Document ZJQZk3VM3ZebYNYggVr99LkV8

LOUISIANA DIVISION CONSOLIDATED AUDIT PROGRAM QUESTIONNAIRES POWER I / UTILITIES MARCH lp, 11,1Z, 1992 DOW CONFIDENTIAL DO A 121142 CONFIDENTIAL. Plant:.. Date: Writer Dow U.S.A. Louisiana Division Consolidated Audit Program Attendance Zc//*Jsk Name 1. M 2. & T/e-PF/z Plant/Department fits* /u-m. Functional Area v-gc-M ^r/v/f/g -/T &rfi/77js' r&re-pofitr //r>9 '/-iyj ________ ________ AT 7. /p's8.. /fVi> tM+la Idt/tjsk+J^Tti/Au^^ <SAG s4Qfl/r-- C/lsnuZ* ^/H- t//iC '/d#- 10. ll. 12. 13. 14. 15. ^ 16. _ 17. 18. 19. 'HWyimk 7/9 1 D0 A 12114-5 CNfrTDBNTTAL Jy/carA //&s dt/p/t^* /y77esJzh9rJc ///hr? G 4jC V <by 'Sn\i-\Vi M $t ^MO /y1Mr7 M-v^/3<vJ &i/cjc /3*/^r ($0*4 H&ic^r &S& jLu. 'or-:- s^-ti*>' * . / ]'-- w /$o h- / e R- /c\s"j o ,rA/^^~ J'pB, &VLttJ&S fthteie* "/Yltv SoL-^fVy Povoe,r X/^>h 1 ^ fi-*r )uAUiy j"Tie* fK)//.i^ 'fiatnt`1. V T~1i-t TV "5 /\/ o,//*/* /3'l~! P*->''lJOf'l'h /^hzi/.*jr/<DAJ T^oc r~ectf <te'vre'Z- Fpcva*- i t/^h/t /4c_s /i \* / /'Cec'. i^ciU DO A 121144 CONFIDENTIAL DOW U.S.A. LOUISIANA DIVISION CONSOLIDATED AUDIT PROGRAM Date: POWER I/UTILITIES March 10,11,12, 1992 Time: 7:30 a.m. - 4:00 p.m. PLACE: TUESDAY, MARCH 10, 1992 7:30 a.m. to 10:30 a.m. B-819 CONF. RM. TUESDAY-Lunch and Evening. WEDNESDAY and THURSDAY all day in the CAUSTIC PLANT CONF. RM. Plant Superintendent: Ken Fox Major Manager: Paul Rozas Plant/Department "CAP" Administrator: Marty Morrison QUESTIONNAIRES ASSIGNMENTS REACTIVE CHEMICALS SECURITY S* A* *F. ETY CHEMICAL EXPOSURE INDEX - LOSS PREVENTION ' " \. OCCUPATIONAL HEALTH ' <1 *'. a rA1 T ` HMTR ELECTRICAL 5-POINT MARTY MORRISON JOE RAWLINGS GERVEY SMITH MARTY MORRISON 4 4 .. JOE RAWLINGS "M.r.tA" RTY MOt- RRISON Mv A-RTY'MORRISON . \vV- i, < : ' : L ONNIE MARCHA^P 2 24-92. hrw D0 A 12^45 CONFIDENTIAL CONSOLIDATED AUDIT AGENDA Tuesday. March 10 7:30 - 10:30 10:30 - 11:30 11:30 - 12:00 12:00 - 1:30 1:30 - 1:45 1:45 - 4:00 Department Presentation (B-819 PCM CONF. RM.) (see separate detailed guideline) Power I/Utilities Plant Tour = . Lunch (CAUSTIC CONF. RM.) Hazardous Material Transportation Review (HMTR) Break Chemical Exposure Index Review (CEI) Wednesday. March 11 (CAUSTIC CONF. RM.) 7:30 - 8:00 8:00 - 11:30 11:30 * 12:00 12:00 - 4:00 Electrical 5 - Point Audit Summary Loss Prevention/Fire Audit Lunch (CAUSTIC CONF. RM.) Occupational Health Audit 2.24/92:hrw DO A 121146 CONFIDENTIAL LAD Consolidated Audit BLDG. 819 (PCM) Date: Time: March 10, 1992 7:30 a.m. - 10:30 a.m. AGENDA I. Department Presentation/Discussion Process and Unit Operations Process Description. Process Flow Sheets Plot Plan Layout Instrumentation and electrical Critical Instrument Devices and Function 85 minutes II. Organization III. Review of Plant/Department Policies/ Procedures and Communications 10 minutes 15 minutes IV. Review of Incidents/Major Concerns Safety - OSHA Recordable Data last 5 years Equipment/Property Loss $50,000 or more last 5 years Reactive Chemicals Incidents last 5 5 years 15 minutes V. Review of Training and Retraining 30minutes.. VI. Plant/Department Indoctrination Video 30 minutes VII. Plant General Tour (break into functional groups) 60 minutes Projects Maintenance Shops Eating Facilities *Areas of Concern *Motor Control Centers *Labs 2 24 92:hrw DO A 121147 CONFIDENTIAL. Thursday. March 12 (CAUSTIC CONF.RM.) 7:30 - 8:00 8:00 - 11:30 11:30 - 12:00 12:00 - 4:00 Laboratory Audit Summary - ,` S>. i ? t Reactive Chemicals Audit s/T . Lunch (CAUSTIC CONF. RM.) Security/Safety Audit Employee Interview Summary- Major Manager/Section Manager Employee Survey Summary Area Safety Superintendent Safety Supt./Safety Dept. Housekeeping Inspection 2 24/92:hrw 0 4 cNFl0 1-21 i etial Dow U.S.A. The Dow Chemical Company P 0 Box 150 Piaauemme. Louisiana 70765-0150 4/29/96 Howard Wilkinson, LAD Consolidated Audit Program Administrator Consolidated Audit Program Closure Report: Power 1, Utilities & Power 2 The closure report is enclosed. I have also enclosed your action items for comparison. The documentation of these action items has been completed with only a few left to complete with new completion dates. If you have any questions, please do not hesitate to ask.' Regards, Marty Morrison Consolidated Audit Coordinator Power and Utilities Enclosure DOW CHEMICAL U. S. AREA CONSOLIDATED AUDIT PROGRAM POWER I/UTILITIES PLANT LOUISIANA DIVISION FINAL UPDATE 07 THE ACTION PLAN OCCUPATIONAL HEALTH AUDIT ACTION ITEM DUE DATE/STATUS GENERAL INDUSTRIAL HYGIENE 1. Finish 1993 CPAI, Update for 1994 HAZCOM Morrison 12/94 COMP. l.Update written HAZCOM program. Morrison 10/94 COMP. 2. Label the few bottles without labels - Power 1. HEARING CONSERVATION Morrison 9/94 COMP. l.Post the requirements for operating shop pedestal grinder. RE8PIRAT0R PROTECTION Morrison 10/94 COMP. 1. Update written respirator plan with Scott-Acme respirators. VENTILATION Morrison 12/94 COMP. 1. Repair analyzer shacks (2825) exhaust fan. ASBESTOS Crousilac 10/94 COMP. 1. The gasket storage area in Power 1 and Utilities needs to be vacuumed. Morrison 9/94 COMP. 2. The non<>asbestos material needs to be removed from the dumpster. COMP. Morrison 8/94 DO A 121150 CONFIDENTIAL ACTION PLAN(cont.) ELECTRICAL RELIABILITY AUDIT ACTION ITEM DUE DATE/STATUS 1. Train block electrical personnel in proper grounding practices. COMP. Brundage 12/94 2. Material stored in clearance zone required by National Electric Code. Move material to give required acess zone. COMP Brundage 12/94 REACTIVE CHEMICAL8 AUDIT ACTION ITEM DUE DATE/STATUS 1. Develop acceptance criteria for the inhibited acid w hich is used for boiler cleaning and verily by performing positive ID testing. COMP Rawlings 5/95 2. Determine if oxygen in the offgas is a credible scenario and provide defenses. COMP Morrison 11/94 i CHEMICAL EXP08URE INDEX(CEI) ACTION ITEM DUE DATE/8TATUS 1. Continue updating P&ID's and implement a method for recording all changes. Taylor 12/97 HAZARDOUS MATERIAL TRANSPORTATION REVIEW(KMTR) ACTION ITEM DUE DATE/STATUS 1. Develop checklist for chlorine bottles/cylinders. COMP Morrison 10/94 2. File the CEI portion of the audit with the Loss Prevention Portion. COMP Morrison 12/94 SAFETY AUDIT To be completed by oervey Smith SEE ATTACHED. Do A 121151 confidential ACTION PLAN(cont.) LOSS PREVENTION AUDIT ACTION ITEM PROJECT REVIEWS: DUE DATE/STATUS 1. Document all project reviews and pre-startup reviews and file them in a central location. COMP Morrison 12/94 FIRED EQUIPMENT OPPORTUNITIES 1. Complete the burner management documentation package to comply with L.P.P.-13.1 and guidelines from the Power Tech Center. COMP Morrison 3/95 ACTION ITEM INSURANCE PACKAGE DUE DATE/STATUS 1. The insurance information form will be completed and reviewed with loss prevention. COMP Morrison 3/95 DO A 121152 CONFIDENTIAL Project No. DR-1 DR-2 SQ-F1 DR-3 DR-4 DR-5 DR-6 DR-7 DR-9 DR-10 DR-11 DR-12 DR-13 DR-14 DR-15 FI-1 FI-2 FI-3 FI-4 FI-5 FI-6 o FI-7 z O Tt fi-b FI-9 Z ^ FI-10 5 in rw POWER 1/UTILITIES Consolidate. Vudit Summary May 6,1996 Project Name Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review Documentation Review FiekJ Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Dept Responsible Power 1 Power 1 POWER 1 POWER 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Person Responsible Gervey Smith Ronnie E. Daigle SAFETY COMM. ROGER HUDSON Tommy Rozas Tommy Rozas Joe Rawlings Ronnie E. Daigle Ronnie E. Daigle AD assigned C-9 activity Gervey Smith Ronnie E. Daigle Gervey Smith Ronnie E. Daigle Tommy Rozas/Shift Tommy Rozas Tommy Rozas Marty Morrison/Gervey Glenn CrousDIac Glenn Crousilac Glenn CrousiDac Glenn Crousiac Glenn Crousilac Glenn Crousilac Glenn Crousilac Est Start 08/01/94 09/01/94 01/01/94 09/01/94 09/01/94 09/01/94 09/01/94 08/01/94 01/01/94 01/01/94 01/01/94 01/01/94 09/01/94 09/01/94 09/01/94 09/01/94 09/01/94 09/01/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 Page 1 A Est Finish 08/20/94 12/31/94 12/30/94 10/15/94 12/01/94 12/31/94 12/31/94 12/31/94 12/31/94 12/31/94 12/31/94 12/31/94 12/31/94 12/31/94 12/31/96 10/01/94 12/31/94 09/15/94 09/30/94 09/30/94 11/30/94 09/30/94 10/31/94 10/15/94 09/30/94 Status Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Working Complete Complete Complete Complete Complete Complete Complete Complete Complet Complete POWER 1/UTILITIES Consolidate Audit Summary May 6, 1996 Project No. Project Name FI-11 Field Inspection #1 at B-2804 FI-12 Field Inspection #1 at B-2808 FI-13 Field Inspection #1 at B-2808 FI-14 Field Inspection #1 at B-2808 FI-15 Field Inspection #1 at B-2808 FI-16 Field Inspection #1 at B-2808 FI-17 Field Inspection #1 at B-2808 FI-16 Field Inspection #1 at B-2808 FI-19 Field Inspection #1 at B-2808 FI-20 Field Inspection #1 at B-2808 FI-21 Field Inspection #1 at B-2808 FI-22 Field Inspection #1 at B-2808 FI-23 Field Inspection #1 at B-2808 FI-24 Field Inspection #1 at B-2808 FI-25 Field Inspection #1 at B-2808 FI-26 Field Inspection #1 at B-1802 FI-27 Field Inspection #1 at B-1802 FI-28 Field Inspection #1 at B-1802 FI-29 Field Inspection #1 at B-1802 FI-30 Field Inspection #1 at B-2804 FI-31 Reid Inspection #1 at B-2804 FI-32 o .oo FI-33 zo T1 FI-34 om i-* FI-35 ZN) " H^ J> Or r Field Inspection #1 at B-2604 Field Inspection #1 at B-2804 Field Inspection #1 at B-2804 Field Inspection #1 at B-1802 Dept Responsible Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 UtiRties Utilities Utilities Utilities Power 1 Power 1 Power 1 Power 1 Power 1 Utilities Person Responsible Glenn Crousiac Glenn Crousillac Glenn Crousillac Glenn Crousillac Glenn Crousiac Glenn Crousillac Glenn Crousillac Glenn Crousillac Glenn Crousillac Glenn Crousiac Glenn Crousiac Getvey Smith Glenn Crousiac Glenn Crousillac Glenn Crousillac Glenn Crousiac Gervey Smith Glenn Crousiac Glenn Crousiac Glenn Crousiac Glenn Crousiac Auditor Glenn Crousiac Glenn Crousiac Glenn Crousiac Pagc2 Est Start 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/01/94 09/09/94 09/09/94 09/09/94 09/09/94 09/01/94 09/09/94 09/09/94 09/09/94 09/09/94 07/07/94 09/09/94 09/09/94 09/09/94 Est Finish 11/30/94 10/14/94 10/14/94 10/14/94 09/30/94 09/30/94 09/30/94 10/15/94 09/30/94 09/30/94 , 09/30/94 09/01/94 09/30/94 09/30/94 09/30/94 10/15/94 09/01/94 10/15/94 09/30/94 12/31/94 09/30/94 07/07/94 11/30/94 09/30/94 10/31/94 Status Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Project No. Ft-36 Fi-37 FI-38 FI-39 FI-40 FI-41 Ft-42 FI-43 FI-44 FI-45 FI-46 FI-47 FI-48 FI-49 FI-50 POWER 1/UTILITIES Consolidate Audit Summary May 6, 1996 Project Name Field Inspection #1 at B-1802 Field Inspection Tearn #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Tearn #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Field Inspection Team #2 Housekeeping (not listed on Audit report, but should be done). Dept Responsible Utilities Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Power 1 Person Responsible Glenn CrousiRac Operations/Glenn Operations Gervey Smith Ronnie E. Daigle Glenn CrousBIac Operations Glenn Crousilac Glenn CrousiNac Glenn Crousilac Glenn CrousMac Glenn CrousiRac Glenn CrousiRac Glenn Crousilac Shift Supervisor/Tommy Rozas Est Start 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/09/94 09/12/94 Est Finish 09/30/94 11/30/94 12/31/96 09/09/94 10/31/94 09/30/94 09/30/94 11/30/94 11/30/94 10/31/94 09/30/94 09/30/94 11/30/94 09/30/94 10/31/94 Status Complete Complete Working Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete Complete oo o zo Mo > m >-* Z N) 3> (jn r cn POWER 1/UTILITIES CONSOLIDATED AUDIT ACTION ITEMS Project No: DR-15 Priority: Must Do | Status: IWorkinc Z3 Cross Reference: Page 16, L-l 1 N Project Name: Documentation Review Project Description: Document training of operators on the following: "See Actions Needed" Estimated Start: 09/01/94 Department Responsible: Power 1 Estimated Finish: 12/31/96 Person Responsible: Tommy Rozas/Shift Supervisor Supervisor: Roger Hudson Actions Needed: * Steps for each operating phase including startup, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown, and startup following a turnaround or emergency shutdown. * Operating limits including consequences of deviations and steps required to avoid deviations. * Safety and health considerations * Safety systems and their functions Completion: Comp. Date: [M:POWER I/SAFET^VAUDITSJCONAUD94.DOC Approval: Yes By: Roger Hudson Dow Confidential Information DO A 121156 CONFIDENTIAL POWER 1/UTILITIES CONSOLIDATED AUDIT ACTION ITEMS Project No: FI-38 Priority: Must Do | Status: IWorkine _! Cross Reference: Page 22, A-2 in Process area 'M Project Name: Field Inspection Team #2 Project Description: Process Area Estimated Start: 09/09/94 Department Responsible: Power 1 Estimated Finish: 12/31/96 Person Responsible: Operations Supervisor: Tommy Rozas Actions Needed: Not a lot of stenciling of lines in the process area. Other than road crossings there does not seem to be a lot of line contents identification. Completion: Comp. Date: [MiPOWER l/SAFETY/AUDITSJCONAUD94.DOC Approval: Yes By: Roger Hudson Dow Confidential Information DO A I21157 CONFrDENTTA! DOW CHEMICAL U. S. AREA CONSOLIDATED AUDIT PROGRAM POWER II PLANT LOUISIANA DIVISION FINAL UPDATE OF THE ACTION PLAN OCCUPATIONAL HEALTH AUDIT ACTION ITEM DUE DATE/STATUS GENERAL INDUSTRIAL HYGIENE 1. Move the coffee pot in the warehouse. COMP. Daigle 8/93 2. Complete 1992 I. H. Report COMP. Morrison 9/93 GENERAL MEDICAL 1. Procedure - Contact medical when an employee transfers into the block. COMP. Smith 6/94 RESPIRATOR PROTECTION 1. Update written respirator plan. 2. Conduct monitoring for ceramic fibers. Include monitoring results in written report. 3. Add monthly SCBA inspection to C-9. COM'r. Murt isOu i2/>3 COMP. Morrison 8/93 COMP. Morrison 10/94 COMP. Smith 12/93 VENTILATION 1. Document weekly/quarterly checks of lab fume hood. COMP. Morrison 1/94 2. Evaluate sandblast cabinet for cyclone/dust collector. COMP. Daigle 12/93 3. Post signs in warehouse associated with welding rods used. COMP. Morrison 8/93 ASBESTOS 1. Move the packing material to the designated storage area and dispose of any unnecessary packing. COMP. Daigle 10/93 2. Put a line on the floor disignating the boundry of the storage area and move the "Do Not Sweep" sign to the floor. COMP. Daigle 10/93 DO A 121158 CONFIDENTIAL ACTION PLAN(cont.) REACTIVE CHEMICALS AUDIT ACTION ITEM DUE DATE/STATUS 1. Establish a procedure to purge the generators to 2% oxygen before reintroducing hydrogen. COMP Daigle 8/93 2, Review/amend disposal of fuel gas filters. COMP. Morrison 11/93 3. Determine if syngas/fiiel gas condensate are compatible with each other during upsets. COMP. Geoffroy 11/93 CHEMICAL EXPOSURE INDEX(CEI) ACTION ITEM DUE DATE/STATUS 1. Conduct 1 emergency drill simulating an in-block chlorine release at least once pre vear COMP. Smith 12/93 HAZARDOUS MATERIAL TRANSPORTATION REVIEW(HMTR) ACTION ITEM DUE DATE/STATUS 1. Give Hazcoin training concerning chlorine. COMP. Morrison 12/93 2, Give "First Alert" Training concerning chlorine cylinders. COMP. Morrison 12/94 SAFETY AUDIT ACTION ITEM EMPLOYEE TRAINING DUE DATE/STATUS 1. Set goals for taking IPT modules. COMP. Rozas12/93 2. Schedule the writing and answers for IPT's. ACCIDENT/INCIDENT INVESTIGATION AND REPORTING COMP. Rozas12/93 1. Become familiar with the "root cause" process. COMP. Smith10/93 2. Track accident/incident daa to determine needs for special emphasis. COMP. Smith10/93 D0 A 121159 confidential ACTION PLAN(COnt.) SAFETY AUDIT(cont.) ACTION ITEM DUE DATE/STATUS SAFETY SUGGESTION SYSTEM 1. Consider implementing a safety suggestion program separate from the use of unsafe condition report form. COMP. Smith 8/93 AWARD/RECOGNITION SYSTEM 1. Re-evaluate the award program to encourage participation by more people. COMP. Smith 8/93 CONTRACTOR SAFETY 1. Develop checklist that documents the pre-job safety conferences including small jobs. COMP. Daiglr 12/93 OFF THE JOB SAFETY 1. Develop a form that will track off-lhe-job safety. COMMUNICATIONS COMP. Smith 12/93 1. Audit all forms of operational communications to insure their effectiveness. COMP. Rozas 12/93 AUDITS 1. Promote the cross-audit practice. COMP. Smith 8/93 SAFE WORK PRACTICES 1. Establish guidelines and timetables for training operators on the 401 job procedures. COMP. Rozas 4/94 2. Consider documentation process to insure that all affected people stay up to date on changes in procedures. COMP. Rozas 4/94 DO A 121160 CONFIDENTIAL ACTION PLAN(eont.) ELECTRICAL RELIABILITY AUDIT ACTION ITEM DUE DATE/STATUS 1. Evaluate the need to rehabilitate the terminal enclosures, sandblast and paint MP-1000(A&B). COMP. Cooper 12/93 2. Evaluate the need to rehabilitate the terminal enclosures, sandblast and paint P2-1 Syn Bus PT enclosure. COMP. Cooper 12/93 3. Update grounding grid drawings to "as built". Show missing grounding wells as grounding rods. COMP. Cooper 12/93 4. Replace the broken well cover. 5. Reseal terminal connections. COMP. Cooper 11/93 6. Repair/rehabilitate grounding wells having covers partially covered with concrete and/or difficult to remove. COMP. Cooper 11/93 LCCS PELVENTION AUDIT ACTION ITEM DUE DATE/STATUS ELECTRICAL SYSTEM OPPORTUNITIES 1. The replacement of the Fuji bushing has begun. Bus 300 was completed in August 1993. All the syn* bus tie breakers should be complete by the end of the year. Two buses are scheduled during 1994. The final bushing replacement will take place in 1995. Syn Bus Tic Bkrs. Completed 1993, Bus 4, Bus 200 Completed 1996, Bus 400 Completed 1995, Bus 100 Scheduled 1996 Craft 2. Cable bus overheating is being monitored. Plans are in progress to modify the existing cable bus system to allow more heat to escape. H-610 will require a new transposition section which has been ordered and is due to arrie in December. Additionaly, all the hot cable buses will have their cable bus covers raised. There are presently three cable buses that are overheating; H-402, H-610, and H-304. All three buses should be modified by the end of the first quarter of 1994. Completed 12/94. Clelchman 3. Modification to the relay protection system is in progress. The.required changes will be coordinated with plant outages to allow access to different buses. These changes will be on-going in conjunction with the Fuji bushing changes. 12/97. Craft 4. The station service transformers for 100/200 are on hold until better economic conditions exist due to high cost; Approximately $700,000. Scheduled completion date 8/97 Craft. DO A 121161 CONFIDENTIAL LOSS PREVENTION AUDIT ACTION ITEM DUE DATE/STATUS FIRE PROTECTION OPPORTUNITIES 1. GT-300 louvers will be repaired at the next overhaul. COMP. Cooper 7/94 2. The Power Tech Center will be contacted concerning hand held HALON fire extinguishers. COMP. Cooper 10/93 3. A champs work order was put into the system concerning "Update of the Power 2 Fire Protection Plot Plan. COMP. Daigle 12/93 4. Power 2 will contact Fire Protection Department to schedule a meeting discussing a credible fire scenario for Power 2. COMP. Daiglel2/93 FIRED EQUIPMENT OPPORTUNITIES 1. The thermocouple runback and trip requirements have been completed on GT-200. These changes will be made on GT-100 during the next available outage. COMP. Cooper 1/94 2. Vibration trip logic changes are in progress. The changes will require software programming upgrades to the tri-sen systems. GT-200 changes will occur during the first available outage of 1994. The vibration system for GT-100 will have to be upgraded before the changes can be implemented. Tire GT-100 vibration upgrade project has been approved and is scheduled for completion by the end of 1994. The vibration logic changes will be implemented with the upgrade. Complete 12/95. Glcichman/Craft 3. The compressor efficiency calculation program is due to be reviewed by the end of 1993. COMP. Geoffroy 12/93 4. Methods for monitoring generator shaft voltage are being investigated. Plans are to have a method in place by the end of the first quarter 1994. COMP. Cooper 2/94 5. Procedures for the checkout of relay trip circuits are being written by the distribution department as the jobs come up. The procedures are provided to the plant for review prior to the start of the job. MOC also require that procedures be written. COMP. Taylor 3/94 A copy of the Tech Center audit questionnaire was included in the audit document file. COMP. Rozas 10/93 DO A 121162 CONFIDENTIAL ACTION ITEM CRITICAL INSTRUMENT OPPORTUNITIES DUE DATE/STATUS 1. The critical instrument test procedures are in the process of being updated and is expected to be completed by the end of the first quarter 1994. GT-300/400 PROCEDURES COMPLETED. 100/200 PROCEDURES -COMPLETED 10/94. Glcichman 2. The failure of the tri-sen modules is currently being addressed with tri-sen. Tri-sen repair reports will now identify the component(s) which failed and whether it appears to have been caused by an external event which we can address and correct. COMPLETED 12/1994. Gleichman ACTION ITEM DUE DATE/STATUS CRITICAL INSTRUMENT RECOMMENDATIONS 1. Procedures are being updated to include testing from the sensing element through the operating device where possible. COMPLETED 10/94 Glcichman. 2. The procedures are being updated to include the proper settings for each instrument, as well as, the equipment I.D. COMPLETED 10/94 Gleichman. EMERGENCY BLOCK VALVES OPPORTUNITIES Emergency block valves are manually operated during each extended outage to ensure that they are working properly. In the future, these functional tests will be documented and any corrective actions required will be noted. PROCEDURES FOR 300/400 BLOCK/ISOLATION VALVES ARE COMPLETE AND BEING USED, 100/200 PROCEDURES COMPLETED 10/94, Glcichman WAREHOUSE STORAGE OPPORTUNITIES Building 3703 warehouse will be repaired/demolished as soon as the economic picture gets brighter. BOARDS WERE ENCAPSULATED 10/94 - MORRISON. PRESSURE VESSELS/RELIEF DEVICES The recommendations outlined in the audit done earlier. A time schedule is being developed. COMP. Daigle, Johnson 10/93 FLAMMABLE MIXTURES The procedure for purging and checking for oxygen depletion prior to putting the fuel gas lines back in service on GT-100/200 is being developed. COMP. Rozas 8/94 MANAGEMENT OF CHANGE The MOC program has been reviewed to make it a more active program. COMP. Rozas 10/93 DO A 121163 CONFIDENTIAL LOSS PREVENTION AUDIT ACTION ITEM INSURANCE PACKAGE DUE DATE/STATUS I. A "B" size scaled plot plan drawing will be obtained and included the F&EI calculation circles on it. COMP. Rozas 3/95 2. The insurance information form will be completed and reviewed with loss prevention. COMP. Rozas 3/95 DO A 121164 CONFIDENTIAL I <I CONSOLIDATE AUDIT FOLLOW-UP ACTIONS The consolidated audit follow-up actions have been reviewed with Bill Sharkey (Plant Superintendent-Power 2) and Johnnie Masey (Major Manager - Hydrocarbons and Power). This review took place d^^i^g October and November 1993. Marty Morrison Power and Utilities DO A 121165 CONFIDENTIAL DOW U.S. AREA CONSOLIDATE AUDIT PROGRAM POWER II PLANT LOUISIANA DIVISION ACTION PLAN OCCUPATIONAL HEALTH AUDIT ACTION ITEM DUE DATE/STATUS GENERAL INDUSTRIAL HYGIENE 1. Move the coffee pot in the warehouse. Patot Daigle COMPLETE 2.1992 Report. Marty Morrison COMPLETE GENERAL MEDICAL 1. PROCEDURE - Contact medical when an employee transfers into the block. Marty Morrison, Garvey Smith 12/31/93 *i RESPIRATOR PROTECTION 1. Update written respirator plan. Marty Morrison 2. Conduct monitoring for ceramic fibers. Marty Morrison Include monitoring results in written report.Marty Morrison 3. Add monthly SCBA inspection to C-9. Garvey Smith VENTILATION 12/1/93 11/15/93 5/94 COMPLETE 1. Document weekly check of lab fume hood. Marty Morrison COMPLETE 2. Evaluate sandblast cabinet for cyclone/dust collector.Patot Daigle-12/31 3. Post additional signs in warehouse associated with the type of welding rods used.. Marty Morrison 11/30 ASBESTOS 1. Move the packing material to the designated storage area and dispose of any unnecessary packing. Patot Daigle 10/31 2. Put a line on the floor designating the boundary of the storage area and move the "Do Not Sweep" sign to the floor. Patot Daigle COMPLETE DO A 121166 CONFIDENTIAL ACTION PLAN (cont.) REACTIVE CHEMICALS AUDIT ACTION ITEM DUE DATE/STATUS 1. Establish a procedure to purge the generators of air to 2% oxygen before reintroducing hydrogen. Ronnie Daigle COMPLETE 2. Review/amend disposal of fuel gas filters.Marty Morrison 11/15 3. Determine if syngas/fuel gas condensate are compatible with each other during upsets. David Geoffroy 11/30 CHEMICAL EXPOSURE INDEX(CEI) ACTION ITEM DUE DATE/STATUS 1. Conduct 1 emergency drill simulating an in-block chlorine release at least once per year. Gervey Smith 12/31/93 HAZARDOUS MATERIAL TRANSPORTATION REVIEW(HMTR) ACTION ITEM DUE DATE/STATUS 1. Give Hazcom training concerning chlorine.Marty Morrison COMPLETE 2. Give "First Alert" Training concerning chlorine cylinders. Bruce Cooper, MartyMorrison 12/31/93 SAFETY AUDIT ACTION ITEM DUE DATE/STATUS EMPLOYEE TRAINING 1. Set goals for taking IPT modules. All COMPLETE 2. Schedule the writing and answers for IPTs.Tommy Rozas 12/31/93 ACCIDENT/INCIDENT INVESTIGATION AND REPORTING 1. Become familiar with the "root cause" process. Gervey Smith 11/30/93 2. Track accident/incident data to determine needs for special emphasis. David Geoffroy, Gervey Smith COMPLETE D0 A CONFIDENTIAL ACTION PLAN (cont.) SAFETY AUDIT(cont.) ACTION ITEM DUE DATE/STATUS SAFETY SUGGESTION SYSTEM 1. Consider implementing a safety suggestion program separate from the use of unsafe condition report form. Gervey Smith COMPLETE AWARD/RECOGNITION SYSTEM 1. Re-evaluate the award program to encourage participation by more people. Gervey Smith 11/1/93 CONTRACTOR SAFETY 1. Develop checklist that documents the pre-job safety conferences including small jobs. Patot Daigle, Gervey Smith 11/30/93 OFF THE JOB SAFETY 1. Develop a form that will track off-the-job safety. David Geoffroy, Gervey Smith 11/30/93 COMMUNICATIONS 1. Audit all forms of operational communications to insure their effectiveness. Tommy Rozas 12/31/93 AUDITS 1. Promote the cross-audit practice. Gervey Smith COMPLETE SAFE WORK PRACTICES 1. Establish guidelines and timetables for training operators on the 401 job procedures. Tommy Rozas Done on a yearly bases and will be completed in 1993. 2. Consider a documentation process to insure that all affected people stay up to date on changes In procedures. Tommy Rozas 11/30/93 ACTION PLAN (cont.) ELECTRICAL RELIABILITY AUDIT ACTION ITEM DUE DATE/STATUS Note: Bruce Cooper will follow up on electrical items. 1. Evaluate the need to rehabilitate the terminal enclosures, sandblast and paint MP-1000(A & B). 12/31/93 2. Evaluate the need to rehabilitate the terminal enclosures, sandblast and paint P2-1 Syn Bus PT enclosure. 12/31/93 . 3. Update grounding grid drawings to "as built". Show missing grounding wells as grounding rods. 11/30/93 4. Replace the broken well cover. 11/30/93 5. Reseal terminal connections. 11/30/93 6. Repair/rehabilitate grounding wells having covers partially covered with concrete and/or difficult to remove. 11/30/93 LOSS PREVENTION AUDIT ACTION ITEM DUE DATE/STATUS ELECTRICAL SYSTEMS OPPORTUNITIES Note: Bruce Cooper will follow up on electrical items. 1. The replacement of the Fuji bushings has begun. Bus 300 was completed in August 1993. All the syn-bus tie breakers should be completed by the end of the year. Two buses are scheduled to be completed during 1994. The final bushing replacement will take place in 1995. 2. Cable bus overheating is being monitored. Plans are in progress to modify the existing cable bus system to allow more heat to escape. H-610 will require a new transposition section which has been ordered and is due to anive in December. Additionally, all the hot cable buses will have their cable bus covers raised. There are presently three cable buses that are overheating; H-402, H-610, and H-304. All three buses should be modified by the end of the first quarter of 1994. 3. Modification to the relay protection system is in progress. The required changes will be coordinated with plant outages to allow access to different buses. These changes will be on-going in conjunction with the Fuji bushing changes. 4. The station service transformers for 100/200 are on hold until better economic conditions exist due to the high cost; Approximately $700,000. DO A 121169 confidential ACTION PLAN (cont.) ACTION ITEM FIRE PROTECTION OPPORTUNITIES DUE DATE/STATUS 1. GT-300 louvers will be repaired at the next overhaul.Bruce NEXT OVERHAUL 2. Power 2 will follow the Dow guidelines for the phase out of HALON. RECOMMENDATIONS: 1. The Power Tech Center will contacted concerning hand held HALON fire extinguishers. Bruce Cooper 10/31/93 2. A champs work order was put into the system concerning "Update of the Power 2 Fire Protection Plot Plan. Patot Daigle COMPLETE 3. Power 2 will contact Fire Protection Department to schedule a meeting discussing a credible fire scenario for Power 2 David Geoffroy 11/30/93 FIRED EQUIPMENT OPPORTUNITIES Note; Bruce Cooper will follow up on fired equipment concerns. 1. The thermocouple runback and trip requirements have been completed on GT-200. These changes will be made on GT-100 during the next available outage. 2. Vibration trip logic changes are in progress. The changes will require software programming upgrades to the tri-sen systems. GT-200 changes will occur during the first available outage of 1994. The vibration system for GT-100 will have to be upgraded before the changes can be implemented. The GT-100 vibration upgrade project has been approved and is scheduled for completion by the end of 1994. The vibration logic changes will be implemented with the upgrade. 3. The compressor efficiency calculation program is due to be reviewed by the end of 1993. 4. Methods for monitoring generator shaft voltage are being investigated. Plans are to have a method in place by the end of the first quarter of 1994. 5. Procedures for the checkout of relay trip circuits are being written by the distribution department as the jobs come up. The procedures are provided to the plant for review prior to the start of the job. MOC also require that procedures be written. RECOMMENDATIONS: A copy of the Tech Center audit questionnaire was included in the audit documentation file. COMPLETE DO A 121170 CONFIDENTIAL ACTION PLAN (cont.) ACTION ITEM DUE DATE/STATUS CRITICAL INSTRUMENTS OPPORTUNITIES Note: Bruce Cooper will follow up on critical instrument items. 1. The critical instrument test procedures are in the process of being updated and is expected to be completed by the end of the first quarter 1994. 2. The failure of tri-sen modules is currently being addressed with tri-sen. Tri-sen repair reports will now identify the components) which failed and whether it appears to have been caused by an external event which we can address and correct. CRITICAL INSTRUMENTS RECOMMENDATIONS 1. Procedures are being updated to include testing from the sensing element through the operating device where possible. 12/94 2. The procedures are being updated to include the proper settings for each instrument, as well as, the equipment I.D. 12/94 EMERGENCY BLOCK VALVES OPPORTUNITIES Emergency block valves are manually operated during each extended outage to ensure that they are working properly. In the future, these functional tests will be documented and any corrective actions required will be noted. Bruce Cooper 12/31/93 WAREHOUSE STORAGE OPPORTUNITIES Building 3703 warehouse will be repaired/demolished as soon as the economic picture gets brighter. PRESSURE VESSELS/RELIEF DEVICES The recommendations outlined in the audit done earlier. A time schedule is being developed. Ronnie Daigle, Wes Johnson 10/31/93 FLAMMABLE MIXTURES The procedure for purging and checking for oxygen depletion prior to putting the fuel gas lines back in service on GT-100/200 is being developed.Tommy Rozas 12/31/93 MANAGEMENT OF CHANGE The moc program has been reviewed to make it a more active program. COMPLETE DO A 121171 CONFIDENTIAL ACTION PLAN (cont.) ACTION ITEM DUE DATE/STATUS INSURANCE PACKAGE 1. A "B" size scaled plot plan drawing will be obtained and include the F&E I calculation circles on it. Tommy Rozas 1/31/94 2. The insurance information form will be completed and reviewed with loss prevention. Tommy Rozas 1/31/94 D A CONfiobnti^l OCCUPATIONAL HEALTH AUDIT (July 7, 1994) AUDIT TEAM: (, Bruce Heinze, Jackie Paul, Dave Albert, Howard Wilkinson PLANT IH CONTACT: Marty Morrison ATTENDANCE: WRITER: Joe Rawlings, Roger Hudson, Ken Fox, Buck Bailey, Eddie Supple Maralee Marchant GENERAL INDUSTRIAL HYGIENE/MEDICAL The I.H. Manual is complete, however, most written programs need to be reviewed and updated as needed. Eating facilities and equipment were clean. Industrial hygiene training was conducted by the shift supervisors on a quarterly basis. The Block Indoctrination video was updated in fall of 1993 and covers the chemical and physical hazards in the block. Recommendations: M 1. The 1993 CPAI is being added to the computer database and needs to be updated for 1994. HAZCOM PROGRAM Power I/Utilities employees receive HAZCOM training annually. The 1993 training was performed quarterly by the shift supervisors. The labeling of plant equipment was good. The HAZCOM/MSDS notebooks are readily available in the control room. Recommendations: M 1. The written HAZCOM program needs to be reviewed and updated (written program, chemical list, vessel ID/cross reference table, current MSDSheets). M 2. There are a few bottles in the lab which need labels to comply with Dow Hazard Communication labeling requirements. M = Must-Do DOW CONFIDENTIAL Page 2 HR = Highly Recommended DO A 121173 CONFIDENTIAL HEARING CONSERVATION Annual training was conducted during 1993. The Power 1 block is posted as a hearing protection required area. The Utilities block is posted as needed. Also, high noise areas in the process area are posted with appropriate double hearing protection signs. Recommendations: M 1. The protective equipment requirements for operating the shop pedestal grinder need updating to include the use of hearing protection. RESPIRATORY PROTECTION The plants written Respiratory Protection Program is current (5/94), training was conducted third quarter 1993 by shift supervisors. The plant respirator cleaning station located in 2801 is posted and equipped with the necessary supplies. We support your decision to move the Life Air units to the permit writer's office at the Utilities plant to assure maintenance. Recommendations: M 1. The Scott-Acme respirator needs to be added to the written respiratory program. PERSONAL PROTECTIVE EQUIPMENT The plant's written program is current for 1994. Recommendations: No recommendations at this time. ERGONOMICS Recommendations: No recommendations at this time. THERMAL STRESS Recommendations: No recommendations at this time. M = Must-Do DOW CONFIDENTIAL Page 3 HR = Highly Recommended DO A 121174 CONFIDENTIAL VENTILATION The laboratory fume hoods are equipped with flow sensing devices and are checked quarterly. The last comprehensive hood survey was performed in December 1992. The housekeeping in the labs and the hoods was good. Recommendations: M 1. Analyzer shack (2825) needs to' have the exhaust fan repaired. WELDING Signs were posted describing the health hazards of welding. Sources of ventilation for the welding area include wall fans at each end of the building at Power 1, one wall fan at Utilities, and large doorways. Recommendations: No recommendations at this time. ASBESTOS Inventory of asbestos-containing material was available for 1993 and 1994. Annual training records were documented for 1993. Recommendations: M 1. The gasket storage area in the Power 1 and the Utilities plant need to be vacuumed. M 2. The non-asbestos material needs to be removed from the disposal dumpster. M = Must-Do DOW CONFIDENTIAL Page 4 DO A 121175 CONFIDENTIAL HR = Highly Recommended ELECTRICAL RELIABILITY AUDIT SUMMARY (May 3,4, 5, 1994) AUDIT TEAM: Mike Gee PLANT CONTACT: Gary Landry WRITER: Mike Gee The electrical reliability audit for the Power I plant was conducted in May, 1994 as per the Five Point Electrical Reliability Program. Those items identified with an index of 4 or higher in the Electrical Reliability report need some attention and a response. Please refer to the report. The overall condition of the electrical assets of Power I reflects a commitment to continuous improvement. The audit team finds Power I has an overall average condition. Recommendations: Power I HR 1. 30 - 40% of junction boxes not properly grounded. Ground junction boxes, bond back panels, and conduits per L7C-0101-00 3.5.1. Train block electrical personnel in proper grounding practices. HR 2. 50-60% of motors are improperly grounded. Ground motors per L7C-0101 5.4 and detail L7C 0118-01. Train block electrical personnel in proper grounding practices. M 3. Material stored in clearance zone required by National Electric Code. Move material to give required clear access zone. NEC 110-16, 110-34. Recommendations: Utilities HR 1. 30 - 40% of junction boxes not properly grounded. Ground junction boxes, bond back panels, and conduits per L7C-0101-00 3.5.1. Train block electrical personnel in proper grounding practices. M = Must-Do DOW CONFIDENTIAL Page 5 HR = Highly Recommended HR 2. 30-40% of motors are improperly grounded. Ground motors per L7C-0101 5.4 and detail L7C 0118-01. Train block electrical personnel in proper grounding practices. M 3, Material stored in clearance zone required by National Electric Code. Move material to give required clear access zone. NEC 110-16, 110-34. CHEMICAL EXPOSURE INDEX REVIEW (July 15, 1994) AUDIT TEAM: Greg Nesmith, Buck Bailey PLANT CONTACT: Marty Morrison ATTENDANCE: Roger Hudson, Joe Rawlings, Ken Fox, Howard Wilkinson, Eddie Supple WRITER: Greg Nesmith The pre-audit review for the Chemical Exposure Index (CEI) was completed on Monday, July 11, 1994. The following people participated and represented their respective areas: Greg Nesmith, CEI; Marty Morrison, Power I/Utilities; Buck Bailey, Safety and Loss Prevention. The pre-audit simply consisted of a discussion of the CEI calculations, a short review of the previous audit, and an overview of the changes in the plant since the last audit. During the course of the pre-audit, the only significant events revolved around the CEI calculations themselves. First, aqueous hydrogen chloride (HC1) is a concern at the Utilities plant; however, the present CEI calculation method is not suited for vapor-liquid solutions. Data for anhydrous HC1 could be used but would be much too conservative (CEI of more than 700) since it is a vapor at ambient conditions. To compensate, the physical properties of water were substituted to model the solution. Vapor pressure data was based on experimental data for aqueous HC1. The resulting CEI of 9 was assumed to be more accurate based on past experience with aqueous HC1 spills. M = Must-Do DOW CONFIDENTIAL Page 6 HR = Highly Recommended 00 A 121177 CONFIDENTIAL On a related note, a slight problem with the Excel spreadsheet program which has been developed for this calculation was discovered in the process of calculating the CEI of chlorine at Utilities. In this program, the total amount released is based solely on the rate of release. The amount contained at the source of the release is not taken into consideration. Hand calculations were completed to compensate for this problem. The CEI for chlorine at Power 1/ Utilities was 378. ACCOMPLISHMENTS/MAJOR CHANGES SINCE LAST REVIEW: The P&ID's have been upgraded since the last CEI review to reflect existing operations although the effort is not yet 100% complete. Recommendations: M 1. Documentation: Continue updating P&ID's to represent existing operations. Once the P&ID's,are up to date, implement a method for recording all changes. Note: Although the CEI for chlorine at Power 1/ Utilities is high enough to recommend a HAZOP review, such action should be postponed at this time. Since these chlorine cylinders are common throughout Dow, a single HAZOP should be conducted for ALL chlorine cylinders rather than redundant doing one for each plant. Power 1/ Utilities will be notified if their assistance is needed in such a process and if any recommendations result from such a review. M = Must-Do DOW CONFIDENTIAL Page 7 DO A 121178 CONFIDENTIAL HR = Highly Recommended LOSS PREVENTION/FIRE (Friday, July 15, 1994) AUDIT TEAM: Buck Bailey, Bill Franklin, Greg Nesmith PLANT CONTACT: Marty Morrison WRITER: Buck Bailey The Loss Prevention recommendations from the previous Consolidated Audit have been properly addressed, and the Power 1 and Utilities plants appear to be in good condition with no serious loss prevention concerns. I appreciate the pre-audit activities and preparations by the plant staff. Following are a few items to be addressed as a result of the current Consolidated Audit: INSURANCE PACKAGE: Recommendations: M 1. Follow up with Loss Prevention to finalize the package of information for transmittal to the Corporate Loss Prevention Department for the insurance companies. FIRED EQUIPMENT: Recommendations: M 1. The Burner Management documentation package should be organized to comply with L.P.P.-13.1 and guidelines from the Power Tech Center. M = Must-Do DOW CONFIDENTIAL Page 8 DO A 121179 CONFIDENTIAL HR = Highly Recommended PROJECT REVIEWS: Recommendations: M 1. To comply with OSHA 1910.119 the project reviews and pre-startup reviews need to be documented and filed so that recommendations are trackable to completion. CHEMICAL EXPOSURE INDEX: The CEI calculation for chlorine resulted in value greater that 200, which will normally require further risk analysis reviews. This is to comply with a new Dow "Risk Management Guideline" that is currently being implemented. The source of chlorine in a pressure cylinder which is practically the same as several other users throughout the site and company. So, individual plant risk reviews are not being done. Recommendations: M 1. A separate CEI review summary has been written by Greg Nesmith to summarize the activities and procedures that were involved in the CEI review. Please file it with the Loss Prevention portion of the Consolidated Audit for future reference and documentation. I appreciate the co-operation and am available as necessary for any follow up or future Loss Prevention activities. M = Must-Do DOW CONFIDENTIAL Page 9 D0 A 121180 CONFIDENTIAL HR = Highly Recommended HAZARDOUS MATERIALS TRANSPORTATION REVIEW (HMTR) AND DISTRIBUTION FACILITIES ASSESSMENT (DFA) (April 8, 1994) AUDIT TEAM: Dean Smith PLANT CONTACT: Donald Yelverton WRITER: Dean Smith Comments and Recommendations: On April 8, 1994 an HMTR/DFA was conducted and completed at the Power I/Utilities Plant as part of the Louisiana Division Consolidated Audit Program. Power I/Utilities Plant does not, as such, ship/transport, load/off-load or store hazardous materials for distribution. Hazardous materials such as chlorine and hydrogen are delivered and used at the facility and the cylinders returned as residue containers. These cylinders being returned have the potential for problem areas as recognized under the US DOT regulations. The Hydrogen tube trailers have recently been cleaned, tested and inspected and are in excellent shape. Chemicals Reviewed Chlorine Chlorine Hydrogen DRI# 4 4 4 TRANSPORTATION MODE: -All received by HwyReceived in 150# cyl Received in l Ton cyl Received in ''Tube" trailers PRODUCT (P) FEED (FT) T-Back-up for water treatment. T*Sewer treat. T-Power turbin HMTR Questionnaire: All areas reviewed were satisfactory. DFA: Only the Highway Mode was applicable for this part of the HMTR/DFA. M = Must-Do DOW CONFIDENTIAL Page 10 HR = Highly Recommended DO A 121181 CONFIDENTIAL Recommendations: HR 1. Chlorine cylinders are received and picked up by the vendor, who, in this arrangement of service, have the main responsibility for the proper paperwork and DOT securement checks. However, because this material is classed as a Poison Gas / Inhalation Hazard, the facility must ensure proper marking and labeling is present while in use and prior to return shipment. A checklist and/or written procedure should be used to verify existing cylinders have the proper markings and labels and that those being received have the same. Two 150# chlorine cylinders were noticed to be in bad shape because of corrosion and/or out of date hydrostatic test. These were recommended to be replaced. All of the 1 Ton cylinders were in good order. The Power I / Utilities Plant is in great shape thanks to the efforts of Marty Morrison. Keep up the good work. Thanks for the continued cooperation. LABORATORY AUDIT (June 6, 1994) AUDIT TEAM: Howard Wilkinson PLANT CONTACT: Marty Morrison WRITER: Howard Wilkinson Overall, the Power I laboratory is excellent shape. The lab inspection found the housekeeping to be in very good condition. Employees have access to all equipment operations manuals and procedures. Very goodjob on labeling equipment and cabinets. Recommendations: None at this time. M = Must-Do DOW CONFIDENTIAL Page 11 DO A 121182 CONFIDENTIAL HR = Highly Recommended SECURITY AUDIT SUMMARY (January 4, 1994) AUDIT TEAM: A1 Lott PLANT CONTACT: Marty Morrison WRITER: A1 Lott/Howard Wilkinson All Dow employees are required to wear ID badges. Employees challenge strangers in their work areas. A sign-in/out log is available for visitors to the control room/plant area. Emergency communications and alert systems are in place and working well. Security awareness seems to be working well at the Power I/Utilities Departments. Keep up the good work. Recommendations: i None at this time. SAFETY AUDIT (Monday, June 6, 1994; Wednesday, July 13, 1994) AUDIT TEAM: Don Jones, Eddie Supple, Roddy Peebles, Howard Wilkinson ATTENDING: Howard Wilkinson, Buck Bailey, Eddie Supple, Joe Rawlings, Ken Fox PLANT CONTACT: Gervey Smith WRITER: Don Jones, Eddie Supple M = Must-Do DOW CONFIDENTIAL Page 12 D0 A 121183 confidential HR = Highly Recommended SAFETY QUESTIONNAIRE A. Program Structure and Planning See Documentation Review (Safety and Health Suggestions) B. Employee Participation No Recommendation C. Contractor Safety No Recommendation D. Accident/Incident Investigation and Reporting See Documentation Review (Accident/Incident Investigations) E. Audits See Documentation Review (Safety Equipment Inspections and Checks) F. Safe Work Practices 1. Conduct annual performance audits of safe work permits, confined space entry and lockout/tagout. Also, identify deviations and track to completion. G. Emergency Planning and Means of Egress See Documentation Review (Unit Emergency Plans) H. Employee Training See Documentation Review (Unit Emergency Plans) DO A 12H84 CONFIDENTIAL M = Musi-Do DOW CONFIDENTIAL Page 13 HR = Highly Recommended I. Safe Operation of Motor Vehicles and Motorized Handling Equipment No Recommendation J. Off-The-Job Safety No Recommendation EMPLOYEE SURVEY A new employee survey is being piloted at this plant. The results are still being evaluated and will be forwarded at a later date. DOCUMENTATION REVIEW A. Audits No recommendations B. Basic Safety HR 1. Prepare and post safety policy. C. Unit Emergency Plans M 1. Update emergency plan. M = Must-Do DOW CONFIDENTIAL Page 14 DO A 121185 CONFIDENTIAL HR = Highly Recommended M 2. After a drill is conducted the results must be critiqued and the critique documented. If any changes are identified they must also be documented such that the following are shown: * What was changed * Who made the change * When the change was made * How the change was communicated * Who communicated the change * Who communicated the change and to whom the change was communicated D. Job Safety Analysis M 1. Operating procedures should include name of person responsible for new or updated procedure instead of shift. HR 2. Use a process (i.e. Power II Procedure Revision Form) other than MOC for updating procedures. M 3. Deficiencies identified in pre-startup reviews must be documented and corrective actions tracked to completion. Documentation must show: * What corrective action was taken * Who completed the corrective action * When corrective action was completed E. Accident/Incident Investigations M 1. Update date due when extends beyond expected. Also, include explanation of why the original date due was missed. F. Safety and Health Suggestions M 1. Assure that all Unsafe Condition Reports are complete. G. Safety Equipment Inspections & Checks M 1. Perform checks on C-9 checklist and sign off on master on or before the due dates. Also complete all blanks including last date, scheduled date, etc. DO A 121186 CONFIDENTIAL M = Must-Do DOW CONFIDENTIAL Page 15 HR = Highly Recommended M 2. C-9 file documentation (checklists, etc.) incomplete. M 3. Deficiencies identified during the C-9 inspections must be documented and corrective actions tracked to completion. Documentation must show: * What corrective action was * Who completed corrective action * When corrective action was completed H. Hazard Identification Inspections No recommendations I. Predictive Preventive Maintenance No recommendations J. Variances 1. Update variances. K. Contractors/Vendor/Visitor Orientation M 1. Document pre-job meetings. L. Safety and Operations Training M 1. Document training of operators on the following: * Steps for each operating phase including startup, normal operations, temporary operations, emergency shutdown, emergency operations, normal shutdown, and startup following a turnaround or emergency shutdown. * Operating limits including consequences of deviations and steps required to avoid deviations. * Safety and health considerations * Safety systems and their functions M = Must-Do DOW CONFIDENTIAL Page 16 DO A 121187 confidential HR = Highly Recommended M. Safety Committee Activities No recommendations N. Safe Work Practices No recommendations FIELD INSPECTION #1 A. LOCKOUTyTAGOUT SYSTEM * Red tag masters are located in the same office from which the SafeWork Permits are issued. There is one central location for all masters. Red Tag system/process seems neat and orderly. * Audited 2 masters for accuracy and found all tags to be in place. HR 1. Have old masters (1992 & 1993) still active. Although they have been routinely audited and updated, should complete needed work or consider permanent isolation or disabling of equipment in lieu of Red Tags. M 2. The masters are not indicating when work crew rosters are NOT used. This practice has been discussed and it is felt that the use OR non use of the work crew roster should be indicated. B. SAFE WORK PERMITS No recommendations C. CONTROL BOARD AREA No recommendations M = Must-Do DOW CONFIDENTIAL Page 17 D0 A 12US8 HR = Highly Recommended D. OFFICE AREAS M 1. OSHA and VPP postings present but need to be replaced with new ones, these are tattered. E. LAB FACILITIES See Lab Audit portion of Consolidated Audit F. MOTOR CONTROL CENTERS See Electrical portion of Consolidated Audit G. MAINTENANCE SHOP and I & E areas B-2804 i 1. Pedestal Grinder M a. No face shield available 2. Pipe threading machine * No recommendation 3. Drill Press M a. No face shield available 4. Horizontal Band Saw * No recommendation 5. Welding and Cutting area M a. Use more shielding, only shielded on one side M b. Modified C-clamps among tools in area 6. Other Equipment * No recommendation 7. Hand held Power tools * No recommendation M = Must-Do DOW CONFIDENTIAL Page 18 DO A 121189 CONFIDENTIAL HR = Highly Recommended w 8. Hand tools * No recommendation 9. Lifting tools M a. At least one sling found in "annex" that had tape covering a large portion of the sling b. Lifting jib and hoist rating not clearly marked 10. Safety Equipment * No recommendation 11. Housekeeping HR a. Annex area of shop area used for storage, etc. is in need of housekeeping. b. Compressed gas cylinders storage area holds water, some of the cylinders are standing in water B-2808 1. Pedestal Grinder M a. Top guards out of adjustment M b. Tool rests out of adjustment M c. Tool rests below center line of wheels M d. No face shield available M e. Soft material imbedded in left wheel M f. Right wheel rounded off on inside edge M g. No waming/required safety equipment signs in area 2. Pipe threading machine * No recommendation 3. M HR Drill Press a. Face shield in garbage can next to drill press b. Metal shavings and small amount of other trash on floor under and around drill press 4. Horizontal Band Saw HR a. Minor housekeeping needed, metal shavings and small pieces of cut angle iron on floor under and around saw M = Must-Do DOW CONFIDENTIAL Page 19 DO A -f - c^WrA1 HR = Highly Recommended 5. Welding and Cutting area M a. No welding shield available 6. Other Equipment M a. Found an extension cord that had exposed wires that had been wrapped with vinyl tape 7. Hand Held Power Tools * No recommendation 8. Hand Tools * No recommendation, 9. Lifting Tools * No recommendation 10. Safety Equipment * No recommendation 11. Housekeeping HR a. Minor general housekeeping needed HR b. Drill press and band saw areas B-1802 1. Pedestal Grinder * No recommendation 2. Pipe Threading Machine * No recommendation 3. Drill Press * No recommendation 4. HR Horizontal band saw a. Has an unconventional means of operation, should be so noted. Have to open valve to bleed press so that blade apparatus will lower once it has been raised M = Must-Do DOW CONFIDENTIAL Page 20 DO A 121191 CONFIDENTIAL HR = Highly Recommended 5. Welding Cutting Area M a. No welding shield available 6. Other Equipment * No recommendation 7. Hand held Power Tools * No recommendation 8. Hand Tools * No recommendation 9. Lifting Tools * No recommendation T- 10. Safety Equipment HR a. Body harnesses not neatly hung M b. Rope wrist harnesses stored with body harnesses, one in particular had hooks with spring loaded safety latches that were not double locking, could have been mistaken for a lanyard (removed and destroyed this one) 11. Housekeeping HR a. General housekeeping needed HR b. Remove things stored on floor along walls and on beams on walls H & I. WAREHOUSES/SPARE PARTS STORAGE B-2804 M a. No load limit posted for upstairs storage HR b. Grinders, drills, bandsaws, etc., stored in common bin and stacked precariously. Tried to remove one and a number of them began to faH. M c. Removed one electrical hand tool that had the ground post missing from the plug HR d. Could use general housekeeping M e. Flex hoses that had no inspection/test tags M = Must-Do DOW CONFIDENTIAL Page 21 HR = Highly Recommended DO A 121192 CONFIDENTIAL B-1802 M a. No load limit posted for upstairs storage HR b. Badly in need of housekeeping/cleaning overall J. MOTORIZED VEHICLES No recommendation FIELD INSPECTION TEAM #2 . A. PROCESS AREA * Guarding in good condition, utility stations labeled, special equipment/procedures/requirements are posted as needed. Housekeeping is in good condition. HR 1. * Noticed a few overhead leaks/drips, i.e. valve packing leak on a steam line above switch for Deluge Valve Station #4, 3 or 4 similar leaks in the area around switch for Deluge Valve Station # 5. M 2. Not a lot of stenciling of lines in the process area. Other than road crossings there does not seem to be a lot of line contents identification. B. EMERGENCY EQUIPMENT * Safety showers visible and accessible, fire extinguishers in the areas and inspections area current. Respirators are carried on the person, none located in the areas. M 1.5 fire extinguishers with seals broken by Fire Extinguisher station #5. C. PLANT HEALTH * Found the plant to be in excellent condition. Painting and insulation good, ditch grating in good shape, no obvious corrosion. Tremendous improvement over 1992 audit. M = Must-Do DOW CONFIDENTIAL Page 22 DO A 121193 CONFIDENTIAL HR = Highly Recommended D. ENCLOSURES No recommendations E. ACCESS SYSTEMS * Portable ladders are in good condition, also noticed that as a rule they are stored in designated areas and not left out in the areas where they were last used. The fixed ladders are also in good shape and have either swing gates or chains at the elevated entry/exit points. 1. Noticed some swing gates/chains left in the open/down position on some of the ladders. Remind folks that these are to be left/retumed to their intended position (closed/up) after use. F. OBSERVING PEOPLE WORKING IN AREA * Observed FD 2A work. Proper tools, in good condition, permit on site and in good order. * Observed two insulators. One was on the ground and one was in the pipe rack sitting on a pipe working. The one in the rack was wearing and using properly the required safety equipment. The one on the ground was going to attempt to throw the Safe Work Permit up to the one in the rack but the one in the rack told him to put it on his buggy on the ground. Stopped the one on the ground and pointed out to him the dangers associated with throwing things from one level to another. He agreed. * Observed two folks working on an air conditioner for the control room building. One was using a pipe wrench to hammer on a bolt trying to drive out another bolt, intervened and asked that the proper tools be used. The other worker was not wearing ear protection, intervened and reminded him to wear ear protection as required. M = Must-Do DOW CONFIDENTIAL Page 23 DO A 121194 CONFIDENTIAL HR = Highly Recommended G. ELECTRICAL * Start/stop stations, breakers, etc. properly labeled. No loose, exposed wires observed. M 1. Noticed that the door was in the open position on electrical panel L-17 for no apparent reason. All panels/etc. should be covered or closed as applicable. H. OVERHEAD HOISTS No recommendations I. HOUSEKEEPING * Process areas are in excellent condition HR 1. Some housekeeping needed as mentioned in other sections HR 2. B-2811 (storage building SW of B-2804) has hoses piled up on and covering most of the floor area. One would have to step on hoses to reach materials stored on shelves or in bins. J. BLOCK ENTRANCES No recommendations GENERAL: HR 1. Drip leg traps/drains by inst. air compressor #5 discharge above the intended drain. These should be routed into the drain. HR 2. There is a cable running under the top deck of the structure on the far west of the process (directly west of the control room) that should be removed if possible M = Must-Do DOW CONFIDENTIAL Page 24 DO A 1211^5 CONFIDENTIAL. HR = Highly Recommended M 3. Found one harness that had gray tape on it to hold the ends of the straps in place. The practice of taping harnesses is not allowed because tape can hide problems. M 4. Found an extension cord that had been taped up. M 5. LOC (on ground just west of stairway on SW comer of the control room deck) has no railing on the top. M 6. Scaffold on west side of the roadway in the middle of the plant had a ladder that did not extend above the handrail and there was no apparent reason that it couldn't. EMPLOYEE/CONTRACTOR INTERVIEWS No employee/contractor interviews where conducted by the Major Manager. REACTIVE CHEMICALS AUDIT . (Thursday, June 2, 1994) AUDIT TEAM: Joe Schell, Gerald Wagener PLANT CONTACT: Marty Morrison ATTENDANCE: WRITER: Roger Hudston, Ken Fox, Joe Rawlings, Howard Wilkinson, Eddie Supple Gerald Wagener The pre-audit review was conducted on Thursday, June 2,1994. Roger Hudson was recently appointed plant superintendent at Power I/Utilities. Roger reviewed the first and second Consolidated Audit Reports, documentation and participated in this Reactive Chemicals Review. It was decided by the audit team and plant supervision that this review would take the place of the new superintendent Reactive Chemical Review requirement. M = Must-Do DOW CONFIDENTIAL Page 25 HR = Highly Recommended DO CONF " `<^196 rDENTlAL Recommendations: M 1. Scenario: Catastrophic corrosion of boiler during cleaning due to inadvertent use of wrong or non-inhibited acid. Develop acceptance criteria for the inhibited acid which is used for boiler cleaning and verify by performing positive ID testing. M 2. Scenario: High or steadily increasing oxygen concentration in off gas from LHC 2 & 3. Determine if this is a credible scenario and, if so, make sure appropriate lines of defense are in place to avoid a flammability problem. PROCESS CONTROL NETWORK AUDIT (June 10, 1994) AUDIT TEAM: Mike Woods PLANT CONTACT: Marty Morrison WRITER: Mike Woods Recommendations: M 1. Install a RUSCO card reader on the EMC building to secure MODICON access. M 2. Remove memory keys from MODICON. The board person will assume ownership of the access to the MODICONs. M 3. Establish a written procedure for the backup of the SPECTRUM/SPEC 200. M Must-Do DOW CONFIDENTIAL Page 26 A 12U97 CONFIDENTIAL HR Highly Recommended * POWER 1 DESCRIPTION NOT A CHEMICAL PRODUCTION BLOCK. THIS IS A UTILITIES BLOCK GENERATING ELECTRICITY AND STEAM FOR CONSUMPTION IN THE DIVISION. ELECTRICITY IS GENERATED FOR USE THROUGHOUT THE DIVISION WITH THE BULK GOING TO THE CHLORINE PLANT FOR ELECTROLYSIS PURPOSES. GENERATORS ARE DRIVEN BY THREE CONDENSING AND ONE NON-CONDENSING STEAM TURBINES THAT ALSO EXTRACT 475 PSI, 235 PSI AND 30 PSI STEAM FOR PROCESS USE. THE NON-CONDENSING STEAM TURBINE EXHAUSTS INTO A 60-150 PSI HEADER TO THE CAUSTIC PLANT FOR CAUSTIC EVAPORATION. FOUR BOILERS GENERATE THE STEAM FOR THIS USE. THE BOILERS ARE MAINLY NATURAL GAS FIRED. TWO OF THE BOILERS HAVE BEEN MODIFIED TO BURN HYDROGEN AND ONE BOILER HAS BEEN MODIFIED TO BURN SYNGAS. THE FOUR BOILERS GENERATE 1250 PSI 9 950 DEG F. STEAM TO DRIVE THE TURRBINE/GENERATORS. JER 111 >/</* CONSAVDA.CHT 00 A 121198 CONFIDENTIAL UTILITIES DESCRIPTION RAW WATER INTAKE PUMPING STATION * 6 PUMPS - CAPACITY 600,000 GPM RAW WATER RETURN PUMPING STATION * 6 PUMPS - CAPACITY 690,000 GPM PROCESS WATER PRODUCTION * 4 CLARIFIERS - CAPACITY 46,000 GPM POTABLE WATER PRODUCTION * 4 GRAVITY FILTERS - CAPACITY 2,000 GPM DEMINERALIZED WATER PRODUCTION ,, * 6 PRESSURE FILTERS * 6 STRONG ACID CATION EXCHANGERS * 5 ANION TRAINS (WEAK & STRONG BASE ANIONS) * CAPACITY 2,800 GPM DIVISION CONDENSATE STORAGE * 6 TANKS - CAPACITY 7,600,000 GALLONS SEWER SYSTEM * 7 SEWER LIFT STATIONS * SEWER TREATMENT PLANT - CAPACITY 180,000 GPD FIRE PROTECTION WATER WELLS * 9 DIESEL POWERED PUMPS - CAPACITY 60,000 GPM OXYGEN DISTRIBUTION * BIG 3 CONTRACT - 1,180 TONS/DAY NITROGEN DISTRIBUTION * BIG 3 CONTRACT - 550,000 SCF/HR DIVISION INSTRUMENT AIR SYSTEM * VARIOUS SUPPLIERS AND USERS ) JIR III // COMtAUOC.CNT DO A 121199 CONFIDENTIAL ELECTRICAL DISTRIBUTION DESCRIPTION 8 GENERATOR BUSES DISTRIBUTE 15KV POWER FROM THE POWER PLANTS. 26 SUBSTATIONS TRANSFORM 15KV POWER DOWN TO 4600 OR 2400 VOLT POWER FOR DIVISION DISTRIBUTION. EACH SUBSTATION IS FED FROM TWO DIFFERENT POWER PLANT SOURCES. AUTOMATIC TIES EXIST FOR SWITCHOVER ON LOSS OF ONE FEED TO A SUBSTATION. 230KV TIE LINE WITH GULF STATES UTILITIES. TIE LINE TRANSFORMER STEPS THE VOLTAGE DOWN FROM 230KV TO 15KV. TIE LINE TIES INTO THE GENERATOR BUS AT POWER 2. JlH III //> COHIMIDI CHT DO A 121200 CONFIDENTIAL RIVER WATER WEAK BASE ANIONS LOUISIANA DIVISION WATER TREATMENT SIMPLIFIED FLOWSHEET J CLARIFIERS \ POTABLE WATER GRAVITY FILTERS PROCESS WATER DISTRIBUTION STRONG ACID CATIONS REGEN WITH HCL REGEN WITH NaOH STRONG BASE ANIONS PRESSURE <upFILTERS CONDENSATE RETURNS TO BOILERS .s DO A 1 2 1 2 0 2 CO NFIDENTIAL CAUSTIC ROAD J ) A 121203 C O N F ID E N T IA L DO A 1 2 1 2 0 4 CO NFIDENTIAL .1 canal POAP WATtRlTR&ATINfr BLOCK ta PrKM SWfje Arb| m J J l X- U STORAG-fc 3HOR QFnce COHIROL 'ROOM ji WARLHCWJt. in P1KI Wall ------- - P\RP-uRa*;k. nvtat Ut/tA^TZK tarn tfelvt PIT^C k *P6taqlc. Hio EliJML 43 \ PlPC, Oftc K VI 0 A 121205 CO NFIDENTIAL INSTRUMENTATION & CONTROL POWER 1/UTIL BOILER COMBUSTION CONTROL BURNER MANAGEMENT TURBINE CONTROLS PLANT AUXILIARIES PLANT MANAGER MOD V UTILITIES MOD V ENERGY MANAGEMENT CENTER DO A 1 2 1 2 0 6 C O N F ID E N T IA L CRITICAL INSTRUMENTS POWER 1 BOILER TRIPS FUEL HEADER EBV'S, ANALYZERS ROTATINQ EQUIPMENT TRIPS GENERATOR PROTECTION DISTRIBUTION BUS PROTECTION 2z-n so L ^ ZX CRITICAL INSTRUMENTS UTILITIES WATER WELL ENGINE OIL PRESS 1 WW ENGINE COOLING WATER TEMP, LEVEL i' PROCESS WATER HEADER PRESS EBV'S INTAKE CANAL LEVEL CONTROL INTAKE/RETURN PUMP MOTOR CONTROLS DO A 1 2 1 2 0 8 C O N F ID E N T IA L CRITICAL DEVICES ELECT DIST SUBSTATION BREAKERS, FUSES PROTECTIVE RELAYS SUBSTATION SUPERVISORY DO A 1 2 1 2 0 9 C O N F ID E N T IA L uo A 121210 c o n f id e n t ia l PRODUCTION SUPERVISOREHV. t WATER~ JOE RAUL INKS TREAT. SPECIALIST MARTY MORRISON, ME/EE SHIFT OPERATIONS At M. ZtSINCUE, ss S. L.TLEk,| SOS a. hums, sos C. JOHkSDN, SOS H. ROUSSEAU, OS K. TMERiitT, OS L. BOUQUET, OS Bt C. LASSE I CHE, SS A. ETIENNE, SOS T. FALICE, SOS H. HILLER, SOS C. TUCKER, SOS L. DAVILA, OS A. ANOERSON.OS Ct B. DELANEY, SS D. PATTERSON, SOS K. PRICE, SOS A. STEWART, SOS R. GARNER, OS U. MITCHELL, SOS B. PEP1TONE, OS Ot A. THOMPSON, SS J. LAURENT, SOS L. ROME, SOS F. SOLOMON, SOS L. BOOKER, OS D. BOUDREAUX,OS L. JONES, OS --------------------- 1--------- AREA ENGINEERS GIL WALKER, HE WT GORDON GEOFFROY, HE PI PI UTIL. ROV. OPR. UTIL. A/B RELIEF PI UT PI PI A/B RELIEF PI UTIL.R.O. PI UT C/D RELIEF PI PI UTIL.R.O. WT PI PI UTIL.R.O. PI UTIL. C/O RELIEF NOTE: DOTTED LINE INDICATES COMMUNICATION t COORDINATION POWER 1 C UTILITIES SUPERINTENDENT KEN FOX PAUL ROZAS MANAGER, IHYDROCARBONS G ENERGY PRODUCTION OFFICE ASSISTANT BRIDGET ADAMS ASSOCIATE POWER CONSULTANT, SAN ALLEN,HE PUT TECH CENTER HAROLD CHAGKARO IBE SUPERVISOR kevin taylor' " \ UTIL. DAY SUPV. W. ARRINGTON W.T. SPEC. T. LEBLANC TRAINING SUPV. R. ANSELHO ___ SAFETY SUPV. G. SHUN ___ PLANT li "SUPPORT PHU G. NASSER, EE E. NOSES, EE C. HARPER, SOS POWER 2, ICE B. DUNCAN, EE ELECTRICAL DISTRIBUTION D. CRAFT, EE H. RABORN, SS POWER T, POWER 2, UTIL. ELECTRICAL DISTRIBUTION *-S. SMITH, EE H. BRUNOAGE, EE POWER 2 SUPERINTENDENT BILL SHARKEY ENERGY SYSTEMS MAINTENANCE COORDINATOR ROBIN ROSS, HE MAINTENANCE SUPERVISOR JEFF ZAGONE POWER 1 HAINT. SUPV. GLENN CROUSILLAC 1 NATL. CONTROUt RHETT BRACKIM UTILITIES NAINT. SUPV. JIMMY RILLS MATL. CONTROL!! AVIS HAMILTON A:\ORGCHT.XIS BCA/10/18/91 3.10 3.11 3.12 3.13 SITE STIDIES 3.10.1 STYRENE MTOROCARBONS & ENERGY CAPITAL SPENDING PROJECTS DEMOLITION PROJECTS LAO FACILITIES CAPITAL 3.13.1 PRIORITIZED PROJECT LIST 4.0 COMPANY/CONTRACT 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 BIG THREE INDUSTRIES 4.1.1 NITROGEN CONTRACT 4.1.1.1 NITROGEN INVOICES 4.1.2 OXYGEN CONTRACT 4.1.2.1 OXYGEN INVOICES RILEY STOKER 4.2.1 CORRESPONDENCE AIR PRODUCTS BETZ GENERAL ELECTRIC 4.6.1 T.I.L. (Technical Information Letter) 4.6.2 G.E. CORRESPONDENCE GSU 4.7.1 GSU BILLS 4.7.1.1 AVOIDED COST 4.7.2 CONFIDENTIALITY AGREEMENT 4.7.3 GSU RATE SCHEDULES 4.7.4 GSU FUEL ADJUSTMENTS 4.7.5 GSU SERVICE TO DOU PIPELINE DEPT. BF GOODRICH DEXCO POLYMERS 4.9.1 POUER COST TO VECTOR/TRIBLOCK NALCO 4.10.1 CORRESPONDENCE 5 CORPORATE POLICY 5.1 PROPRIETARY INFORMATION 5.1.1 USE OF FOIA BY DOU 5.1.2 GUIDELINES FOR GATHERING COMPETITIVE INFORMATION 5.1.3 RELEASE OF DOU PROCESS TECHNICAL INFORMATION 5.2 RECORDS RETENTION 5.3 SAFETY l ENVIRONMENTAL RESPONSIBILITIES OF MANUFACTUR1N 5.4 USE OF PERSONAL AUTOMOBILES ONDOU BUSINESS 6 OIVISION POLICIES/PRACTICES 8 PROCEDURES 6.1 AGENDA TOPICS FOR LADMC 8SUNRISE MTG. 6.1.1 FORMS 6.2 GENERAL INFORMATION 6.2.1 VISITORS SAFTEY INDOCTRINATION 6.2.2 SUBSTANCE ABUSE POLICY 6.2.3 OPERATION UPSWING 6.2.4 ENTERTAINMENT _ 6.2.4.1 CANTEEN CORP. (CAFETERIA) 6.2.4.2 APPRECIATION DINNER DO A 121211 CONFIDENTIAL 6.3 COMPUTER POLICIES/PRACTICES 6.3.1 COMPUTER SECURITY 6.3.2 IBM 6.3.3 VAX 6.3.4 PC'S 6.3.5 REALLOCATION OR DONATION OF COMPUTER EQUIP. 6.4 6.5 PERSONNEL 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6:19 6.5.1 PEER REVIEW 6.5.2 HARASSMENT 6.5.3 MILITARY SERVICE BENEFITS 6.5.4 POLICY ON CH1LD8IRTH ABSENCES 6.5.5 FIRST LINE SUPERVISORS POOL GUIDELINES 6.5.6 FLEXIBLE WORK ARRANGEMENT POLICIES 6.5.7 ADOPTION ASSITANCE PROGRAM VENDING MACHINES TELECOMMUNICATIONS TRAVEL/AIRCRAFT INFO SUPPLIER PARTNERSHIP CAR PASSES ACCEPTANCE OF GIFTS 6 FAVORS LITHIUM BROMIDE POLICY LAD EMERGENCY PLAN 6.13.1 CHEMICAL RELEASE CLASSIFICATION SHIPPING/RECEIVING 6.14.1 AIR FREIGHT PROPERTY MANAGEMENT 6.15.1 NORRISONVILLE PROJECT UNITED WAY PROGRAM THEFT CONTROL CONTRACT COWITTEE 6.18.1 COST PLUS APPROVAL REQUEST SECRECY AGREEMENTS 7 ENVIRONMENTAL 7.1 CLEAN AIR ACT 7.1.1 CLEAN AIR/ACID RAIN LEGISLATION 7.1.2 REPORTS 7.2 TOXICS RELEASE PREVENTION ACT 7.3 LAD ENVIRONMENTAL PERFORMANCE 7.4 WATERWORKS WARNING NETWORK PLAN 7.5 ENVIRONMENTAL HIGHLIGHTS 7.5.1 ENVIRONMENTAL MONTHLY REPORT 7.5.2 MINUTES Of ENVIRONMENTAL SUPT. MEETINGS 7.6 ENVIRONMENTAL NOTIFICATION 7.6.1 CALCULATIONS FOR SPIL RELEASE QUARTERLY DETERMINA 7.6.2 SPILLS/RELEASES REPORTED 7.7 ASBESTOS MANAGEMENT MAINTENANCE PROGRAM 7.7.1 PLANNED SHUTDOWN ASBESTOS QUESTIONAIRE 7.7.2 ASBESTOS GASKET REMOVAL LOGIC DIAGRAM 7.8 AIR EMISSION 7.8.1 TASK FORCE: OZONE NON-ATTAINMENT, NOX REDUCTION DO A 121212 confidential 7.9 7.10 7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 7.21 7.22 7.23 7.8.1.1 ADMINISTRATIVE CONTROLS 7.8.2 AIR PERMITTING PRIORITIES 8 TIMING 7.8.3 OEQ CAPIIANCE ORDER 7.8.4 URBAN AIRSHED MODEL 7.8.5 SYN GAS ANNUAL REPORT 7.8.6 FUGITIVE EMISSIONS 7.8.7 EIO REPORTS 7.8.8 HOUSEKEEPING FOR REDUCTION OF ORGANIC COMPOUNDS E 7.8.9 NOX REDUCTION PROGRAM AND TECHNOLOGY LAO PRIORITIES ENVIRONMENTAL ACRONYMS SYNGAS PERMIT MISCELLANEOUS COMMUNICATIONS8 INFO. 7.12.1 DRAGER TUBE SHELF LIFE8 DISPOSAL 7.12.2 DEQ/EMVIRONMENTAL ADVOCATE 7.12.3 DOW WASHINGTON OFFICE PRINCIPAL ISSUES P18U ENV. SAMPLES ENVIRONMENTAL AWARENESS TEAM SARA WATER EMISSIONS 7.16.1 WATER PERMIT EARTH DAY CONSTRUCTION POLICIES 7.18.1 AUTHORIZATION TO CONSTRUCT GROUNDWATER MANAGEMENT PROGRAM 7.19.1 LAD GROUNDWATER ASSESSMENT TSCA (TOXICS SUBSTANCE CONTROL ACT) ENVIRONMENTAL REPORTING REQUIREMENTS 7.21.1 REPORTABLE QUANTITIES ENVIRONMENTAL TECH CENTER - MEMO 7.22.1 TABLE OF CONTENTS 7.22.2 TN 29 CONTINUOUS EMISSION MONITORS (CEM) FOR OXIDES OF NITROGEN FROM COMBUSTION SOURCES TECH CENTER WASTE DATA COLLECTION 8 GOVERNMENTAL 8.1 OSHA 8.1.1 HEARING CONSERVATION-DOW PROGRAM REQUIREMENTS 8.2 PUBLIC UTILITY REGULATORY POLICIES ACT 8.3 U.S. DEPARTMENT OF ENERGY 8.3.1 ANNUAL NON-UTILITY POWER PRODUCERS REPORT 8.4 TAX EXEMPTIONS 9 INSURANCE 9.1 9.2 TRAVELERS - MECHANICAL LOSS CIGNA 10 PERSONNEL 10.1 PERSONNEL FILES 10.1.1 DAILY PERSONNEL SHEETS 10.1.2 TIME INPUT SHEETS 10.1.3 ATTENDANCE AWARDS" 10.1.4 OVERTIME REPORT DO A 121213 CONFIDENTIAL to.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 EXPENSE REPORTS CAR MILEAGE MILITARY LEAVE RANDOM DRUG TESTING JOB DESCRIPTIONS PEOPLE MOVEMENT/ACCOUNT CHANGES VACATION/HOLIDAYS SMOKING POLICY BENEFITS 10.10.1 HEALTH CARE 10.10.2 CORPORATE OWNED LIFE INSURANCE (COLI) OVERTIME GUIDELINES 10.11.1 POWER 1 A UTILITIES 10.11.2 OTHER PUNTS FLEXIBLE WORK ARRANGEMENT POLICIES 11 POWER A UTILITIES 11.1 11.2 11.3 11.4 11.3 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 PAU ACCOUNTING ACTIVITIES 11.1.1 UTILITIES PRODUCTION REPORTS 11.1.1.1 WATER TREATING PROO. REPORT PROGRAM 11.1.1.2 DAILY INPUT SHEETS 11.1.1.3 MONTHLY PRODUCTION SUM1ARY 11.1.2 POWER 1 DAILY INPUT SHEETS 11.1.2.1 POWER 1 INTEGRATOR REAOINGS 11.1.2.2 POWER 1 AUXILLARY INTEGRATOR REAOINGS 11.1.2.3 POWER 1 PRODUCTION REPORT PROGRAM 11.1.3 METERING OF UTILITIES 11.1.3.1 VARIANCE SlMtARY 11.1.4 MANUFACTURING COST REPORT SUMMARY QUARTERLY REVIEW PRESENTATION UTILITIES BALANCES 11.3.1 PROJECTED SYSTEM DEMANOS ANALYTICAL REPORTS HISTORY TRAINING 11.6.1 CONTINUOUS IMPROVEMENT PROCESS (CIP) 11.6.2 DIVISION CROSS TRAINING 11.6.3 LAD TRAINING SCHEDULE 11.6.4 THE LEARNING CENTER 11.6.5 IMPLANT TRAINING IPT PSU GOALS BUILDING RENOVATIONS COMMUNICATIONS TO/FRON PIUCUSTOMERS 11.9.1 NITROGEN 11.9.2 OXYGEN 11.9.3 POTABLE WATER 11.9.4 CENTRAL AIR SYSTEM 11.9.5 ELECTRICAL POWER OFFICE EQUIPMENT/FURNITURE 11.10.1 OVERHEAD PROJECTOR ORGANIZATIONAL CHART SERVICE INTERRUPTION INVESTIGATION REPORTS PROPERTY APPRAISAL _ WATER TEAM EMPLOYEE SURVEYS DO A 121214 CONFIDENTIAL. POWER 1/UTILITIES PROCEDURE INITIATION/UPDATE/APPROVAL POLICY NEW PROCEDURES INITIATED OR PROCEDURAL CHANGES OF ANY KIND MUST BE APPROVED PRIOR TO DISTRIBUTION PURPOSE 1. INSURE ACCURACY AND COMPLETENESS OF PROCEDURES. 2. REDUCE NUMBER OF COINCIDING REVISIONS OF THE SAME PROCEDURE. 3. IMPROVE QUALITY OF DEPARTMENT PROCEDURES. APPROVAL POLICY PRIOR TO DISTRIBUTION OF ANY HEW OR REVISED PROCEDURES, THE PROCEDURES NEEC TO BE REVIEWED AND APPROVED BY ONE OF THE FOLLOWING PROCEDURAL REVIEW COMMITTEES- SAFETY PROCEDURES - PRODUCTION SUPERVISOR - SAFETY SUPERVISOR (OTHER SUPERVISOR CAN BE SUBSTITUTED IN ABSENCE OF SAFETY SUPERVISOR) - OPERATIONS PERSON - SOS OPERATIONAL __QR QUALITY_PROCEDURES - PRODUCTION SUPERVISOR - SHIFT SUPERVISOR - OPERATIONS PERSON - SOS - AREA ENGINEER AS APPLICABLE / DOCUMENTED REVIEW PROCEDURES APPROVED FOR DISTRIBUTION WILL BE GIVEN TO EACH OF THE SHIFT SUPERVISORS FOR REVIEW WITH APPROPRIATE MEMBERS OF THEIR SHIFT TEAMS. A COPY WILL ALSO BE DISTRIBUTED TO THE STAFF, AFTER REVIEWING EACH PERSON WILL INITIAL THE SIGN OFF SHEET FOR THAT PROCEDURE. A FILE OF SIGN OFF SHEETS WILL BE MAINTAINED BY THE OFFICE PROFESSIONAL AS PART OF THE DEPARTMENT FILES. THE NEW OR REVISED PROCEDURE AFTER REVIEW AND APPROVAL WILL BE INPUT TO THE PDP-1144 SO THAT IT IS ACCESSIBLE TO ALL OPERATIONS & STAFF. PROCEDURE QUALITY ALL PROCEDURES SHOULD ADHERE TO THE SAME GENERAL FORMAT AND BE WRITTEN SO THAT A NEW HIRE OR SOMEONE UNFAMILIAR WITH THE Pl&U AREAS CAN UNDERSTAND THE PROCEDURE AS WELL AS THE REASON FOR HAVING IT AND POSSIBLE CONSEQUENCE OF NOT FOLLOWING IT. THE PROCEDURE NEEDS TO INCLUDE: X. PURPOSE 2. SAFETY CONCERNS (SAFETY EQUIPMENT REQUIRED, HAZARDS, REACTIVE CHEMICAL CONCERNS, ETC.) 3. QUALITY CONCERNS (PROBLEMS THAT MAY OCCUR IF PROCEDURE IS NOT ADHERED TO, SPECIFICS, TARGETS, ETC.) 4. ENVIRONMENTAL CONCERNS 5. BACKGROUND INFORMATION OR HISTORY IF POSSIBLE. 6. DATE REVISED AND PERSON UPDATING PROCEDURE. 7. SPECIFICS. DO NOT ASSUME ANY PART OF AN OPERATION IS "UNDERSTOOD IF SOMETHING IS STANDARD OPERATING PROCEDURE, DOCUMENT THAT IN TH PROCEDURE. IDENTIFY THINGS SPECIFICALLY BY NAME OR DESCRIPTION A NUMBER. A:\3292PRO.DOC PI o p g OVEf'VI EL.J CHLORINE RECTIFIERS! STEAM OTUVERRBVINIEEW OILER VERVIEU RAN BRNG TEMPS PUMP BRNG TEMPS MINI MUM L OhQS ISSott ST 473# ST TRB #1 TPB # BLR #1 BLR #2 HIGH PRESSURE HEATERS SAFETY VmLVES ; FUEL ENERGY REPORT | PICTURE KRftCTTC- 33# S'l 30# ST ! TRB #3 TPB #4 BLR #3 BLR #4 PHONE DIRECTORY * UTILITIES I PRODUCT I SPECS | PWR 1 AIR SYSTEM UTILITIES SAFE WORK PROCEDURES CONDENSATE SYSTEM . 4 HYDROGEN _SYSTEM 1 POWER ONE I SAFE I Wf?RK * |PROCEDOHES DO A 121216 CONFIDENTIAL VESSEL ENTRY PROCEDURES BOILERS STARTUP,-SHUTDOWN BOILERS TESTS' DOILEPS j MI SC !_______ i e:l.ectrical LU STRIBUTION DEAERATOR S TURBINES PROCEDUREsI HOUSE KEEPING AREAS ! MODIFYING i LOAD i SHEDDER TIE LINE OPERATING DISCIPLINE } i ORGANICS. ANALYZER BOILERS BURNERS BOILERS INSTRUMENT GENERATORS POWER PLANT ELECTRICAL BUS 4 FUJI BKR ALARM PROCEDURES COMPUTER ROOM FIRE FLAN ENVIRON MENTAL DO A 121217 CONFIDENTIAL CEOfOLlDLECr' O1NDSITThIOPNT-UF FROn BOILER,NO. 3 START-UP FROM COLD CONDITION .* t BOILER SHUTDOWN PROCEDURE / \ ISOLATING BOILER NO.1 FOR [ I. INSPECTION AND'OR OVERHAUL o ISOLATING BOILER NO. FOR INSPECTION AND' OR OVERHAUL o ISOLATING BOILER NO. 3 FOR INSPECTION hND'"GR OVERHAUL o BOILER 4 SHUTDOWN PROCEDURE % O; BOILER 4 START-UP iron cold coNcyrrioN .. - ,r~--v BOILER 3 SHUTDOWN PROCEDURE u -O ISOLATING BOILER NO. 4 FOR INSPECTI ON AND-"OVERHAUL i \ BOILER START-IJP PROM I I COLD CONDITION BOILER SAFETY DEVICES i i V, v BOILER ENTRY PERMIT L o`jv PILLING BOILER 3 f S. FILLING BOILER 4 C\ BOILER ONE SHUTDOWN 1 m - s**. 'SB, D0 A 121218 CONFIDENTIAL POWER DEPARTMENT APPROVED SAFE WORK PROCEDURES BOILER 1 LIGHT-OFF FROM COLD CONDITION , BOILER PROCEDURE NO. A-l BOILER CLOSE-UP AND PREPARATION PROCEDURE 1. INSURE ALL PERSONNEL ARE OUT OF BOILER; YELL INTO EACH OPENING AMD EXAMINE INTERIOR WITH FLASHLIGHT BEFORE CLOSING UP. ADVISE CRAFTSMEN SUPERVISOR OF THIS PROCE DURE AND THAT HE IS, TO MAKE.A HEAD COUNT OF HIS PEOPLE. POWER SUPERVISOR IS TO DO THt SAME FOR POWER DEPARTMENT PERSONNEL. 2. ASK AN INSTRUMENT MAN TO -iJAKE SURE THAT ALL SWITCHES AND RELAYS RELATED TO THIS B071-ER ARE ENABLED IN THE MODICON. 3. STARTING?-AT TOP OF BOILER, INSPECT EACH ACCESS DOOR IN CLUDING TOP AND BACK OF ECONOMIZER SECTION, ACCESS TO SUPERHEATER SECTION, PENTHOUSE, ETC. , FOR SCAFFOLDS, LADDERS, TOOLS. IN9BRE EVERYTHING IS REMOVED BEFORE BO ILER ACCESS DOORS ARE CLOSED. INSURE ALL ACCESS DOORS ARE CLOSED AND TIGHTLY BOLTED- 4 INSUREifeTHAT ALL RED TAGS HAVE BEEN PROPERLY RELEASED, CLEARED, AND REMOVED. SAFETY CONSIDERATIONS FOR BOILER START-UP 1. ABOVE PROCEDURES COMPLETED. - tsE-' 2. ALWAYS TRICKLE FEED BOILER WHEN BRINGING IT UP. OVERHEATING THE ECONOMIZER FROM LACK OF FLOW COULD CAUSE A RUPTURE. 3. ALWAYS USE IGNITORS FOR LIGHTING BURNERS. NEVER TRY TO IGNITE FROM HOT BRICK WORK tJR ADJACEN^EBURNERS. 4. OBSERVE FIRES CLOSELY DURING PRESSURE RAISING. 5. MAKE SURE ALL GAGS ARE REMOVED FROM SAFETY VALVES. 6. WEAR NOMEX SUIT WHEN LIGHTING GAS BURNERS. 7 TRIP BOILER AMY TIME WATER LEVEL DROPS OUT OF SIGHT IN GAUGE GLASS ~ PRIOR TO LIGHT OFF C0O0NFf1t 0ENTTftL BUkiN Tlj riwi- wATr\ LtVEu UPON CCNTIHuEC HEATING fill with MAKE-UP, NOT DEMIN, BECAUSE MAKE-UP WATER HAS A LOWER 02. OPEN THE FOLLOWING VALVES. _____ A. EYE-HYE WATER COLUMN AND DRAIN BLOCK VALVES (AT DRUM). _____ B. DRUM VENTS. (2 TURNS) _____ C. SUPERHEATER OUTLET VENT. (FULLY OPEN) D. EAST St WEST SUPERHEATER DRAINS ON DRAIN MANIFOLD (FULLY OPEN) _____ E. DRUM PRESSURE GAUGE. _____ F CONTINUOUS 3L0WDQWN VALVES ( AT THE DRUM ) _____ G CHEMICAL FEED VALVES. _____ H. FL.QW AND PRESSURE TRANSMITTERS. I. ECONOMIZER INLET. _____ J. DRAIN ON BOILER SIDE OF MOV FOR BOILER STEAM LEAD LINE. _____ K. FLASH TANK BY-PASS. _____ L. DRUM LEVEL TRANSMITTERS. _____ M. ALL BLOWDOWN VALVES. _____ N. AUTO BLOWDOWN SLOCK VALVES. _____ 0. H. P. H. FEEDWATER B. V. 'S CLOSE THE FOLLOWING VALVES: _____ A. GAUGE GLASS WATER COLUMNS AND DRAINS. _____ B. ECONOMIZER DRAIN (AT DRAIN MANIFOLD). _____ C. FEEDWATER MOTOR OPERATED SHUTOFF VALVE. _____ D. 2" MANUAL FEEDWATER BY-PASS VALVE. _____ E. FEEDWATER MOTOR OPERATED BY-PASS VALVE. _____ F, AUTO BLOWDOWN VALVE AND SHUT-OFF. _____ G. 4" FILL VALVE ON S. H. OUTLET HEADER. _____ H. CONTINUOUS BLOW DOWN GRADUATED VALVE. 1. FLASH TANK B, V. AND STM. B. V. TO DEAERATORS. PLACE SUPERHEATER DAMFER IN 100*/. POSITION. (ALL FLUE GAS THROUGH THF. PRIMARY SUPERHEATER) PLACE AIR PREHEATER BY-PASS DAMPERS IN OPEN POSITION. OPEN ALL BURNER AIR REGISTERS. CLOSE ALL BURNER GAS COCKS. TURN ALL BURNER GAS SWITCHES AND IGNITOR SWITCHES OFF. INSURE THAT OUTLET DAMPERS ON FD FANS ARE OPEN AND LOCKED IN POSITION. INSURE THAT FLEXIBLE CONNECTOR IS REMOVED FROM 5. H. OUTLET HEADER FILL VALVE AND PLUG IS INSTALLED IN GRALOCK FITTING PRIOR TO LIGHTING OFF BOILER. START EDTA AND CQRTRCL PUMPS AND SET FOR NORMAL PROJECTED BOILER LOAD INSURE Tm-t INSTRUMENT AIR 13 TURNED ON TO FAN VANE OP ERA? r.'S ' -n ) DO A 121220 CONFIDENTIAL i ESTABLISH NECESSARY AIR FLOW FOR PURGING (APPROX. 60V.) C. . "VALVES CLOSED" LIGHT ON. THE FOLLOWING VALVE SHOULD BE CLOSED: IGNITOR SSO GAS SSO 3. DISABLE DRUM LEVEL TRIP SWITCH " LOW DRUM TRIP " LIGHTS SHOULD- FLASH. 4. ESTABLISH AMD MAINTAIN APPROX. 40# GAS PRESSURE ON GAS LINE. 5. SET MIN GAS FLOW CONTROL VALVE AT 20*/ ON MANUAL. 6. "OPEN CV" LIGHT FLASHING. 7. OPEN GAS CONTROL VALVE. 8. "OPEN SSO" LIGHT FLASHING. 9. OPEN GAS SSO VALVE. 10. "GAS SSO OPEN" L.TGHT ON. 11. BURNER HEADER PRESSURE (25#) MUST BE ESTABLISHED WITHIN 30 SECONDS THEN GAS SSO VALVE CLOSES AUTOMATICALLY. 12. CLOSE GAS CONTROL VALVE. 13. "PURGE ON" LIGHT ON; HEADER PRESSURE PROVING; AIR PURGE ON; GAS HEADER FRESSURE MUST REMAIN A30VE 10 PSIG FOR 5 MINUTES TO CONTINUE. 14 AFTER A 5 MINUTE DELAY, "OPEN SSO" LIGHT FLASHING. 15. OPEN GAS SSO VALVE. 16. "GAS SSO OPEN" LIGHT ON. 17. BURNER HEADER WILL PURGE 2 MINUTES. 18. "END PURGE" LIGHT ON. 19. ADJUST AIR FLOW TO APPROX. 25*. IF AIR FLOW IS ALLOWED TO DROP BELOW 2D7. PRIOR TO LIGHT-OFF, BOILER WILL TRIP. 20. RESET ALARMS AMD TRIPS. 21. OPEN IGNITOR SSO HEADER VALVE. 22 "L.. 0. READY" LIGHT ON. SAFETV TRIP CHECKS (ROUTINE) J3E MGDICON T"Tp CHECK' .ITT D0 A 121221 CONFIDENTIAL A Sr'1-" uF- TV ICKLS FEr.0 TO 0=UM AND OPEN SLOWDOWN VALVE= WHEN DRUM LEVEL DR0F3 TO -10". GAS SSO VALVE SHOULD CLOSE. n REPURGE BURNER LIGHT-OFF (TYPICAL FOR #1 IGNITOR) 1. AIR FLOW SHOULD BE 25%; CLOSE AIR REGISTERS ON BURNERS TO EE i_I7 4Om * "L. 0. READY" LIGHT ON 3. TURN IGNITOR SWITCH #1 TO ON POSITION, 4. WHEN IGNITOR LIGHTS, OPEN REGISTER TO AEOUT 107.. IF IG NITOR FAILS TO LIGHT, TWO MINUTE FURGE IS REQUIRED. AFTER TWO MINUTES, "L.0. READY" LIGHT IS ON AND IGNITOR IS READY TO BE TRIED AGAIN. ON THE FIRST IGNITOR ONLY, THE BOILER WILL TRIP AFTER UNSUCCESSFUL FLAME DETECTION ON THE SECOND TRY. THIS WILL REQUIRE RE-PURGING OF THE BOILER. AFTER A FLAME IS ESTABLISHED, IGNITORS MAY BE TRIED OVER AND OVER WITH ONLY A TWO MINUTE DELAY BETWEEN TRIES. 5. IGNITOR LIGHT WILL REMAIN ON AS LONG AS IGNITOR FLAME IS PROVEN. BOILER LIGHT-OFF (GAS BURNER): (TYPICAL FOR #1 BURNER) NOTE. MAKE SURE WINDBOX IS NO HIGHER THAN 2# PSI TO MINIMIZE BLOW BACK OF GAS THROUGH BURNER GUN. 1. TURN GAS BURNER SHUT-OFF VALVE SWITCH TO OPEN AND HOLD UNTIL "VALVE OPEN" LIGHT COMES ON, THEN RELEASE SWITCH. AO. . OPEN GAS COCK ON #1 BURNER, WHILE ADJUSTING AIR REGIS TER 3. IF FLAME FROM BURNER IS NOT PROVEN WITHIN 4 SECONDS, BURNER SSO VALVE WILL CLOSE. 4. "FLAME ON" LIGHT IF FLAME IS PROVEN; IGNITOR WILL SHUT DOWN (5 SECOND DELAY). IF NO IGNITORS ARE LIT, THE IG NITOR HEADER VENT WILL 3E OPEN; THEREFORE, IT IS BEST TO EITHER HAVE AN IGNITOR LIT OR CLOSE THE IGNITOR SSO VALVE. 5. PUSH DIFFUSER IN UNTIL IT GLOWS. THEN BACK IT OUT UNTIL THE GLOWING STOPS. 6. CLOSE ALL REGISTERS EXCEFT ON BURNER LIT AND THOSE DI RECTLY ABOVE. AFTER FIRST BURNER IS LIT ADJUST MINIMUM PRESSURE FOR 2-3* 'is i DO A 121222 CONFIDENTIAL THROTTLING THE SUPERHEATER VENT AND/CR ADJUSTING MINIMUM BURNER PRESURE REGULATOR. 2. INSPECT FURNACE FREQUENTLY,FOR PROPER COM3USTION. 3. TRICKLE FEED BOILER WITH 1-1/2" BY-PASS AND CONTINUE UNTIL BOILER IS ON THE LINE TO PREVENT WATER FLASHING IN THE ECONOMIZER. 4. BLOW DOWN FRONT AND SIDE HEADERS EVERY 20 MINUTES FOR FIRST TWO HOURS OF FIRING AND EVERY 30 MINUTES THER EAFTER UNTIL BOILER IS ON THE LINE. (OPEN AS FAST AS POSSIBLE AND CLOSE AS FAST AS POSSIBLE) 5. AS BOILER STARTS TO STEAM* SNUG UP ON HANDHOLE AND MAN HOLE COVERS IF GASKETS HAVE BEEN REMOVED. 6. INSURE THAT CONTINUOUS BLOW-DOWN BLOCK VALVE AT FLASH TANK IS CLOSED AND BY-PASS IS OPEN. RAISING STEAM PRESSURE: 1. SET EDTA PUMP STROKE AT MANUAL PROJECTED 30ILER LOAD AND START PUMP. 2. AT 25 PSIG* CLOSE DRUM VENTS AND THROTTLE SUPERHEATER VENTS 3. WHEN BOILER REACHES 500# AND AT 100# INTERVALS THEREAFTER CLOSE SUPERHEATER VENT FOR 15 SECONDS AND THEN OPEN WIDE FOR SURGING THE SUPERHEATER TUBES TO AID IN REMOVAL OF CONDENSATE. 4. BEGIN WARMING BOILER STEAM LEAD LINE FROM HEADER TO NON-RETURN* THROUGH LEAD LINE WARM UP BY-PASS AND LEAD LINE VENT. PUT ALL BOILER METERING , ON CRT * IN SERVICE. 5. ROTATE #1* #2* #3. #4, AND #5 BURNERS EVERY HALF HOUR TO CLEAR CONDENSATE IN SUPERHEATER TUBES BEING CAREFUL TO OBSERVE PROPER PROCEDURES AS DESCRIBED IN SAFE WORK PRO CEDURE C--1. 6. WHEN FLOW OF STEAM EMITTING FROM LEAD LINE APPEARS TO BE DRYING OUT, ADJUST VENT VALVE TO MINIMIZE FLOW ALLOWING LEAD LINE TO PRESSURE UP. 7. PUT POWER ON MOTOR-OPERATED VALVE ON BOILER LEAD LINE AND FEEDWATER LINE. 8. WHEN DRUM PRESSURE REACHES 1200 PSIG, HAVE LEAD LINE PRESSURED AND WARMED UP AND OPEN NON-RETURN. INSURE ALL TUBES ARE CLEAR OF CONDENSATE. TUBE METAL TEMPERAURES SHOULD NOT EXCEED B75-9C0 DEGREES F. 9. RAISE BOILER PRESSURE BY INCREASING GAS OR CUTTING 3ACK ON SUPERHEATER VENT. HOLD BOILER LOAD AT 50 TO 60M/# HR. FOR 15-30 MINUTES AS A PRECAUTION AGAINST CONDEN SATE REMAINING IN SUPERHEATER TUBES THAT DO NOT HAVE THERMOCOUPLES. 00 A 121223 CONFIDENTIAL 1. CLOSE DRAIN AND VENT VALVES. CLOSE SUPERHEATER DRAINS. 2. GO TO MAIN FEEDWATER REGULATOR AS SOON AS PRACTICAL. 3. ADJUST SUPERHEATER DAMPER TO OBTAIN MAXIMUM OUTLET STEAM TEMPERATURE NOT TO EXCEED 950 DEGREES F. PLACE DAMFER CONTROLLER IN AUTOMATIC AS SOON AS P0SSI3LE. 4. CLOSE AIR PREHEATER BY-PASS DAMPERS WHEN OUTLET FLUE GAS TEMPERATURE FROM THE PREHEATER REACHES 212 DEGREES F. 5. AFTER ALL T. C. 'S INDICATE THAT THE SUPERHEATER ELEMENTS ARE CLEAR OF CONDENSATE, INCREASE BOILER LOAD TO 100M#/HR AND RUN AT THIS LOAD FOR AT LEAST TW0<2) HOURS 3EF0RE INCREASING LOAD. 6. INSPECT BOILER THOROUGHLY FOR LEAKS, SIGNS OF UNEVEN EX PANSION, PROPER COMBUSTION, ETC. 7. AS SOON AS PRACTICAL, PUT COMBUSTION CONTROL ON AUTO. AND ENABLE DRUM LEVEL TRIP. 8. INSURE THAT BLOCK VALVES IN FEEDWATER MOTOR-OPERATED BY-PASS LINE ARE OPEN AND ALSO THAT STAND-BY GAS REGULA TOR IS READY FOR SERVICE. 9. OPEN BLOCK VALVE TO FLASH TANK AND CLOSE BY-PASS. 10. CLOSE IGNITOR SSO VALVE AS SOON AS ALL BURNERS ARE LIT, OR AT LEAST ONE IGNITOR IS NO LONGER REQUIRED. 11. OPEN C. B. D. GRADUATED VALVE 2-3 TURNS. REV:04/24/91 TF DO A 121224 CONFIDENTIAL PRESSURE FILTER PLP-4100 INTERNAL INSPECTION RE: Vessel entry procedure for pressure filter Willie Arrington Scott Davis Jimmy Rills Gill Walker Plater Gooden 1. Enter backwash step(246) with DM(246). 2. Enter wait step(241) with DM(241). 3. Enter maintenance step(240) with DK(240). 4. Drain unit by opening vents on each end of filter and open rinse valve DO(244). 5. Close and red tag manual inlet block valve (valve #1 on photo and yellow tag on valve). 6. close and red tag manual outlet block valve (valve #2 on photo and yellow tag on valve). 7. After unit is drained close rinse valve DO(244). 8. Close and red tag air supply to unit. 9. Check dbl. block and bleed for leakage. a. Blind vessel if valves leak through b. Red tag blinds 10. Contact Plant Security prior to entry. 11. Have vessel entry bag on job site. 12. Have qualified safety observer. 13. Check vessel for oxygen and combustibles. 14. Make on site inspection. 15. Issue permit and begin work. DO A 121225 CONFIDENTIAL TEAIt'D DATE DAYS, NIGHT BOILERS AND AUXILIARIES /f<A 4 - Sfig/6/Jtiks A J* S&dtfT &lTSi ~&xdb ^ ~- -TL^ jrfass/u -< ^ 4^ ^ ^ -ZfJ% _ 6*6 tM*? & ikuJ &a -... ......... I TURBINES AND AUXILIARIES vm /&A, 44JJ&i jjtA^i} UTILITIES AND POWER 2 *r,,r T,^*Zr f go vf>1 <*" "*i4^faUts /3!uru9 <!-slaSa;*, L*/ //. 2~ DIVISION LOADS AND PLANS /^sagg' f j-> &taa&z> ds&tf mtyC&s %&#&. 7 W *tT- EOUIPMENT TO BE SHUTDOWN. STARTED UP. OR RED TAGGED lSLl PUNCH LIST 1. .Afietf tqif 2. '7//1f///i^* a*rf 'TZistji. A 3. MA /Lntss/&T75Zv 4. 5. 6. ~7. .8 9. 10. MTSC. INFORMATION 21.. 3. 4. 5. 6. .7. 8 " 9. 10. DO A 121226 CONFIDENTIAL Attn: Ken Fox, Joe Rawlings, Gordon Geoffroy, Marty Morrison Date: 2 TEST -PH_________ Conductivity BFW #1 /o. / 6/ TEST RESULTS #2 #3 /os Jo4 /Z5~ /0<f #4 /o.o 76 Phosphate Steam Rate K#/Hr. Acct/Target BP, qpd Acct/Target CT, and Dissolved Oxvoen fait* P)Aj ?./ /US' 369 489 /5 *13^^ ^ns+t3 20 $-o ___~o-0 3.H jo.85' ;/. 2- &3Z 909 ZO^-^ ^^B'7 ^w> 7.0 --"`tf.ft ^^7.2 BP P-1B (Tank 6805) CT 778P (Tank #8685) BP 78101 INVENTORY (GALS) 2jO<JC .iaz<=L. * />rc> FEEDRATE (GPD) /7* V 13 REMAININ * ru Comments: ---------- AL* / i/iou^g_ I'UrfT' AtT- S /l & + l itf A -.f - , CtO . AP 79t$ 2. )a77*cc. jFm&L QAtukrat- SGstxms...4evr>*uwD t*V -A/*CJ5 ----------Tgrtwu/^ Wi La. Gnn/'tutuuiZ--Feit. Itiff MSIVT u*ui ---------- vwu**tn,, *s -.TXrOmitm ; Arr lAStrt^ J Per* ~6P fi-t6 - JZ0O re TZvK. ,,#_, , /*--7p_jEaafe_* ,,&6JB.EZ------------------------ ________________ .__ ______ ,____________________ ___ _______ -;V.V / J1-. /fe.. jg/sc*ni4B". u/ Ja* %aHs*u, .cv/UM^cr .,, A*72JjQL . j i-____ <aA->*r t^ts- _____thaTX3d*t A/HM. ****** y*y /it/ Anum <Jifw <tuj/w ___ _-- Signed: DO A 121227 CONFIDENTIAL