Document dKa2bwG6kRrOKgo3mke384Ee
ESCAMBIA PLANT INTEROFFICE MEMORANDUM
To: Distribution
From: D. C. Fee Ra; Amines Vent Gas Burning
Process Hazards Review
Dote; 6 November 1980
Copies: R- L- Duggan
R. E. Jones T. J. Regan
Please attend a Process Hazards Review on Amines Vent Gas Burning in the B&cW Boiler, held on Wednesday, November 12 at 9:30 a.m. in the Old Administration Building, upstairs con ference room. Attached is an updated PID for your review be fore the meeting.
A
DCFjdl '^Attached drawings
D. C. Fee
Distribution:
J. Adams R. B. Chandler * D. R. Emert* J. R. Evers*
D. W, Henn* W. T. Johnson* J. R. Walsh *
AP00036320
A c^c^T^oe&ietl and G^e^mca&-
ESCAM8IA PLANT
INTEROFFICE MEMORANDUM
To: Distribution
from 0- C' Fec
Re: No. 1 Nitric Acid Process Hazards Review
Date:
26 November 1980
Copies:
R. B. Chandler G. D. Cooper R. L. Duggan R. E. Jones T. J. Regan
Please attend a Process Hazards Review on No. ] Nitric Acid, held December 3, 4 and 5 from 8:00 a.m. - 4:00 p.m. in the Old Adminis
tration Building, upstairs conference room.
DCF :dl
Distribution:
J. Adams W. M. Brown J. R. Evers D. W, Henn W. D. Henry H. H. Newsom
D. C, Fee
AP00036321
To From
INTEROFFICE MEMORANDUM
Distribution
M. R. Chmura
DISTRIBUTION;
R. R. Baker R. L. Duggan L. S. Forrester J. W. Gentile
A. K. McMillan R. W. Ormsby G. E. Pareja
Subject
Date
THR Teams
3 October 1980
(Location, Oranlcationt or Department)
Chem Hfo - Trexlertown
(Location, organization, or Department)
Please consider attached memo from J. Sykes when you are assembling PHR Teams for reviews scheduled at your faclltly.
MRC/na Attachment
m7 R. Chmura
(320)
AP00036322
INTEROFFICE MEMORANDUM
Date 30 September 1980
Subject Process Hazards Reviews j
ToM. R. Chmura__________________________________ From______J. A. Sykes__________________________
cc: ICT Management
Chemicals Manufacturing
(Location, Oroinuation, or Dtpjrtmont)
Ind. Chetn. Technology
(Location, Orpareintlon, or Oapartmcnt)
Using Table 1 of your 25 September memo on "Schedule-Process Hazards Reviews Chemicals Group - Existing Facilities", I have recommended staff or contacts within Industrial Chemicals Technology for providing technical representation to the PHR teams.
Please keep me informed of the teams and technical staff needs to carry out these PHRs.
JAS/st Attachment
fe. A. Sykes
i> (320)
AP00036323
SCHEDULE FOR PROCESS HAZARDS REVIEWS CHEMICALS GROUP - EXISTING FACILITIES
25 SEPTEMBER 1980
Fad 11ty/Process/Product
Escambia - Area MB" (AN, Urea, etc.)
South Brunswick - Ethylene Handling, Raw Material Handling, Balance of Plant
Escambia - Methanol Project
Escambia - Higher Amines, Amines Storage and Handling
Calvert City - Pipeline Systems
Escambia - Nitric Acid #1 (1)
Escambia - Methanol (existing) (2)
Calvert City - PVOH
Escambia - Amnonia (2)
Paulsboro - Catalyst Plant, Utilities and Waste Treatment
Escambia - Nitric Acid #2 (1)
Escambia - Ammonia Recovery and Storage
Calvert City - Emulsions (Remainder of Plant = A.F. #1 and #2)
Escambia - Boilers and Utilities
Pasadena Nitric Acid (1)
Escambia - Waste Treatment
Pasadena - Pipelines, Strippers and Utilities
Calvert City - Boilers and Utilities Cleveland - RP, Methanol Handling,
Utilities and Storage Pasadena TDA
Dates Scheduled 17 Oct. 80
27 - 31 Oct. 80 28 - 31 Oct, 80
* ffjJL VVuyyifv* .
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10 - 14 NOV. 80 10 - 14 Nov. 80
1-5 Dec. 80 8-12 Dec. 80 12 - 16 Jan. 81 2-6 Feb. 81
Uvr^ 13a ^
* Plift TiHWHUor ^ GAL
Hi JG
2-6 Feb. 81 2-6 Mar. 81 4 - 8 May 81
Vh'cr Ttawpis'Joe
15 - 19 Jun. 81 6-10 Jul. 81
13 - 17 Jul. 81 13 - 17 Jul. 81
TfrVstfrues1 4- Jexrw^
10 - 14 Aug. 81 10 - 14 Aug. 81
24 - 28 Aug. 81 7-11 Sep. 81
a?- \U
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AP00036324
(2) '
Facl Hty/Process/Product Calvert City - Catalyst Plant Escambia - Methyl amines City of Industry - Total Plant
Dates Scheduled 7 - 11 Sept. 81 7-11 Sept. 81
14 - 18 Sept. 81
w
On Hold: Calvert City - PVC Escambia - PVC
Notes: (1) Use common team members (2) Use common team members
AP00036325
A&$k7%odic& cutei C&emicti$-
ESCAMftIA PLANT
IftlC.
INTEROFFICE MEMORANDUM
To: R. E. Jones
From: Re:
D. D. Hurder
Process Hazards Review No. 2 Amines Plant
Dote:
4 December 1980
Copies: G. D. Cooper WO/A L. S. Forester WO/A
Attached is a copy of the recommendation section of the process hazards review. Please review the recommendations and relay any questions or comments you may have so they can be addressed by the hazards review committee. A formal transmittal of the recommendation will be made after
your comments have been addressed.
The recommendations are rated on a priority basis of 1 to 5 with 1 being items of highest priority. The severity of a hazard has been rated as high, medium or low, where:
High Severity Medium Severity
A hazard which may cause a lost time accident or an excessive property loss.
A hazard which may cause damage to equipment or an injury other than lost time.
Low Severity
A hazard which may cause minimal property damage.
The probability of a hazard has also been rated as high, medium or low, where:
High Probability
A hazard which has occurred in the past or requires only one primary cause.
Medium Probability A hazard which requires a combination of two primary causes.
Low Probability
A hazard which requires a combination of three or more primary causes, or one or more secondary causes.
DDH:ms
D. D. Hurder
AP00036326
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Category: f ^Equipment Changes I ^Procedural Changes, Inspection & PM rterns f (Eng Studfes I /Rejected
Status as offlecaaber
1, 19___ SO
Page 1 of___ ^Pages
Management
Action
Needed
Action Items from Hazard Review
ZO
Hazard
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Responsi bility
Recommendations
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1 Chemical release resulting from M H 1 incomplete combustion of an un controlled surge to the flare.
2 Vehicles driving over the flare line could cause the line to
rupture.
H M1
3 High temperatures in the gas fired heater could cause coil
failure.
H H1
4 The vent line on storage tanks 68202, 205, and 206 can be booked in, eliminating any means for pressure relief.
H M1
5 Vessel rupture of the low pressure absorber.
HM1
6 The recirculation line between H L 2 the low pressire absorber cooler
and its absorber can be blocked in causing overpressure in the cooler.
7 600 psi steam can be added to the separation column reboiler causing vessel rupture.
HM2
Emert
Emert Emert Emert Emert Emert
Emert
Install a properly designed flare with adequate safety controls.
Barricade the make shift road passing over the flare line.
Upgrade the heater controls to meet minimun requirements.
Remove the block valve between the tank and the seal pot.
12/81 3/81 12/81 5/81
Pressure rate the low pressure
12/81
absorber and install a relief vldlve.
Remove the block valve between f'e cooler and the low pressure absorber.
6/81
Remove the 600 psi jumper line : r 12/81 rerate the reboiler to 600 psi.
Action Status
Remarks (Include Estimated Costs) $50,000 No cost $20,000 No cost
$2,000 No cost
A new reboiler rated at 600 psi is on order.
Category: fx jEquipment Changes [~ lProcedural Changes, Inspection 1 PH Items | |Eng Studies 1 [Rejected Action Items from Hazard Review
^ ^December Status as of;1, HT P9C of j Pages
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Action Status
Management
A c tio n
Needed
Hazard
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Recommendations
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8 Cooling water on exchangers can H L 2 be blocked in causing over pressure and possible rupture of the lines and/or exchangers.
Emert
A relief valve should be placed on the cooling water lines for all exchangers.
12/81
9 Loss of ttie nitrogen blanket on the 116 tanks could cause a vessel to collapse from vacuum.
10 Vacuum can cause collapse of tank 68213.
11 Uncontrolled fire in the gas fired heater.
12 A flame can back up the vent of the product storage tanks.
H M2
H M3 H H3 K L3
Emert
Emert Emert Emert
Provide vacuum relief for all 116 tanks.
L2/82
Provide vacuum relief for tank 213.
12/82
Install a steam.snuffer in the gas fired heater.
12/81
Install flame arresters on all
12/SI
storage tank vents to the atmospherje
13 Purap/motor failure can cause overheating and possible fire
in process lines.
H L3
Emert
Install discharge pressure gauges L2/81 on all pumps.
14 Vehicles in the area could strike equipment located adjacent to the roadway.
15 Inadequate dykes may not restrain a liquid spill.
M L3
Emert
M L4
Emert
Install an access gate on the road 5/81 by the converter.
All dykes that are not in good repair should be upgraded.
12/82
16 Employee,'exposure to hazardous process chemicals.
KH4
'Emert
All sight glases should have drain: 12/82
and all pressure gauges should hav< bleeds.
Remarks (Include Estimated Costs) $5,000
$30,000 $2,000 $20,000 $25,000 $10,000 No cost $50",000 + on-going major maintenance. $10,000
AP00036328
Category: | X (Equipment Changes | [Procedural Changes, Inspection & PH Items j " " ^
ng Studies I (Rejected
`Status as ofjfecsnber--
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AP00036329
Category: 1 jEgulpment Changes 1 x" |Procedural Changes, Inspection & PM Iteas I ^Eng Studies l'~~]ReJected Action Items from Hazard Review
-Status as of___j2ecsnbL_J > Page 2 of____ j^Pages
Action Status
Management
A c tio n
Needed
H^zard
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Responsf* Wtty
Recommendations
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Chemical release due to incom plete maintenance
MM3
Emert
All work permits should be
1/81
signed by production personnel
after visual Inspection and approv .
of the work.
2 Lack of operator knowledge about the fire water system could delay efforts to control a fire or chemical spills.
MM2
Emert
A diagram of the fire water pro-' tection system should be posted In
the control room and covered in shift safety meetings.
3/81
3 A chemical release can result
fron poor welds on pipes and equipment.
MM3
Emert
A small percentage of all new main 1/81 tenance welds should be x-rayed.
A hydrogen leak in the area of the gas fired heater could
cause an explosion.
HL 3
Emert
All flanges in the immediate vicinity of the gas fired heater should be bubble tested for leaks while on nitrogen during start-up.
1/81
Chemical spills or unwanted
MLS
chemical mixing could occur
from an Incorrectly turned blind.
Emert
A blind list should be prepared an 6/81 a systematic method of changing
lines during turnaround should be studied.
6 The dirt and sand that is cover- L M 4 ing the sleeper racks by the 10 track loading rack can
accelerate corrosion and cause a chemical spill.
Emert
The sleeper racks should be kept clpan of'dirt and sand.
6/81
Remarks (Include Estimated Costs) No cost No cost S5,000/year No cost
No cost No cost
AP00036330
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Category: j (Equipment Changes I 1 Procedural Changes, Inspection 4 PH Items | x |ng Studies 1 IRejected
Status as of December Pago 1 of____ 3_Pages
I,' ISM
Action Itens from Hazard Review
O
Hazard
ResponsfHI tty
Recommendations
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1 Overpressure in vessels
causing rupture.
HH1
Forester
The relief valve slzfng verifi
12/82
cation program should be institute^
This should include checks of reli
valve piping supports, outlet pipiji
and valve sizes.
It may be possible for process chemicals to back up Into the nitrogen system.
HM2
Emert
A hazards review should be perforn - 12/81 ed on the nitrogen system.
It was not known if the dis tillation columns are vacuum rated.
HL3
Cooper
All columns should be checked for 6/81 vacuum rating. ,
Uncontrolled fire In the area. H L 4
Henry
Review the fire water protection for the area.
3/81
Internal vessel fire from a static charge
HL4
Cooper
a) Determine if all top loading
storage tanks are equipped with dip tubes and install vrtiere needed.
6/81
b) The grounding system in the plant should be checked to Insure that all equipment is
, properly grounded.
c) Determine the conductivity for the major No. 2 plant chemical
6 A hydrogen release from the recycle compressor could be ignited by an internal com
bustion engine in the area.
HL3
Emert
The procedure for allowing internal 6/81 combustion engines in the area should be reviewed.
Action Status
Remarks (Include Estimated Costs) No cost No cost No cost No cost No cost
No cost
Management
A c tio n
Heeded
M-1
\Category: 1 [Equipment Changes
{Procedural Changes, Inspection & PM Items | X |Eng Studies I Rejected
'Status as of December Pgc 7 of____ 3j>ages
1 IS
Action Items from Hazard Review
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Response htltty
Recommendations:
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7 The high pressure absorber knockout pot is rated at a lower pressure than the high pressure absorber and must be pressure relieved through the high pressure absorber.
HL3
Cooper
Upgrade the knock out pot to the same pressure rating as the high pressure absorber.
3/81
8 The lines in the vicinity of
ML4
the high pressure absorber can
be overpressured if during shut
down the lines were closed and
the caustic feed left on.
Cooper
Insure that the caustic line
6/81
pressure does not exceed 330 psi.
9 The pressure rating of the ammonia column preheater
bonnet, and channel cover was not known.
ML4
Cooper
Oetermine the pressure rating of the channel and bonnet.
6/81
10 The alkyl preheater must be vented through the alkyl
vaporizer in the event of an overpressure.
HL4
Cooper
Determine if a relief valve is
3/81
required for the alkyl preheater.
11 Imbrittlement of the coil in the gas fired heater can cause a line rupture;
HL4
12 The compressor can overheat and bind up from a loss of cooling water.
Ml 4
Eroert/ Dean
Cooper
Investigate the possibility of
6/81
hydrogen imbrittlement. For IBN
production determine if there is
any possibility of zinc imbrittl en: it
being caused by the zinc oxide cat lilyst.
Investigate a cooling water failure for the compressor.
6/81
Action Status
Remarks (Include Estimated Costs) No cost
No cost
No cost
No cost $5,000
NO COSt
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04
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04
04
Category: | ^Equipment Changes | |Procedural Changes, Inspection A PM Items j X )cng Studies
{Rejected
Action Items from Hazard Review
status as of December
Page
_of____ j_Pages
1, ISO
Action Status
Management
A c tio n
Needed
Hazard
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13 An overpressure may occur in the vessels due to the heat of mixing of two chemicals.
HL5
14 A flaauiafale atmosphere could
Ht5
occur in the equilization tanks
after a dehydration column upset.
IS Catalyst dust during converter H L 5 charging could be toxic or cause an explosive atmosphere.
Cooper Cooper Cooper
Quantify the heat of mixing for the major chemicals used in the Mo. 2 plant.
6/81
Quantify the possibility of a
12/81
flammable atmosphere being formed.
Investigate the toxicity of the
catalyst dust and the possibility of a dust explosion.
12/81
Remarks (Include Estimated Costs) No cost No cost No cost
AP00036333