Document ZnGvO8L01Dk6LQMj17XDN4eqV

CHEMICALS INTEROFFICE / LAKE CHARLES TO FROM Distribution Ben Reynolds DATE February 7, 1984 SUBJECT Incident at VCM-II At 21:01 on 2/6/84, deluge valve #9 tripped on high vapor. Within the next six (6) minutes, vapor detectors throughout the VCM-II process area, OHC area, and VCM bullet area alarmed at levels of 402 LFL. The ambient air monitor report detected high VCM levels throughout the plant (including the control room air intake) with the time of maximum VCM concentrations ranging from 21:05 to 21:08. All of the air monitor points except one averaged 1.5 ppm or higher for the day. The operators reported a large low-hanging vapor cloud passed through the area, emanating from the scrubber, through OHC and the bullet areas. The National Weather Service recorded winds of 5 MPH from the southwest for 9:00 PM on February 6. The incident occurred shortly after the EC plant was shut down. VCM-II HC1 production (from VCM) and consumption (to OHC) had been essentially balanced. When EC shut down, 50-60 TPD of HC1 was put to the VCM-II atmospheric scrubber. Apparently a good bit of VCM had been put into the header during the upset at VC-I earlier in the day. Whe$ the vinyl hit our scrubber, it vaporized rapidly. The demister was torn apart and blown out the top of the scrubber in many pieces. The scrubber will be inspected during the upcoming outage to assess further damage. At 9:00 AM on 2/7, the scrubber boot was still completely iced up, indicating that it was still completely full of liquid VCM. We were very fortunate the cloud did not find an ignition source. /bjm ATTACHMENTS Air Monitor Report PLC Message Report VCM-II OHC Logbook Entries r. ortiz P. Trew SL 049472 fp^ Or % CorOc . ,l'1 AVERAGE VC AREA readings MONITOR !T, T "'mtt;Tt': - '.A' prarasWirv'irMJU. :r^t0^pJ:^xP` V;T^'-t*r'5' '''' ''* . 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M>fiV X*- ' <> ^ ` tj jt _ y-'3.; r ;, /; - - i 't; ..l.a: 1 :*> v 1 J-; .'v ` * 'j- \tf* * W i -tfL- f'- VAPOR DETECTOR 211 01 VAPOR DETECTOR 21S01 -jmPQfi._I>ETCT0R_2U 01 VAPOR DETECTOR 21 *01 43.3 47.0 51,2. 58.7 * 1 t > i, w u w~ w Mh U N UUU -- * - - - - - --- DELUGE DV"? CONFIRMED OPEN . 6B-13 THROUGH 1?t DOW FURNACEt AND SHIFT STG SCS BYPASSED .FURNACE AREA 6Arl THROUGH 8 AND SCS.SYSTEM BYPASSED______ VAPOR DETECTOR 21 02* 06,2~ VAPOR DETECTOR 21 02 13.2 V.AP QR--B-E.T ECT.QR .21 02 .20,5.. VAPOR DETECTOR 21 02 27.9 VAPOR DETECTOR 21 02 35,2 V.A FlQ_R_DE.T ECXD R_ 2.1 0.2 -42j6. VAPOR DETECTOR 21 02 49,3 VAPOR DETECTOR 21 02 52.5 VAPCRDETECTOR 21 .02 . 55,7VAPOR DETECTOR 21 02 58,9 VAPOR DETECTOR 21 05 38.8 VAPOR DETECTOR 21 07 ..28, ? VAPOR DETECTOR 21 07 36,2 VAPOR DETECTOR 21 07 41.7 -HYDR0SH1ELD/REF--AREA -6A^9/.12 AND-FURN- SCS -BYP-ASSEDVCM/EDC SOUTH AREA 6A-14 BYPASSED VCM/EDC MID AREA 6A-15 THROUGH 17 BYPASSED .UCM/EBC NORTH ..AREA _ 6 A".18__THRQUSH--2Q_ BYPASSED_________ CONTROL ROOM VAPOR DETECTOR 6A-24 BYPASSED LAB FRESH AIR VAPOR DETECTOR 6A-23 BYPASSED _SQU-TH..PROCESS AREA..JL(1W-__________________ _ . _A/_ ________ HIGH TRIP INITIATED TO DELUGE DV-6 GUCHIGH TRIP INITIATED TO DELUGE PV-7 OtfC -.HIGH TRIP..JNin.A.TElL_T.Q^EUUGE.^lLV^a^<C.--.M^!.______ DELUGE DV-8 CONFIRMED OPEN DELUGE OFF DV-7 THROUGH DV-14 _12.. SUT.TQHGEAR_.ROOM JJ1H_______________________ _______ __________ 12 SUITCHGEAR ROOM HIGH TRIP INITIATED HIGH TRIP INITIATED TO DOW FURNACE 12 OHC REACTOR 21 *12 04,0 VAPOR DETECTOR 21 *55 14.1 ------ M- -OHC-REACTUR-21*59-----4?. 0 12 OHC REACTOR 21*59 54.1 22J00 02/HCL FLOW RATIO WARNING NORTH PROCESS AREA LOW -SCS OFF-KEYED BYPASS---------------SCS SYSTEM OFF KEYED BYPASS 12 OHC REACTOR 22!14 SCS KEY BYPASSED H OHC REACTOR 22*31 SCS KEY BYPASSED - tl-0HC-RSACT0Jr22T3 B' "SCS" OFF KEYED "BYPASS------------------------------------------------------------------------ 12 OHC REACTOR 22*38 29.6 SCS SYSTEM OFF KEYED BYPASS VAPOR DETECTOR 22142 13.6 FURNACE AREA 6A-1 THROUGH S AND SCS SYSTEM OFF BYPASS "493----------------------------------------- " VAPOR DETECTOR 22J42 23,7 HYBROSHIELD/REFER AREA 6A-9/12 AND SCS OFF BYPASS VAPOR DETECTOR 22142 31.3 VCM/EDC SOUTH AREA 6A--14 OFF BYPASS _____ "VAPOR' DETECTOR"22T42---- 38T3----- VAPOR DETECTOR 22J42 45.7 VCM/EDC NORTH AREA 6A-1B THROUGH 20 OFF BYPASS VAPOR DETECTOR 22*42 53.2 CONTROL ROOM VAPOR DETECTOR 6A-24 OFF BYPASS ------ VAPOR--DETECTOR--22T4 3" 00.7 VAFOR DETECTOR 22*43 08.2 "CAB"FRESH" ATR VAPOR" DETECTOR "6A-23 OFF"BYPASS"..................... -- TB-13 THROUGH 19i DOW FURNACEr AND SHIFT STG SCS OFF BYPS 23*00 VAPOR DETECTOR 23*27 05.9 VAPOR DETECTOR -23*33 02.5 NORTH PROCESS AREA LOU NORTH PROCESS AREA LOW 2 ~(o~%f l^J>-f f\Katv 21 OHc. c viC* *' ,>2i *2v *$ ^* fpX^JjljL^- '* UU*. 1 CLfjAx. ^ pv iVvniu-1 s h r-c V< \ v iW u*fO /, Ltj ' yv\Cu^> cr , 4^\5t5- ~b 4v*-v-t. fV (?<//<_ j u. tSjaA-- S'* \JLr4U^^ 'f^tt-S Csfc U*><. 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' J&rtrfu, 0,K . . .7W &zl^ gU^ ^ Vr6? ^WWM- J tCP U0**UL- /W- llk*J*%tMl. IpydljL . J$. 6U*\. st^- //4^0 "< A- l^ld0 (UttJL /L, /6<-i V ^ Xv^ ' , 0 ^7-0 S# Sy,^I/V lrbsL.fi'/Q sc*Ul4ir Pde ni&desP 0 ire*b/2 Szji -fcif (ZPf\ ues^J.f.ei ^ *%4<sZLAkL -7/L.J @)t^/)o-f c4 jql 3o3> 4-^jqI BoHO k d*h fi) f^dei l dru.n^ r\] -dofa odHTr b y CuX /6 fa 2 fafa 0*1 zf dS' fa /Jcl* O #C Rs fpf flisork* j Q) /}JbseriesJ5 could/&/' -A?/0- // 0j!/ *ie\l h*J (^>^/ A d~0 /% f5 O -/rtsiJS AJcsc-roJ'far* 0/1 INDUS! Ml S e INTEROFFICE/LAKf CHARLES TO See Distribution FROM F. Ortiz DATE SUBJECT Location: February 13, 1984 VCM Plant Absorber Upset VCM I Description of Upset; On February 6, 1984 Vinyl Chloride, HC1 and EDC migrated from the VCM I plant absorber into the Plant B HC1 system. Cause; 1. The loss of lean oil to the absorber. Both pumps had mechanical problems. See Maintenance Foreman's report attached. 2. The introduction of VCM rework to the bottom of the absorber. 3. The introduction of recycle from the Product Still into the bottom of the absorber. The VCM Stripper steam flow was off. However the recycle EDC fr m the product still input enough energy to counter-measure the refrigeration available. Only the absorber upper intercooler and absorber condenser was available. The lower intercooler was out for repairs. See the VCM I Foreman's report for details. Duration: The lean oil flow was lost from 11:10 A.M. to 3:50 P.M. The organic evolution is speculated to have occurred from 12:00 P.M. until 3:50 P.M. Quantity: A total of 12.3 tons of VCM migrated from the absorber into the HC1 system. It is estimated that 7.19 tons traveled toward VCM II and 5.104 tons were fed to the Ethyl Chloride plant. See basis for the split in the appendix. Environmental Impact: The VCM that entered the EC reactor left the EC plant as byproducts. No releases to the atmosphere were made through the Ethyl Chloride Plant. The 7.19 tons that traveled to VCM II was distributed as follows: a. It is speculated that approximately 2 tons was fed to OHC reactors, due to the slight unbalance on the HC1 at VCM II. No environmental consequences. Ttev+t'*? , b. Tto-5.19 tons remained in the HC1 system. SL 049477 VCM Plant Absorber UpBet February 13, 1984 Conclusion: Part or all (It is impossible to say for sure) of the 5.19 tons of VCM that remained in the HC1 system as condensed liquid was released when the HCL PCV to the VC-11 scrubber was opened. The PCV opened at 21:01 on the 6th. Some liquid VCM trapped in the host of the scrubber continued to evaporate during the day of the 7th. Recommendations to Avoid Reoccurrence: 1. Review the incident with all VCM plant operators and front line super vision. 2. Have a policy to cut the HC1 flow from the VCM absorbers to the HC1 system should its temperature reach 100 for more than 15 minut s. The policy should be Incorporated in the SOP manual. Warning notes should be installed on the appropriate temperature recorder. 3. The Incident should be Incorporated as part of the regular situation response for the VCM operators. 4. Have the VCM II scrubber inlet boots level switch checked. It did not activate during the incident. / ds Si 04 9vs CHEMICALS f "1 I INTEROFFICE / LAKE CHARLES TO FROM F. Ortiz L. Ware DATE February 7, 1984 SUBJECT Lean Oil Pumps VC I The #1 lean oil pump was pulled at VC I on the morning of 2/6/84. The seal had failed and the EDC that escaped was Introduced Into the bearing housing. The pump repair required a new seal, bearings, gaskets, and oil seals. I was notified of the needed repairs by C. Brazitls prior to 7:30 AM. X responded by borrowing Randy Hutchins, a machinist from J. Warden at VCM II. The pump repairs and installation was complete at 3:30 PM. At approximately 11:00 AM, 2/6/84, I was notified that the #2 lean oil pump had failed. The pump was pulled by R. Burgess. He found that the outboard bearing had frozen up. The necessary repairs and installation was completed on overtime by Burgess at approximately 8:00 PM. F. Ortiz communicated the urgency of the lean oil pumps* situation to me some time near noon on 2/6/84. I relayed this to Hutchins and he responded with a positive effort. /bb CHEMICALS C INTEROFFICE / LAKE CHARLES TO FROM F. Ortiz J, GuBtin February 7, 1984 SUBJECT EC Plant Upset On the morning of 2/6/84, I was informed by the EC operator that he was having problems getting catalyst into the .EC reactor. Several attempts were made to shock the catalyst pot to free the catalyst. These attempts were only partially successful. It is not unusual to experience this type of problem. In addition, an incident that occurred on the previous shift led us to believe the catalyst pot was more than likely plugged. Shortly after the lean oil pump shut down in VC I, the operator cleared the catalyst pot of organics. This allowed him to open the pot and with the aid of a board physically broke the surface crust on top of the catalyst. The catalyst pot was then put back in service and it appeared the problem was somewhat resolved. Several heat peaks were witnessed indicating the reactor was indeed getting catalyst. At approximately 2:30 PM the operator started experiencing what was thought to be catalyst addition problems again. The day operator held over to assist the evening operator in trying to unplug what was thought to be a plugged catalyst pot. Pressure n the EC reactor continued to rise slowly. At 8:30 PM the operator cut feeds from the reactor and put the plant on recycle. Unfortunately, the symptoms of low catalyst levels in the reactor and "foreign" organic feeds to the reactor will be about the same. The vinyl and HC1 mix being fed to the reactor will go to DCE in a liquid bed with ferric chloride catalyst. Any EDC fed will act as a heavy and accumulate in the heavy still. Therefore, with the feed mix we were getting it would be very difficult to determine foreign feeds because they would not appear in any of the "in-plant" analysis we sample for. /bb SL 4948q CHEMICALS (. J % INTEROFFICE / LAKE CHARLES -j-Q FROM F. Ortiz C. Brazitis DATE February 7, 1984 SUBJECT Abnormal Operating Incident On 2/6/84 Situation Prior To Incident: VCM I was processing 115 TPD VC from TE II. The furnaces, quench tower and heavies still are down. Day tank rework is going to the bottom of the absorber. Vinyl production is going into the reworking tank. The product still LCV is in service to the heavies still feed tank. HeavieB feed tank material is being recycled by the heavies feed pumps back to the bottom of the absorber. The #1 lean oil pump was pulled earlier on day shift for a seal leak that occurred on graveyard shift. The #2 lean oil pump was running but it was reported to be tight when first put on line earlier. The HC1 absorbers were consuming VC produced HC1 and VCM I is open to the HC1 system. The lower intercooler is out of service to replace a pump suction valve. Operations relatively stable. Incident; At 11:10 AM the #2 lean oil pump tripped off the line. After quick investigation it was realized that the pump had frozen up and would remain inoperable. At this time the transfer from TE II was backed down over a period of several minutes. Once the transfer was blocked off an attempt was made to line up the off gas from the VC absorber to the scrubber. The HC1 absorbers had been blocked off when lean oil could not be restored. The scrubber was not able to handle the off gas and would pressurize up to 10-15 psig so the off gas was left in the HC1 system. It was thought that at this time there was still HC1 evolution from the system. In fact, the incinerator vent system was tripped by WTU at one point for about 10 minutes and most likely this with the result of problems caused by the high vent load due to scrubbing the off gas. The system was left in the HC1 header. The absorber became relatively hot quickly and by noon the off gas temperature was 85F and still rising. At this time there was an HC1 flow on the chart shoving on off gas flow. Also, the absorber bottoms flow had diminished and was very near non-existent. The product still feed tank level was decreasing and the heavies still feed tank level was increasing. The stripper steam flow had been cut to zero by the automatic temperature control. The absorber eventually leveled off with tray 35 temperature of 136F and overhead tempera ture of 120F. Jhe #1 lean oil pump was finished and given back to Operations at approximately B 30 PM. The pump was put on line at about 3:50 PM. Shortly after this the product still bottoms was routed to the product still feed tank and steam was cut on the product still because of a low level in the still. When the lean oil flow was established the abosrber began to cool off slowly and the Bystem pressure began to fall, eventually reaching a low of 60 psig. The system was # SL 049481 F. Ortiz February 7, 1984 Page 2 blocked off from the HC1 system. As the product still fe d tank level and product still levels were re-established, steam was Introduced back to the product still slowly. Shortly after 4:00 PH the abosrber bottoms flow was re-established bb the absorber cooled off. Steam was put back to the stripper. By 6:00 PM the system temperature profiles were such that some transfer from TE II was started. The system pressure was allowed to come up to 78# and then it was unblocked to the HC1 system. Attachments /bb SL 049482 S C^H s%` i _ 3. fAt ;}? /! At/- i>l* *v# ,*-(# C*ct ^ V J Je-v O^J. pv*eUr*4 C>aJ ^-W ^SIt-W A-/lpV<rk* |\ij S --w 4 V) fw-- 4< L i^i-v^Aiti c 4 &<-cfc ^9 ^W fc-Vf ft^V<v* /I^A 4c/v/ . jt / (/f/Y) j. C ^W# r*fV 3 ... Ai ^-06fc L*te/_^*U*. /^Cy/- i//>m tf `S'* if to - tfVp a t fW-Cl Vvvo*,$ SL 49485 Revised: 12/15/oc ENVIRONMENTAL UPSET REPORT SUBJECT: __ j/^A/Ti ~75 FROM: ZjBrZ#4^ 77 s\/ ROUTING - OPERATIONS . General Foreman Production Superintendent Operations Superintendent Plant Manager Environmental Control m Please complete the following questionnaire and forward as soon as possible. [This report must be received by the Environmental Control Department within five (5) calendar days of the incident.] 1. DATE OF INCIDENT: ___________ 2. SOURCE OF RELEASE: r/M {sju/t 3. TIME AND DURATION: 4. WEATHER CONDITIONS (Circle One): Clear Partly Cloudy Cloudy Rain 5. WIND SPEED AND DIRECTION (if a gas release): mph __________________________ 6. HAZARDOUS MATERIAL RELEASED: 7. ESTIMATED QUANTITY RELEASED: too lbs 8. CAUSE OF RELEASE: <oF Ms<**,*& > stA/a a/&, 7 & c/i&ur 9. IMMEDIATE ACTION TAKEN: 10. ACTION PLANS TO PREVENT REOCCURRENCE: 11. NOTIFICATION MADE (Who, When): /?#/&//? yZ&ttJ 9/to*> ivio~f" v-ea^'W. PC. pl^oj' \jQyj~ iz rep*rh>J )r* FiQ <4-; A- ,)ftvfvp \)ej\. Environmental File 1 received FEB 8 1984 twc- DECEIVED 685,6*o 7S IAH 2 6 1984 ENVIRONMENTAL UPSET REPORT File # Environmental Department fIr Subject: From: Responsible Department Head: M \Jlm ~TC4-Hi Please complete the following questionnaire and forward to the Environmental Control Department AS SOON AS POSSIBLE. j/tf41. Date of incident: __ / 2. Time and duration*/'"' // 5<= to / >' /o ? Aa. (minutes, hours) 3. Weather conditions (circle one): Clear Partly Cloudy ^Cloudy Light Rain Heavy Rain 4. Wind speed and direction:0^A/g" Aa^P j-) 5. Hazardous material released: WoL. 6. Quantity released: Oi\JfCK(.ftvO d -- c^OMtrny <$F ___________________________________________________________ 7. Source of release: ycvuAT 8. Cause of release: ~TTO /xl '~nk&- Tste- fhMuw* SrAgryfl om /feo&S /vvAryg-^ ,.. 9. Countermeasures taken: ArtLPT' ------ r?^~ vArV^ C^(A^> AMO TTfcrl TTCytfTEhkf vi THf^ fl\cJCU(hr .: 10. People/Agencies notified: k levi-V up ^1~~ pi<e 1 P- .// T?^ S=>rf-fFT 06^6^0 7s INDUSTRIES PPG INDUSTRIES, INC. INDUSTRIAL CHEMICAL DIVISION P, 0. BOX 1000 LAKE CHARLES, LA. 70602 January 16, 1984 Mr. Tom Coerver Department of Natural Resources Air Quality Division P. 0. Box 44066, Capitol Station Baton Rouge, LA 70804 Dear Mr. Coerver: RE: EC Plant Vent In accordance with Section 17.11 of the Louisiana Air Quality Regulations, this letter is the follow-up to my telephone report of January 3, 1984, regarding the venting of the Ethyl Chloride process waste gas vent on that date. At approximately 7:30 p.m. on 1/3/84, the EC plant vent was diverted to the emergency scrubber due to plugging of the EC Vent Recirculation Cooler. The cooler is utilized to reduce heat generated during the compression of the vent stream. After many attempts to unplug the cooler, the cooler had to be taken out-of-service and hydroblasted. The cooler remained out-of service until 1/6/84 at 11:30 p.m. From 1/3 to 1/6 the EC process waste gases were controlled by scrubbing with water in a packed tower. During the time that the vents were being scrubbed the amount of hydrocarbons released to the atmosphere has been estimated to be 500 pounds. If you should have any questions concerning this incident please call me at (318) 491-4576. Respectively, Philip S. Trew Environmental Control Specialist cc: Mr. Joe Withers bcc: E. J. Tullier Francisco Ortiz File #109.8 , Revised: 12/15/82 , ^CEIVtb mjan 13 ENVIRONMENTAL UPSET REPORT ROUTING - OPERATIONS General Foreman Production Superintendent Operations Superintendent Plant Manager Environmental Control SUBJECT: FROM: -J <g Pc#*it r/V 75 c- Please complete the following questionnaire and forward as soon as possible. [This report must be received by the Environmental Control Department within five (5) calendar days of the incident.] 1. DATE OF INCIDENT: /'3~8+ T/Safim 2. SOURCE OF RELEASE: fa4A/r 3. TIME AND DURATION: /- 3-*</ ) 7S /-4-A+ 4. WEATHER CONDITIONS (Circle One): Clear (partly Cloudy) Cloudy Rain 5. WIND SPEED AND DIRECTION (if a gas release): mph __________________________ 6. HAZARDOUS MATERIAL RELEASED: _________________________ 7. ESTIMATED QUANTITY RaEASED: .<Tbolbs 8. CAUSE OF RELEASE: ___________________________________ 9. IMMEDIATE ACTION TAKEN: ZJfur lM*rr C+~i/>****** 4*0 10. ACTION PLANS TO PREVENT REOCCURRENCE: /2oujt>4j Ct&tA/ 4tAs/-r / A .11 NOTIFICATION MADE (Who. When): p. 7^ Dh/R , FC uerJ'l' Wi^ 'ip 'r<LP<r`~ ujAs 'Ke FTO PtoL/Lmv /r o i2 Environmental File # & SL 049491 fLc r" t