Document ZnxReQkBqLe4ao6ozz2M0dmVZ
Page No. 09/08/87
1
Review Itei
ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEN SEPTEMBER 1, 1987
Concerns
Action
Date
A
Propane Systew-Tank5 and Vaporizers
Catalyst Freezers
Bleeder Valve Program Emergency/Disaster Plan Eaergeney/Disaster Plan Power Failure Procedures
H Electrical equipwent not 1) Project 8SX cowplete.
12/31/87 TFL
explosion proof t instrument Existing sequencer obsolete so
revisions needed.
ordering new one.
2) Material of construction of 2) Transfer pumps are ductile 02/03/87 TFL
transfer puaps.
iron which are acceptable.
3) Rewote shutdown
3) AFE approved June 11. Nov. 11/15/87 TFL
capabilities. 4) Full port sight glass in
15, 1987 startup time. 4) Eliminated sight glass but 02/03/87 JNE
unloading systew.
retained flow indication.
(Bate with external lever
which rotates with the gate).
5) Absence of leak detection 5) Project complete and
08/12/87 TFL
system in sphere and boiler operational.
area.
&} Use of the direct fired
6) Having another natural gas / / JHN
vaporizers as backup. The
supplier will eliminate the
direct fired vaporizers are need for the direct fired
for emergency use only and
vaporizers.
appropriate safety
revisions must be made before
use.
7) Guardposts protecting the 7) Project complete and
08/12/87 TFL
unloading station and pump
operational.
pad.
1) Insrumentation PM needed. 1) Up to date except will
/ / TFL
start yearly control system PH
and calibration il-E
supv.). To be done during
August and October
shutdowns.
2) Backup temperature
2) Installed and operational 02/03/87 DNH
indication.
in little freezers,
3) Honitoring by operations 3) A-operator logsheets have 08/20/87 DNH
been revised and are being
used.
4) Emergency plan does not exist for freezer failures
4) P. Engineering will investigate.
09/30/87 HLN
5) Extended power outage,
5) Project complete and
08/12/87 TFL
operational.
1) Program not up to date.
1) Program is up to date but 09/28/87 HLN
the surveys are not. Plan and
surveys up to date by 9/87.
1) Plant preparedness.
1) Plant emergency plan
12/31/87 KLF
revision is complete.
Community awareness Plan in
progress.
2) Community Awareness
2) Community awareness plan is 12/31/87 KLF
in progress.
1) PH of AHS system valves and 1) PH determined adequate. See 01/29/87 TFL
instrumentation.
attached PH sheet from
01/29/87
meeting.
VAB. OOO1128293
Page No. 09/08/87
2
Review Item
ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW SEPTEMBER 1, 1997
Concerns
Action
Date Resp
VCM Sphere/Unloading Area
2) Eaergency generator PM.
2) Same as number one.
01/29/87 TFL
3) Reactor T/P chart drives 3) Installed - will be
12/31/87 SK6
not on eeergency power.
operational with new module
shutdown in
September.
4) Fire puap run lights.
4) Installed and operational. 02/03/87 REP
51 Instrument air pressure
51 Have requested funding for 12/31/87 REP
indicators not on eaergency additional 120V supply. No
power.
spare 110V available.
61 Reactor aechanical seal
6) Bladders in both reactor 02/03/87 JME
integrity.
aodules are installed and
operational.
7) Eaergency equipaent -
71 Estiaate coaplete by 8-31. 0B/31/87 REP
diesel supply.
8) Operator training on
8) Training is coaplete.
02/03/87 JHE
reactor aechanical seal power
failure
procedures.
1) Need to "mothball* bullets. 1) Vapor phase corrosion
02/03/87 TFL
inhibitor has been injected to
coaplete aothball plans.
21 PM on unloading compressor 2) Annual PM and docuaentation / / TFL
shutdown instrumentation
of pressure and temperature
(temperature 1 pressure
switches is planned. See
switches).
attached PM sheet from
01/29/87 meeting.
31 Compressor belt drive PM. 31 A aonthly check of belt
/ / TFL
tightness will be aade and
documented. See attached PM
sheet froa 01/29/87 aeeting.
4) Development of effective 41 Completed and implemented. 02/03/87 TFL
railcar chock.
5) 6rounding system upgrade 51 6rounding bolts in plant to 09/30/B7 DAM
be installed as 2nd quarter
1967
maintenance budget
item. Project to be complete
9-87.
6) Routine inspection of
61 On chief operators
02/03/87 DHH
sphere transfer pumps and of checklist (once/shift).
the tandem seals required.
71 Shere puap cavitation problem may cause puap
7) Under evaluation by process 08/30/87 MLN engineering. To be complete
failure.
8-87.
8) Remote operated valve installation and
81 This project is part of the 09/30/87 F6J other Remote Operated Valve
instrumentation.
Project. Waiting for VCM
sphere shutdown. Installed &
operational by 9-87.
91 Firewater supply to railcars may be inadequate.
9) Determined inadequate. 4th fiscal quarter 19B7 budget
/ / JSC
itea.
VAB. OOO1128294
Page No. 09/08/87
3
Review Itea
ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW SEPTEMBER 1, 1987
Concerns
Action
Date Reap
Fire Training Mechanical Seal Systeas
Reactor Relief Valve PH Non-Reactor Relief Valve Fixed Point Monitors P-i PA Tank
10) Redundant level & pressure 10) Part of reaote operated 09/28/87 TFL
alaras for the sphere should valve project. Installed by
be pursued.
9/87.
11) Drain valve on dike area 11) Under evaluation by EBB. 09/28/B7 MLN
left cracked.
Project coaplete by 9/87.
12) Eliainate bullseyes in
12) Process Engineering
12/31/87 MLN
unloading lines.
investigating. A trial device
has been
purchased.
Estisated project coapletion
12-B7.
1) Maintenance involveaent.
1) Personnel have been trained 02/03/87 KLF
and instructed on their role
in a fire.
i) Reactor seal failures
1) Prograa to reduce seal
08/13/87 JME
prevalent.
failures ongoing. Status
report of 7/17/86 latest
update. JME following up.
2) Training on reactor seals 2) Coaplete.
02/03/87 JME
3) Routine inspection of
3) The A" operator check list 02/03/87 J6C
aechanical seals in VCM
has been revised to include
service aay be
inadequate, routine inspection of
aechanical seals in VCM
service due to Subpart V of
the new EPA regulations. (J6C
& JME)
1) Need aaintenance procedures 1) Issued aaintenance PM
02/03/87 TFL
for relief valves.
prograa.
2) Relief valve PM prograa
2) The relief valve project 08/13/87 TFL
iapleaentation and the relief has been coapleted on the 10
valve
project.
reactors.
1) Need non-reactor relief
1) Non-reactor relief valves 12/31/87 DAM
valve prograa.
in both reactor aodules were
serviced during the 8/86 &
9/B6 shutdowns. Plans are
underway to routinely
service all non-reactor relief
valves. To be coaplete 12/87.
1) Line pluggage/leakage aay give erroneous results.
1) Plans to check all 40 points once/year. See attached
//
TFL
sheet froa 01/29/87 PM
aeeting.
1) Tank aay be unsafe due to 1) Preliainary thickness tank condition and/or support. testing on the vessel was
/ / TFL
favorable.
Further
testing will be incorporated
in the Pthalic Anhydride
Fluff Containaent project.
2) PA fluff froa tank -exposure and enviroaental
{3rd Fiscal Qtr. budget itea). 2) Class "A" design (revised) is coaplete & issued. (3rd
//
TFL
problea.
Fiscal Qtr.budget itea).
VAB. OOO1128295
Page No. 09/08/87
4
Review Itea
ABERDEEN CHEMICAL PLANT SAFETY SYSTEMS REVIEW SEPTEMBER 1, 1987
Concerns
Action
Date Resp
Safety Systeas PM (attached) 1) Are listed iteas still being cDepleted.
Gas Detectors in the Dryer 1) Dryer detectors not
Area
operational.
Infrared Surveys of Electrical Equipaent
H Yearly survey.
Aaaonia Systea
1) Annual inspection and relief valve check.
2) Written safety prograa for unloading trucks.
3) Leak patrol.
Reaote Operated Valve Project Sulfuric Acid Systeas
Chlorine Cylinders
Valve Indications
1) Project Caapletion.
1) Procedure on unloading.
2) Training on unloading procedures. 1) Training on use of leak repair kit. 21 Operator training on cylinder handling. 1) Coapliance plan liait switches. 2) 1986 liait switch project
Portable Gas Detectors
3) 1987 liait switch project.
1) Quality of repair inconsistent.
1) Process Engineering will 09/12/87 EBB
aonitor prograa and establish
the routines. EBB is in
the process of putting the
inforaation in the coaputer
for easier access and
docuaentation.
1) Detectors have been
/ / REP
installed. Mechanical will
talk to operationsto decide
when to Bake operational. 1)Docuaentation is up to date.
/!
TFL
Cover letter of each survey to
be sent to process
engineering. (I h E Supv.)
1) Annual inspection will be
/ / TFL
started in 1987. R.V. will be
on a five year prograa. See
attached sheet froa 01/29/87
PH aeeting.
21 The new unloading procedure / / TFL
is still under review. Utility
supv. will take care of
unloading.
3) A detection technique and
/ / TFL
survey procedure are being
investigated See attached
sheet froa 10/30/86 PM
aeeting.
1) Systeas to be coaplete fay 09/30/87 TFL
9-87. 1) Unloading procedure was
m11/13/86
issued 11/13/86.
2) Training has been
02/03/87 DHM
coapleted.
1) Training has been
02/03/87 TFL
coapleted.
2) Training has been
09/01/87 HHM
coapleted.
1) Project installed and
02/03/87 TFL
operational.
2) 46 of 46 liait switches are 02/03/87 TFL
installed and operational
which
coapletes this
project.
3) Class 'A* design coapleted. Bent to aechanical. (2nd Str.
/ / TFL
1968 budget project).
1) 2 training sessions have 02/03/87 TFL
enhanced the repair quality.
VAB. OOO1128296
Page No. 09/08/87
5
Review Itee
ABERDEEN CHENICAL PLANT SAFETY SYSTEMS REVIEW SEPTEMBER 1, 19B7
Concerns
Action
Date Resp
VCH Piping I & E Alare and Shutdown Interlock PM Prograe
Incinerators VCH Recovery Systeas
2) Water condensation on the detection head. 3) Test procedure.
4) PM is done weekly.
U Baurdposts to protect VCM piping
concrete west side of road passing with curb. 2) Protection against overturned railcar.
1) Boilers-coeplete once/year
2) Solved using aabient
02/03/87 TFL
teaperature charging cabinet.
3) Operations has been
02/03/87 TFL
provided with HNU test
procedure to coaplete this
itea.
4) Process engineering will be 09/12/87 EBB
getting report to check.
1) Coaplete.
02/03/87 TFL
2) 3rd and 4th rail required/ 09/01/87 DAM
planned. Funded in aaintenance
budget. Installed 9/1/87.
1) Up to date.
02/03/87 TFL
2) Incinerators- coaplete
2) Will start a seai-annual 01/01/01 DAM
twice/year
inspection (April and October)
and docuaent it.
3) Eaergency kill systea
3) See attached sheet froa
/ / TFL
twice/year.
01/29/87 PM aeeting.
4) Catalyst freezers-annualy. 4) See attached sheet froa
/ / TFL
01/29/87 review aeeting.
5) Vinyl dryers (rotary and 5) Burner aanageaent systeas
/ / TFL
fluid bed) once per year.
will be done annually and
docuaented. (I6E Supervisor)
6) Propane vaporizers
6) Will be docuaented. PM done / / TFL
once/year.
currently.
7) Inert gas generator
7) PM sheet will be generated / / TFL
once/year.
and PM will be done every
spring and docuaented.
8) Reactor instruaentation.
8) Pressure alaras checked
/ / TFL
once per year and when
reactors opened. Teaperature
systea will be checked
once/year during shutdown V
will be calibrated and
docuaented.
1) PM prograa to check
1) See attached sheet froa
/ / TFL
internals of liquid seal flaae 01/29/87 PH aeeting.
arrestor.
2) Refresher training prograa. 2) Coaplete by
/ / TFL
3) Revise and update
3) Coaplete.
02/03/87 TFL
incinerator logsheets.
1) VCM recovery coapressor
1)
/ / TFL
casings and rotors are being Process/aechanical/operations
daaaged
(severely) by
investigating the problea.
corrosion and/or errosion.
*
VAB. OOO1128297
Page No. 09/08/87
1
Review Item
PREVENTATIVE MAINTENANCE CONCERNS
AND SOLUTIONS FROM 1/29/87 MEETING
Existing PM
Action Coapleted/Planned
Resp
CATALYST FREEZERS
1) Big Freezers
2) Chest Freezers POWER FAILURE PROCEDURES
1) Refrigeration systea
1) Will start yearly control systea TFL
checked weekly. Controllers PM and calibration, and docuaent
checked only if N.O.
written.
2) Checked on shutdown
2) No action needed.
TFL
basis only.
1) AMS Kill Systea.
2) Emergency Generators VCH SPHERE/UNLOADINS AREA
DAnnual PM of entire
11 No further action is planned.
systea during aodule
shutdowns. Operations
checks pot alaras when any
reactor shutdown.
Operations also checks the
valves weekly
21 Large generator is run 21 No further action is planned.
weekly by operations.
Maintenance does aonthly PM
and instruaentation PM.
TFL TFL
1) Unloading compressor 21 T-201 Pressure snitch. 3) Coapressor belt drive PH. FIXED POINT NONITORS
1) No up to date documented 1) Annual PM and documentation of TFL
PM. all pressure and temperature
switches is planned.
2) Done annually, not
21 Will be documented.
TFL
docuaented.
3) None
3) A monthly check will be made for TFL
belt tightness, and it will be
docuaented.
1) 40 Fixed Point Monitors AMMONIA SYSTEM
1) Only checked if a problem is discovered.
11 Will check all 40 points once/year and docuaent (1 6C/quarter).
TFL
11 Annual Inspection. 21 Relief Valve 3) Leak Survey INCINERATORS
11 None 21 None 31 None
11 Annual inspection plan is being TFL determined. 21 Relief valve will be put on five TFL year program. 31 A detection technique and survey TFL procedure are being investigated.
1) Liquid Seal Flaae Arrestor. 1) None
11 Check and document baffle integrity once/year.
TFL
VAB.0001128298