1 '1^- H1 t-rr-'fi* 'W Review Item_________________ VCM Sphere/Unloading Area (Continued) ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW 1/29/87 Concerns 5) Grounding system upgrade 6) Routine inspection of sphere transfer pumps and of the tandem seals required. 7) Sphere transfer pump cavitation problem may cause pump failure. iS'Q) Remote operated valve installation and ins trumentation * is'9) Firewater supply to railcars may be inadequate. 10) Redundant level & pressure alarms for sphere should be pursued. 11) Drain valve on dike area left cracked. Fire Training 1) Maintenance involvement Mechanical Seal Systems Reactor seal failures prevalent 2) Training on 3) Routine inspection of mechanical seals in VCM service may be inadequate nr page 4 Action Completed/Planned 5) Grounding bolts in plant/to be Installed as 2nd Qtr. 1987 maintenance budget item. (DAM) 6) On chief operators checklist (Once/shift). (DWH) 7) Under evaluation by Process Eng ineering. Will be complete by 4/87. (MLN). 8) This project is part of other Remote Operated Valve project. Waiting for VCM sphere shutdown. Installed & operational by 4/87. (FGJ) 9) Determined Inadequate. 4th Fiscal Qtr 1987 Budget Item. (JGC) 10)Part of remote operated valve project Installed by 4/87. (FGJ). 11)Under evaluation by EBB. Project com plete by 3/87. 1) Personnel have been trained and Instructed in their role in a fire. (AHS). 1) Program to reduce seal failures ongoing. Status reports being Issued. Status report of 7/17/86 latest update. JME following up. 2) Complete 3) The "A" operator check list has been revised to Include routine inspec tion of mechanical seals in VCM service due to Subpart V of the new EPA regulations. (JGC & JME) A. . -- h- I bins* 41IT c* : an * 1-^' ....................... M> tHW VA^IOOl166958 ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW * page 5 1/29/86 Review Item Relief Valve PM Reactors Relief Valve PM-Non Reactor Fixed Point Monitor P-1 PA Tank Concerns 1) Need maintenance procedures for relief valves 2) Relief Valve PM Program implementation and the relief valve project. 1) Need Non-Reactor Program 1) Line pluggage/leakage lay give erroneous results. 1) Tank may be unsafe due to tank condition and/or support. 2) PA fluff from tank exposure and environmental problem. Action Completed/Planned 1) Issued Maintenance PM program. (TFL) 2) The relief valve project has been completed on 4 of the 10 reactors. Minor changes to complete the project on the other 6 reactors will be com plete by 2/87. (TFL) 1) Non-reactor relief valves in both reactor modules were serviced during the August and October shutdown. Plans underway to routinely service all non-reactor relief valves. Plans will be complete by 12/87. (DAM). 1) Plans to check all 40 points once/year. See attached sheet from 10/30/86 P.M. Meeting. 1) Preliminary thickness testing on the vessel was favorable. Further testing will be incoorporated in the Pthalic Anhydride Fluff Containment project (3rd Fiscal Qtr. budget item). (TFL) 2) Class "A" design (revised) is comp lete & issued. 3rd Qtr. 1987 Cap. Budget item. Safety Systems PM (attached) Gas Detectors in Dryer Area 1) Are listed items still being completed. ^1) Dryer Detectors not operational. 1) Process Engineering will monitor pro gram and establish the routines. 1) Have been installed. Will be opera tional by end of 2/15/87. (SKG). Infrared Surveys of Electrical Equipment 1) Yearly survey 1) Documentation is up to date. Cover letter of each survey to be sent to Process Engineering. (I & E Supv.) VAB.0001166959 H-p-' ^ .|-............... H|' ' .S-- ||: Wl-p-l J'N Review Item Ammonia System Remote Operated Valve Project Sulfuric Acid System Chlorine Cylinders Indications r ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW 1/29/87 Concerns 1) Annual inspection and RV check 2) Written Safety program for unloading trucks. 3) Leak patrol 1) Project Completion 1) Procedure on unloading 2) Training on unloading procedures. Training on use of leak repair kit. --) Operator training on cylinder handling. ^-'''1) Compliance plan limit switches 2) 1986 limit switch project 3) 1987 limit switch project 1) Annual inspection will be started in 1987. R.V. will be on 5 year program. See attached sheet from 10/30/86 P.M. Meeting. 2) The new unloading procedure is still under review. Utility supv. will take care of unloading. (TFL) 3) Will find a detection technique and survey procedure by 3/1/87. See attached sheet from 10/30/86 P.M. Meeting. (TFL) 1) Old module valve installation 70% complete. System to be completed Jan, 1987. New module valve installation is 70% complete. Systems to be completed by April 4, 1987. (FGJ) 1) Unloading procedure was Issued 11/13/86. (DWH) 2) Training has been completed. (DWH) 1) Training has been completed. 2) Training complete on all utility operators execpt for one new hire. New hire will be trained by April 1, 1987. (MHL) 1) Project installed & operational. 2) 46 of 46 limit switches are installed and operational which completes the project. (FGJ). 3) Class "A" design completed. Sent to Mechanical. (4th Qtr. 1987 Cap. Budget project.) (FGJ). VA^OO1166960 ^ v # -gi*. nr r > r i. ' v,.r i --i> ( "tm. : -j f. T^ri-T 1 r ' 1i I i idq iktH.f IJH11 `I j *1. ! _*. LqK.-'i rJi ' -'f*'s I -h u. ^ ` t- h = i i* i- r. ir -n Pb.-. jl'hi '' il 4i h- "f i - Review Item Portable Gas Detectors VCM Piping I & E Alarm and Shutdown Interlock PM Program 1 ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW 1/29/87 Concerns 1) Quality of repair inconsistent i 2) Water condensation on detection head. 3) Test procedure. 4) PM is done weekly. 1) Guardposts to Protect VCM Piping; concrete west side of road passing w/curb. 2) Protection against overturned railcar. 1) Boilers - complete once/year 2) Incinerators - complete twice/year 3) Emergency kill system twice/year 4) Catalyst freezers annually 5) Vinyl dryers once/year, (rotary & fluid bed) 6) Propane vaporizers once/year 7) Inert gas generator once/year 8) Reactor Instrumentation page 7 Action Completed/Planned 1) 2 training sessions have enhanced i repair quality. 2) Solved using ambient temp, charging cabinet. 3) Operations has been provided w/HNU test procedure. (TFL) 4) Process Engineer will get weekly HNU PM report. 1) Complete 2) 3rd & 4th rail required/planned. Funded in maintenance budget. Installed in May, 1987. (DAM) 1) Up to date. 2) Will start a semi-annual inspection. (April & October) and document it. (I & E supv.). 3) See attached sheet of 10/30/86 PM meeting. 4) See attached sheet of 10/30/86 PM meeting. 5) Burner management systems will be done annually & documented. (I & E Supv.) 6) Will be documented. P.M. done currently. 7) P.M. sheet will be generated & P.M. will be done every spring and documented. (TFL) 1 8) Pressure alarms checked once/year and when reactors opened. Temperature system will be checked once/year during shutdown & will be calibrated and documented. -h < ...................... r b -.H I--.- p - I- ... i .4-:..-,- tfd4rn lj- Review Item Incinerators ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW 1/29/87 Concerns 1) PM program to check internals of liquid seal flame arrestor. 2) Refresher training program. 3) Revise and update incinerator log sheet page 8 Action Completed/Planned 1) See attached sheet from 10/30/86 P.M. Meeting. 2) Complete by 4/87. 3) Complete. - .'.If H'-T r >1 t- ! -- g-icr- ** ^1 ~ . 'H .........."[L+* -|? !!.................. I J- . >#--. . lii?'- trr.-L. K'-l-'.ir--"'-'-- Ink-PW'- VARBC.0, 001166962 r Review Item CATALYST FREEZERS 1) Big Freezers 2) Chest Freezers POWER FAILURES 1) AMS Kill System 2) Emergency Generators VCM SPHERE/UNLOADING AREA 1) Unloading Compressor 2) T-201 Pressure Switch 3) Compressor Belt Drive P.M. FIXED POINT MONITORS 1) 40 Fixed Point Monitors PREVENTIVE MAINTENANCE CONCERNS AND SOLUTIONS FROM 1/29/87 MEETING Existing P.M Action Completed/Planned 1) Refrigeration system checked weekly. Controllers checked only if W.O. written. 2) Checked on shutdown basis only. 1) Will start yearly control system P.M. and calibration, and document. (TFL) 2) No action needed. 1) Annual P.M. of entire system during module shutdowns'. Operations checks pot alarms when any reactor is shut down. Operations also checks the valves weekly. 2) Large generator is run weekly by operations. Maintenance does monthly PM & instrumenta tion P.M. 1) No further action is planned, 2) No further action us planned. 1) No up to date documented P.M. 2) Done annually, not documented. 3) None - 1) Annual P.M. and documentation on all pressure & temperature switches is planned. (I & E Supv.) 2) Will be documented. 3) A monthly check will be made for belt tightness, and it will be documented. (TFL). 1) Only checked if a problem is discovered. 1) Will check all 40 once/year and document (1 GC/quarter). (TFL) u - ! . v fV'W" --r- VAROOO1166963 9 Review Item AMMONIA SYSTEM 1) Annual inspection. 2) R.V. 3) Leak Survey INCINERATORS 1) Liquid Seal Flame Arrestor PREVENTIVE MAINTENANCE CONCERNS AND SOLUTIONS FROM 1/29/87 MEETING Exi8tln 1) None2) None3) None- 1) None- 1/ Action Completed/Planned 1) Annual inspection will be generated by 1/1/87. (TFL) 2) R.V. will be put on 5 year program. 3) Will find a detection technique and survey procedure by 3/1/87. (TFL) 1) Check and document baffle integrity once/year. (TFL) M V--I-JI^-. -r w|. ,I. M-M- I-- "*1^1 IM|.. -nln -r'ardl-l |V r " > > - - I-I- -I * I IPT.I--4.' fa-* L ik-' i hhI JF-THWH V"-1 VAB. m01166964