Document jNQXDRbK1vd8zM8ZV4Q6xLrVp
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page I
VIII. LOSS PREVENTION INSURANCE REPORT (Including F&EI Risk Analysis)
Contact your Loss Prevention Contact for instructions to assist you in filling out this document.
(Revised 02/18/94; cmk) 1/8/97; LAD:bwb
DO a 036985 O0NFTDFNTTA1
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page II
LOSS PREVENTION INSURANCE REPORT II. UNIT LOSS PREVENTION INFORMATION
1. Summary of Unit Features and Status
Area/Country North America
Site Plaquemine Unit Superintendent G. C. LeBlanc
Division Louisiana
Unit Chlor-Alkali 2
Location
Date
Piaquemine, LA
1-6-97
Building Number/s
Date of Previous Inspection
3601
10-28-94
Type Of Operation
Manufacturing - Chlorine / Caustic
Inspected By (from Safety & Loss Prevention) Buck Bailey
Inspected by (from Plant) John Dizor
Give a written summary including overall evaluation comments, comparison to previous inspection, and summary of
recommendations:
(Revised 02/18/94; cmk) 1/8/97; LAD:bwb
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page III
LOSS PREVENTION INSURANCE REPORT
2. Summary of Ratings and Recommendations for Unit
UNIT RISK FEATURES
3. Plant Condition and Appearance
4. Unit Risk Analysis Package
5. Changes Since Last Inspection
6. Features for Areas in Unit
7. Drainage and Containment
8. Tank Storage
9. Electrical & Instrument Conditions
10. Chemical Inventory & Isolation
11. Management Considerations
12. Plant Reliability R = Recommend Upgrading
F = Fair
G = Good E = Excellent
R F G E N RECOMMENDATION A NUMBER(S)
NA = Not Applicable
Refer to Guideline for definitions of ratings. For recommendations see Pages
Give a brief narrative background summary including history of unit with details on age, construction phases, original plant, etc. Chlor-Alkali 2 was started up in 1969 as a completely integrated chlorine/caustic production facility. The original plant has a two (2) rectifier/circuit operation with M-80 vintage cells.
The 1970's New liquefaction train installed and started up.
The 1980's Hydrogen collection trains installed and started up.
MOD 5 control system installed on cell area. New ecology system with WP-800 and D-803 above ground tanks installed. Chlorine evaporation train installed. Bird centrifuges replaced flatbed filters for sulfate salt removal from caustic.
The 1990's Completed MOD 5 conversion of chlorine and caustic areas. Sodium bisulfite replaced sodium thiosulfate for hypochlorite reduction in cell effluent. Electrolytic metals removal cells (iron cells) shutdown and demo'd. Eliminated C-201-B, spare dry chlorine compressor. Replaced CTW interstage coolers with air cooled fin fan interstage coolers. New R-123 freon system. Sped chlorine compressor, C-201A, gear box up. Demo'd weak sulfuric acid tanks (D-210, D-211). New vacuum breaker, VRD-201, replaced old vacuum breaker. Replaced brine salt column, D-108.________ ____________ _______________________________________________
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Rebuilt Sump-1.
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LOSS PREVENTION INSURANCE REPORT
3. General Unit Information
Plant Unit
Chlor-Alkali 2__________________________________
Unit Products
Chlorine (gas & liquid), 50% Caustic, and Hydrogen
Raw Materials
Brine, Fuel Gas (Methane), Cell Effluent, Hydrochloric Acid, Sulfuric Acid
Operating Days/Week?
7
Operating Hours/Day?
24
No. of Shifts?
2
Date
1/6/97
Hours per Shift?
12
Plant Condition & Appearance - Description
Operationally plant condition is acceptable, although, corrosion in the plant is noticeable in some areas. An active maintenance painting program is in place to address this situation.________________________________________ __
4. Unit Risk Analysis Package
Items which must be attached as part of Risk Analysis Package (Check if attached/Give any explanations)
Block Flow Sheets
OK
Process Description
OK
Plot Plan with Areas of Exposure and Protection Features
OK
F. & E. 1. Risk Analysis Summary
OK
F. & E. 1. Calc. Sheets for Highest MPPD and Highest MPDO & Bl
OK
C. E. 1. Summary Sheets
OK
Business Interruption Data
OK
Replacement Value
$99 MM
Interdependencies with Other Dow Facilities & Which Facilities?
Brine is supplied by Brine Production 30 miles south of Ptaquemine. Hydrochloric acid is supplied by Solvents. Chlorine
1 supplies sulfuric acid via pipeline. Fuel gas is supplied by Power & Utilities via pipeline. Chlorine 1 supplies some cell
effluent, the rest is produced internally. Chlorine 1 takes all chlorine (gas & liquid) and hydrogen to distribute. Caustic 1
takes all 50% caustic to distribute.
____
Interdependencies with Non-Dow Facilities - Raw Material supplier, Utility Supplier, Final Processing, Sole Supplier, etc.
Power can be supplied by the outside grid. Hydrogen to distribute is sent to Air Products just outside the Dow fenceline
via pipeline from Chlorine 1.
Spare Parts Available for Critical Equipment? Which Critical Equipment?
Yes
List Top 3 Critical Items 1. C-201A 2. C-520 3. RT-1/2 A/B
Spares Available? Yes
5. Changes Since Last Loss Prevention Inspection
Significant Changes to Plant Since Last Loss Prevention Inspection? Any Incidents Since Last Inspection?
Eliminated undersized spare chlorine compressor, C-201B Sped up chlorine compressor gearbox, GR-201A Replaced cooling tower water / chlorine cross exchange interstage coolers with air / chlorine fin fan interstage
coolers New R-123 freon system No incidents._______________ ______________________________________________________________________
Management of Change Program Established?
Yes, in compliance with US Area standard and LAD supplement.
Significant Capital Projects in Progress or Planned? Give Title and Amount of Capital.
CA-2, Gas Turbine Control System
$1,500 M
CA-2, Acid Area Upgrade
$ 846 M
CA-2, First Effect Cross Exchanger
$ 300 M
L/P Review Done/Planned?
Done Done Done
Date?
11/96 7/96 7/95
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LOSS PREVENTION INSURANCE REPORT
6. Features for Areas in Unit
REFER TO PLOT PLAN WHICH IS TO BE ATTACHED.
FEATURE AREA
X
Caustic Area
Power Area
Cell Area
SEPARATION PER LPP 2.2?
YES
NO
YES
(CHANGE TOP HEADING NAME IF NEEDED.)
Chlorine Hydrogen Ecology Warehouse
Area
Recovery
Area
Area
YES NO
YES YES
Office/ Control Room
YES
FIRE WALLS FOR
SEPARATION?
HOUR RATINGS?
PERCENT OF PLANT
20
30
25
15
5
2
1
2
VALUE?
STRUCTURE AREA?(sqft)
130,800 29.5%
108,000 24.3%
67,200 15.1%
50,400 11.4%
24,000 6.4%
26,400 6.0%
4,800 1.0%
32,400 7.3%
STRUCTURE HEIGHT?(ft)
50 40 15 50 30 50 30 15
NUMBER OF
3 22434 1 1
OPERATING LEVELS?
TYPE OF CONSTRUC TION? (COMBUSTIBLE OR NOT?)
OPEN OR CLOSED CONSTRUCTION? (PERCENT OPEN?)
FIREPROOFING USED? (TYPE?)
NC OPEN
NC OPEN
NC OPEN
NC OPEN
NC OPEN
NC OPEN
PARTIAL PARTIAL CLOSED CLOSED
DELUGE & DRAINAGE IN
LIEU OF FIRE
PROOFING?
SPRINKLER
C-201A
SYSTEMS?
WATER
DELUGE
SYSTEMS?
FOAM
SYSTEMS?
AUTOMATIC OR
MANUAL
MANUAL TRIGGERING
OF SYSTEMS?
HYDRANTS
NO YES YES NO YES NO NO NO
IN AREA?
FIRE WATER
NO YES YES NO YES NO NO NO
MONITORS?
INERTING
Steam in
N2 Purge N2 Purge N2 Purge
SYSTEMS?
turbine
tunnels
FIRE EXTINGUISHING
Halon in
SYSTEMS? (COjHALON,
Computer
ETC.)
Room
OTHER FIRE
Smoke
PROTECTION SYSTEMS?
detectorsComputer
and Lunch
____________________
Rooms
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HO A 036990 CONFIDENTIAL
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page VII
1 OTHER SYSTEMS?
YES
YES
YES
YES
YES
YES
YES
YES
SPECIFY.(portable flra
I extinguishers)
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7. Drainage and Containment
Type of Impoundment - Remote Pit Vs Dike
Dike
Volume per LPP 7.6.2.G?
Yes
Testing of Drainage System? Yes
Firewater Containment Considered? N/A
Tank separation distances per LPP 7.6.6? Yes
Worst Rainfall Considered? Yes, 24'/24hrs
Open Trenches or Closed Drains? Open Trenches
Plans/Equipment for emptying Pits/Dikes? Yes
Drainage Away from Tanks & Equipment? Yes
Vapor Suppression of Pit/Dike using Foam? Available from Fire Protection Dept.
Impervious Containment Surfaces? Yes
Operating Discipline to Keep Pits/Dikes Empty? Yes
8. Tank Storage
Types of Tanks (Press. Vessels, Atm. tanks, etc.) Pressure Vessels and Atmospheric Tanks
Redundant High Level Alarms?
Yes
Pressure Relief? PSV's, open vents, seal pots
Codes Observed(A.P.I., A.S.M.E. U.L., T.U.V., etc.) API and ASME
Interlock Between High Level Alarms & Pumping? No
Vacuum Relief? VRD's, open vents, seal pots
Vessel Registration Program? Yes
With Inspection & Testing? Yes
Pressure Vessel Relief Registration? Yes
With Inspection & Testing? Yes
9. Electrical and Instrument Conditions
Electrical Classifications Areas Well Defined?(See LPP 3.1)
Yes
El. Classification Drawing Up-To Date? Last Revision Date?
Yes, 12/96
Redundant Electrical Feeds?
Yes
Backup Generators?
No
Grounding with Inspection Program? Yes, 1Q94. 5 year frequency.
Oil Filled Electrical Equipment? Yes
Oil Filled Equip. Indoors or Outdoors? Outdoors
Cable Penetrations Sealed? Yes
Cable Trays Exposed to Potential Fires? No
Cable Trays Sprinkler Protected? No
Type of Process Control MOD Control? MOD S, pneumatic
Process Information Systems? GPI Vax
Periodic Review of MOD Program? Yes
Audits of MOD Program and Alarms? No
10. Chemical Inventory & Isolation
Handling Flammable, Toxic or Corrosive Liquids and/or
Gases
Are There Flammable Liquids/Gases? Yes
Is There Flammable Gas Detection? No
Hazard Ratings Shown on Tanks? No
Are there Toxic Liquids/Gases? Yes
NFPA Ratings or Other Shown? No
Are there Corrosive Liquids/Gases? Yes
Emergency Block Valves
Are EBVs Identified in Drawings?Yes, P&ID's and MOD graphics
Frequency of Testing of EBVs? Bi-weekly
What are they? Hydrogen and fuel gas (methane)
Frequency of Testing Gas Detectors? N/A
What are they? Chlorine
What are they? Chlorine, Hydrochloric Acid, Caustic, & Sulfuric Acid Are EBVs Identified in Field? Partially
Are EBVs Fire Rated in Flammable Service? N/A
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1 Other Special Hazards i________________________________
Any Other Special Hazards which Increase Risk of Operation? No
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LOSS PREVENTION INSURANCE REPORT
11. Management Considerations
Last Loss Prevention Inspection?
11/94
Last Consolidated Audit?
11/94
Other Audits or Reviews of Plant? (e.g. T/C) 6/96 - Tech Center
Implementation of Minimum Requirements? Yes
Emergency Plans Written for Unit? Yes
Written Plans for Fire Protection Impairment? Yes, per LAD S&LP Standard
Operator Training Procedures Written & Current?
Yes
Date of Last Hypothetical Emergency? 4Q96
Critical Instrument Program Established?
Yes
Operating Procedures Written & Current? Yes
Emergency Plans Shared with Other Units & Off Site?
NO
Testing of Critical Instruments? Yes
Preventative Maintenance Program in Place? Yes
Reactive Chemicals Program?
Yes
Date of Last Reactive Chemicals Review? 10/94
Plant Contact Person for Loss Prevention? Gretchen LeBlanc
Contractor Safety Program Established? Yes
Smoking Regulations & Enforcement? Yes, LAD smoking policy
Other Management Programs in Place Affecting Loss Prevention? List - e. g., Fire Protection Inspections, Insurance Inspections
S&LP Audits - LAD C-9 Audit Program Safety Committee . Training - IPT Program MOC Program . Behavior Based Safety Program
12. Plant Reliability
Production Capacity 720.0 MMIbs/yr Chlorine 839.0 MMIbs/yr Caustic
Theoretical Hours/Year for Production Capacity?
Hours/Year Loss Due to Outages or Reduced Rates
Per Cent of Capacity for Year (1996) 102.4% Chlorine 105.6% Caustic
Percent Reliability
(Hours Operation at Theoretical Rate) (Total Hours Available)
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00 A 036994
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page I
VIII. LOSS PREVENTION INSURANCE REPORT (Including F&EI Risk Analysis)
Contact your Loss Prevention Contact for instructions to assist you in filling out this document.
(Revised 02/18/94; cmk) 1/13/97; LAD;bwb
00 * 036995
conftdfnttai
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page II_________ __________________________________
LOSS PREVENTION INSURANCE REPORT II. UNIT LOSS PREVENTION INFORMATION
1. Summary of Unit Features and Status
Area/Country North America Site Plaquemlne Unit Superintendent G. C. Leblanc
Division Louisiana
Unit Caustic 1
Location Plaauemlne, LA
Building Number/s 2901
Type of Operation Caustic Manufacturing
Date 1/7/97
Date of Previous Inspection 2/22/94
Inspected By (from Safety & Loss Prevention) Buck Bailey
Inspected by (from Plant) John Dizor
Give a written summary including overall evaluation comments, comparison to previous inspection, and summary of
recommendations:
(Revised 02/18/94; cmk) 1/13/97; LAD:bwb
00 A 036996 cONFTbFNTTAl
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page III_________ _________________________________
LOSS PREVENTION INSURANCE REPORT
2. Summary of Ratings and Recommendations for Unit
UNIT RISK FEATURES
3. Plant Condition and Appearance
4. Unit Risk Analysis Package
5. Changes Since Last Inspection
6. Features for Areas in Unit
7. Drainage and Containment
8. Tank Storage
9. Electrical & Instrument Conditions
10. Chemical Inventory & Isolation
11. Management Considerations
12. Plant Reliability
R = Recommend Upgrading
G = Good
F = Fair
E = Excellent
R F G E N RECOMMENDATION A NUMBER(S)
NIA = Not Applicable
Refer to Guideline for definitions of ratings. For recommendations see Pages_____________________________
Give a brief narrative background summary including history of unit with details on age, construction phases, original plant, etc.
The Caustic plant was built in 1958 with one (1) evaporator train and a capacity of 100,000 Ibs/day.
In 1967, the second evaporator train was started up and the plant capacity was increased to 1,000,000 lbs/day.
The train 1 evaporators were shut down in 1976.
In 1984, the fourth effect evaporator was installed raising the capacity to 2,100,000 lb/day.
In 1988, an evaporator area capacity upgrade increased plant capacity to 2,500,000 lb/day.
73% caustic production was stopped in 1990.
In 1992-93, a new evaporator cross exchanger and expansion project increased the capacity to 3,300,000 lb/day.
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LOSS PREVENTION INSURANCE REPORT
3. General Unit Information
Plant Unit
Caustic Plant___________________________________
Unit Products
50% Caustic
_______
_____
Raw Materials
Cell Effluent
Operating Days/Week? 7
Operating Hours/Day? 24
No. of Shifts? 2
Plant Condition & Appearance - Description The plant is in very good condition. The product storage tank farm needs a little work on drainage, however.
Date
1/7/97
Hours per Shift? 12
4. Unit Risk Analysis Package
Items which must be attached as part of Risk Analysis Package ( Check if attached/Give any explanations)
Block Flow Sheets
Yes
Process Description
Yes
Plot Plan with Areas of Exposure and Protection Features
Yes
F. & E. 1. Risk Analysis Summary
N/A
F. & E. 1. Calc. Sheets for Highest MPPD and Highest MPDO & Bl
N/A
C. E. 1. Summary Sheets
N/A
Business Interruption Data
N/A
Replacement Value
$82.3 MM
Interdependencies with Other Dow Facilities & Which Facilities?
Steam and power supplied by Power 1. Condensate returned to Power 1. Cell effluent supplied by Chlorine 1.
Interdependencies with Non-Dow Facilities - Raw Material supplier, Utility Supplier, Final Processing, Sole Supplier, etc. None.
Spare Parts Available for Critical Equipment? Which Critical Equipment?
Yes.
List Top 3 Critical Items 1. P-201 2, MP-201 3. P-204
Spares Available? Yes.
5. Changes Since Last Loss Prevention Inspection
Significant Changes to Plant Since Last Loss Prevention Inspection? Any Incidents Since Last Inspection?
Installed HE-201X, evaporator cross exchanger. Replaced primary salt column, D-205. No incidents.
Management of Change Program Established?
Yes.
Significant Capital Projects in Progress or Planned? Give Title and Amount of Capital.
CAU, Tank Farm Sump Upgrade
$145 M
CAU, Square D Switchgear
$350 M
E-201 Replacement (expense)
$4000 M
L/P Review Done/Planned? Planned Planned Done
Date? 3/94
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LOSS PREVENTION INSURANCE REPORT
6. Features for Areas in Unit
3EFER TO PLOT PLAN WHICH IS TO BE ATTACHED. (CHANGE TOP HEADING NAME IF NEEDED.)
FEATURE AREA
X
UNLOAD ING/
LOADING
TANK FARM
CELL
EVAPORA
EFFLUENT
TION
STORAGE
CAUSTIC FINISHING
CAUSTIC STORAGE
WARE HOUSE
SEPARATION PER
Yas
Yes
Yes
Yes
Yes
Yes
LPP 2.27
FIRE WALLS FOR SEPARATION? HOUR RATINGS?
PERCENT OF PLANT VALUE?
4.5%
9.0%
5.8%
47.1%
28.1%
4.3%
0.6%
STRUCTURE AREA? (sqft)
50,000
400,000
163,000
80,000
73,000
41,000
50,000
STRUCTURE HEIGHT? (ft)
20 50 40 80 30 40 20
NUMBER OF
2 1 2421 1
OPERATING LEVELS?
TYPE OF CONSTRUC TION? (COMBUSTIBLE OR NOT?)
OPEN OR CLOSED CONSTRUCTION? (PERCENT OPEN?)
FIREPROOFING USED? (TYPE?)
NC Open
NC Open
NC Open
NC Open
NC Open
NC Open
Partial Closed
DELUGE & DRAINAGE IN LIEU OF FIRE PROOFING?
SPRINKLER SYSTEMS?
DELUGE SYSTEMS?
FOAM SYSTEMS? AUTOMATIC OR MANUAL TRIGGERING OF SYSTEMS? HYDRANTS IN AREA? FIRE WATER MONITORS? INERTING SYSTEMS? FIRE EXTINGUISHING SYSTEMS? (COjHALON, ETC.)
OTHER FIRE PROTECTION SYSTEMS?
OTHER SYSTEMS? 1 SPECIFY.
OFFICE/ CONTROL
ROOM
0.6% 19,500 15 1 Partial Closed
Halon in Computer Room Smoke Detectors
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LOSS PREVENTION INSURANCE REPORT
7. Drainage and Containment
Type of Impoundment - Remote Pit Vs Dike
Dikes
Volume per LPP 7.6.2.G?
Yes
Testing of Drainage System?
N/A
Firewater Containment Considered?
N/A
Open Trenches or Closed Drains?
Open
Drainage Away from Tanks & Equipment?
N/A
Plans/Equipment for emptying Pits/Dikes? Yes
Vapor Suppression of Pit/Dike using Foam?
N/A
Tank separation distances per LPP 7.6.6?
Yes
Worst Rainfall Considered?
Per LAD standard.
Impervious Containment Surfaces?
Block 29 Yes. Tank Farm No.
Operating Discipline to Keep Pits/Dikes Empty?
Yes
8. Tank Storage
Types of Tanks (Press. Vessels, Atm. tanks, etc.) Atmospheric
Redundant High Level Alarms?
Yes
Pressure Relief? Yes
Codes Observed(A.P.I., A.S.M.E. U.L., T.U.V., etc.)
Yes
Interlock Between High Level Alarms & Pumping? No
Vacuum Relief? Yes
Vessel Registration Program? Yes
With Inspection & Testing? Yes
Pressure Vessel Relief Registration? Yes
With Inspection & Testing? Yes
9. Electrical and Instrument Conditions
rr. . , ,
...
. ... TT~ .. 1
^
Electrical Classifications Areas Well Defined?(See LPP 3.1)
i
. ...
_
El. Classification Drawing Up- To Date? Last Revision Date?
Yes Yes
Redundant Electrical Feeds?
Yes
Backup Generators?
No
Grounding with Inspection Program? Yes
Oil Filled Electrical Equipment? Yes
Oil Filled Equip. Indoors or Outdoors? Outdoors
Cable Penetrations Sealed? Yes
Cable Trays Exposed to Potential Fires? No
Cable Trays Sprinkler Protected? N/A
Type of Process Control - MOD Control? No TDC, Vax, Modicon
Process Information Systems? Vax
Periodic Review of MOD Program? No
Audits of MOD Program and Alarms? No
10. Chemical Inventory & isolation
Handling Flammable, Toxic or Corrosive Liquids and/or
Are There Flammable Liquids/Gases? No
Gases
Is There Flammable Gas Detection?
N/A
Hazard Ratings Shown on Tanks? No
Are there Toxic Liquids/Gases? No
NFPA Ratings or Other Shown? No
Are there Corrosive Liquids/Gases? Yes
Emergency Block Valves
Are EBV's Identified in Drawings? Yes
Frequency of Testing of EBV's? Per critical instrument program
What are they? N/A
Frequency of Testing Gas Detectors?
N/A
What are they? N/A
What are they? Caustic
Are EBV's Identified in Field? No
Are EBV's Fire Rated in Flammable Service? N/A
(Revised 02/18/94; cmk) 1/13/97; LAD:bwb
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| Other Special Hazards
1
Any Other Special Hazards which Increase Risk of Operation? No
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LOSS PREVENTION INSURANCE REPORT
11. Management Considerations
Last Loss Prevention Inspection?
2/94
Last Consolidated Audit?
2/94
Implementation of Minimum Requirements? Yes
Emergency Plans Written for Unit? Yes
Operator Training Procedures Written & Current?
Yes
Date of Last Hypothetical Emergency? 4Q96
Written Plans for Fire Protection Impairment? N/A
Critical Instrument Program Established?
Yes
Other Audits or Reviews of Plant? (e.g. T/C) 6/96 - Tech Center
Operating Procedures Written & Current? Yes
Emergency Plans Shared with Other Units & Off Site?
No
Testing of Critical Instruments? Yes
Preventative Maintenance Program in Place? Yes
Reactive Chemicals Program?
Yes
Date of Last Reactive Chemicals Review? 10/94
Plant Contact Person for Loss Prevention? G. C. Leblanc
Contractor Safety Program Established? Yes
Smoking Regulations & Enforcement? Yes, per LAD Smoking Policy
Other Management Programs in Place Affecting Loss Prevention? List e. g., Fire Protection Inspections, Insurance Inspections
S&LP Audits - LAD C-9 Audit Program Safety Committee Training - IPT Program MOC Program Behavior Based Safety Program
12. Plant Reliability
Production Capacity 1,190 MMIbs/yr Caustic
Per Cent of Capacity for Year (1996) 79.2%
Theoretical Hours/Year for Production Capacity?
Hours/Year Loss Due to Outages or Reduced Rates
Percent Reliability
(Hours.-Qperation at Theoretical Rate) (Total Hours Available)
(Revised 02/18/94; cmk) 1/13/97; LAD:bwb
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XI
APPENDIX A - OSHA PSM EVALUATION AND DOCUMENTATION
OSHA Process Safety Management of Highly Hazardous Chemicals
These questions are to ascertain if OSHA 1910.119, Process Safety Management, applies to this facility.
1. Yes [X] No [] Does any process or storage area of this facility have any materials on the attached list in excess of the threshold quantity.
2. Yes [X] No [] Does any process or storage area of this facility have any flammable liquids or gases (flashpoint less than 100F) in quantities greater than 10,000 pounds, except for:
Hydrocarbon fuels used solely as a fuel if not part of a process containing another highly hazardous chemical
Flammable liquids stored in atmospheric tanks or transferred which are kept below their normal boiling point without benefit of chilling or refrigeration.
If the answer to either question is Yes, then this facility is covered by the OSHA PSM Standard and all plant action items in the following summary need to be evaluated and specific plant needs determined.
The OSHA Process Safety Management regulations are consistent with Dow requirements. Compliance with Dow requirements will comply with OSHA PSM. Those that have the listed chemicals in the quantities listed by OSHA need to assure that documentation is in order.
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Appendix A to 1910.119 -- List of Highly Hazardous Chemicals. Toxics and Reactives (Mandatory)
This Appendix contains a listing of toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantity.
CHEMICAL NAME Acetaldehyde Acrolein (2-Propenal) Acrylyl Chloride Allyl Chloride Allylamine Alkylaluminums Ammonia, Anhydrous Ammonia Solutions (>44% Ammonia By Weight) Ammonium Perchlorate Ammonium Permanganate Arsine (also called Arsenic Hydride) Bis (Chloromethyl) Ether Boron Trichloride Boron Trifluoride Bromine Bromine Chloride Bromine Pentafluoride Bromine Trifluoride 3-Bromopropyne (also called Propargyl Bromide) Butyl Hydroperoxide (Tertiary) Butyl Perbenzoate (Tertiary) Carbonyl Chloride (see Phosgene) Carbonyl Fluoride Cellulose Nitrate (Concentration >12.6% Nitrogen) Chlorine Chlorine Dioxide
CAS* 75-07-0
107-02-8 814-68-6 107-05-1 107-11-9
Varies 7664-41-7 7664-41-7 7790-98-9 7787-36-2 7784-42-1
542-88-1 10294-34-5 7637-07-2
7726-95-6 13863-41-7
7789-30-2 7787-71-5
106-96-7 75-91-2
614-45-9 75-44-5
353-50-4 9004-70-0 7782-50-5 10049-04-4
2500 150 250
1000 1000 5000 10000 15000 7500 7500
100 100 2500 250 1500 1500 2500 15000 100 5000 7500 100 2500 2500 1500 1000
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
Do A 037005 CONFIDENT TAl,
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XIII
CHEMICAL NAME Chlorine Pentrafluoride Chlorine Trifluoride Chlorodiethylaluminum (also called Diethylaluminum
Chloride) 1 -Chloro-2,4-Dinitrobenzene Chloromethyl Methyl Ether Chloropicrin Chloropicrin and Methyl Bromide Mixture Chloropicrin and Methyl Chloride Mixture Cumene Hydroperoxide Cyanogen Cyanogen Chloride Cyanuric Fluoride Diacetyl Peroxide (Concentration >70%) Diazomethane Dibenzoyl Peroxide Diborane Dibutyl Peroxide (Tertiary) Dichloro Acetylene Dichlorosilane Diethylzinc Diisopropyl Peroxydicarbonate Dilauroyl Peroxide Dimethyldichlorosilane Dimethylhydrazine, 1,1Dimethylamine, Anhydrous 2,4-Dinitroaniline Ethyl Methyl Ketone Peroxide (also Methyl Ethyl Ketone
Peroxide; Concentration >60%) Ethyl Nitrite Ethylamine Ethylene Fluorohydrin
CAS* 13637-63-3 7790-91-2
96-10-6
pQ**
1000 1000 5000
97-00-7 107-30-2
76-06-2 None None
80-15-9 460-19-5 506-77-4 675-14-9 110-22-5 334-88-3
94-36-0 19287-45-7
110-05-4 7572-29-4 4109-96-0
557-20-0 105-64-6 105-74-8
75-78-5 57-14-7 124-40-3 97-02-9 1338-23-4
5000 500 500 1500 1500
5000 2500
500 100 5000 500 7500 100 5000 250 2500 10000 7500 7500 1000 1000 2500 5000 5000
109-95-5 75-04-7 371-62-0
5000 7500
100
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
i;o37,
conftdfntjai
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XIV
CHEMICAL NAME Ethylene Oxide Ethyleneimine Fluorine Formaldehyde (Formalin) Furan Hexafluoroacetone Hydrochloric Acid, Anhydrous Hydrofluoric Acid, Anhydrous Hydrogen Bromide Hydrogen Chloride Hydrogen Cyanide, Anhydrous Hydrogen Fluoride Hydrogen Peroxide (52% by Weight or Greater) Hydrogen Selenide Hydrogen Sulfide Hydroxylamine Iron, Pentacarbonyl Isopropylamine Ketene Methacrylaldehyde Methacryloyl Chloride Methacryloyloxyethyl Isocyanate Methyl Acrylonitrile Methylamine, Anhydrous Methyl Bromide Methyl Chloride Methyl Chloroformate Methyl Ethyl Ketone Peroxide (Concentration >60%) Methyl Fluoroacetate Methyl Fluorosulfate Methyl Hydrazine Methyl Iodide
CAS* 75-21-8 151-56-4
7782-41-4 50-00-0
110-00-9 684-16-2 7647-01-0 7664-39-3 10035-10-6 7647-01-0
74-90-8 7664-39-3 7722-84-1 7783-07-5 7783-06-4 7803-49-8 13463-40-6
75-31-0 463-51-4
78-85-3 920-46-7 30674-80-7 126-98-7
74-89-5 74-83-9 74-87-3 79-22-1 1338-23-4 453-18-9 421-20-5 60-34-4 74-88-4
TQ** 5000 1000 1000 1000 500 5000 5000 1000 5000 5000 1000 1000 7500 150 1500 2500 250 5000 100 1000 150 100 250 1000 2500 15000 500 5000 100 100 100 7500
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
DO A 037007 CONFTDENTIAl
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XV
CHEMICAL NAME Methyl Isocyanate Methyl Mercaptan Methyl Vinyl Ketone Methyltrichlorosilane Nickel Carbonly (Nickel Tetracarbonyl) Nitric Acid (94.5% by Weight or Greater) Nitric Oxide Nitroaniline (para Nitroaniline) Nitromethane Nitrogen Dioxide Nitrogen Oxides (NO; NO2; N2O4; N2O3) Nitrogen Tetroxide (also called Nitrogen Peroxide) Nitrogen Trifluoride Nitrogen Trioxide Oleum (65% to 80% by weight; also called Fuming Sulfuric
Acid) Osmium Tetroxide Oxygen Difluoride (Fluorine Monoxide) Ozone Pentaborane Peracetic Acid (Concentration >60% Acetic Acid; also
called Peroxyacetic Acid) Perchloric Acid (Concentration >60% by weight) Perchloromethyl Mercaptan Perchloryl Fluoride Peroxyacetic Acid (Concentration >60% Acetic Acid; also
called Peracetic Acid) Phosgene (also called Carbonyl Chloride) Phosphine (Hydrogen Phosphide) Phosphorus Oxychloride (also called Phosphoryl Chloride)
CAS* 624-83-9
74-93-1 79-84-4 75-79-6 13463-39-3 7697-37-2 10102-43-9 100-01-6 75-52-5 10102-44-0 10102-44-0 10544-72-6 7783-54-2 10544-73-7 8014-94-7
TQ** 250
5000 100 500 150 500 250
5000 2500
250 250 250 5000 250 1000
20816-12-0 7783-41-7
10028-15-6 19624-22-7
79-21-0
100 100 100 100 1000
7601-90-3 594-42-3
7616-94-6 79-21-0
5000 150
5000 1000
75-44-5 7803-51-2 10025-87-3
100 100 1000
(Revised 02/18/94; cmk) 1/3/97; LAD.bwb
03700B
DO A
OONF"1
OFNTT
Al
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XVI
CHEMICAL NAME Phosphorus Trichloride Phosphoryl Chloride (also called Phosphorus Oxychloride) Propargyl Bromide Propyl Nitrate Sarin Selenium Hexafluoride Stibine (Antimony Hydride) Sulfur Dioxide (liquid) Sulfur Pentafluoride Sulfur Tetrafluoride Sulfur Trioxide (also called Sulfuric Anhydride) Sulfuric Anhydride (also called Sulfuric Trioxide) Tellurium Hexafluoride Tetrafluoroethylene Tetrafluorohydrazine Tetramethyl Lead Thionyl Chloride Trichloro (Chloromethyl) Silane Trichloro (Dichlorophenyl) Silane Trichlorosilane Trifluorochloroethylene Trimethyoxysilane
CAS* 7719-12-2 10025-87-3
106-96-7 627-3-4 107-44-8 7783-79-1 7803-52-3 7446-09-5 5714-22-7 7783-60-0 7446-11-9 7446-11-9 7783-80-4 116-14-3 10036-47-2 75-74-1 7719-09-7 1558-25-4 27137-85-5 10025-78-2 79-38-9 2487-90-3
JQ**
1000 1000
100 2500
100 1000 500 1000 250 250 1000 1000 250 5000 5000 1000 250
100 2500 5000 10000 1500
* Chemical Abstract Service Number ** Threshold Quantity in Pounds (Amount necessary to be covered by this standard.)
Appendix B to 1910.119 - Block Flow Diagram and Simplified Process Flow Diagram (Nonmandatorvl
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
DO
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37009
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XVII
DEPARTMENT VPP/OSHA PROCESS SAFETY MANAGEMENT PROTOCOL
(Refer to the OSHA PSM Communication)
Compliance to OSHA regulation requirements is a basic tenant for participation in OSHA's Voluntary Protection Program. All elements of the OSHA Process Safety Management regulation must be in compliance as a prerequisite for VPP participation.
I. EMPLOYEE PARTICIPATION
A. Develop a written list of those safety activities that involve employees (examples in the OSHA PSM communication). Be sure employees participate in appropriate Process Hazard Analysis activities.
B. Document the employee's participation in those programs. C. Provide access to Process Hazard Analyses.
II. PROCESS SAFETY INFORMATION
A. Review plant status on the following Operating Discipline sections. Process Technology Process Risk Management Industrial Hygiene
B. Review the OSHA PSM communication and document the minimum process safety information that is required.
III. PROCESS HAZARD ANALYSIS (Refer to OSHA PSM Communication)
A. Retain the documentation of each Process Hazard Analysis. B. Assure that recommendations from the process hazard analysis are resolved in
a timely manner and the resolution is documented. C. Communicate the results of the Process Hazard Analysis to affected
employees.
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A 037010 CONFIDENT! Al.
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XVIII
IV. OPERATING PROCEDURES A. Assure that operating procedures are reviewed at least annually and certified. (See Texas Operations Safety Standard T-13; III. E, F, G.) B. Assure that operating procedures include the elements listed in the U.S. Area Operating Discipline Standard and the OSHA PSM communication.
V. TRAINING A. Assure that all operating employees in their job as of May 26, 1992, have been certified. B. Assure that new employees are trained as per the U.S. Area Operating Training Standard and the training is documented.
VI. CONTRACTORS Assure that plant contractor orientation and safety communication is documented.
VII. PRE-START UP SAFETY REVIEW A. Assure that projects have pre-start up reviews. B. Assure that resolution of the finding of these reviews are documented.
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DO A 037011 CONFIDENT! Al
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page VIII
APPENDIX B - PROCESS SAFETY AND LOSS PREVENTION FIELD VERIFICATION
The Process Safety and Loss Prevention auditor will evaluate the following items during a field inspection. Answer all questions. Explain any questions answered "No" in the Comment Sections.
A. OPERATING DISCIPLINE
1. Yes [X]
No [] Is process safety information complete and available to the operating personnel? (Examine Sample Documents for Operating Discipline Questions 4A, 4B, 4C)
2. Yes [X]
No [] Are operating procedures complete and available to the operating personnel? (Ask Control Room Operators) (Examine samples of Operating Discipline Questions 5C, 5D)
3. Yes [X]
No [] Are operating procedures reviewed annually with documentation of the review? (Ask Operators) (Examine Samples to Verify Updating)
Comments:
B. DRAINAGE AND CONTAINMENT
1. Yes [X] No [] Is drainage generally away from the process area? (Field Observation)
2. Yes [] No [X] Are tanks located far enough away from dike walls so that a leak will not spray over the wall? (Field Observation)
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ft o r 3?0^
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page IX
3. Yes [X] No [] Are dikes without visible defects? (Field Observation) 4. Yes [] No [X] Area all pumps fitted with deadhead protection (i.e.; temperature
or flow)? (Field Observation) Comments:
C. WAREHOUSE STORAGE 1. Yes [X] No [] Are materials stored so as not to restrict the distribution of fire water from a sprinkler head (at least 18")? (Field Observation) 2. Yes [X] No [] Are empty pallets stacked less than eight feet in height? (Field Observation) Comments:
D. BUILDING LOCATION AND FIRE RISK 1. Yes [X] No [] Are buildings of non-combustible construction? (Field Observation) 2. Yes [] No [X] Are fire doors, tracks, hardware and fusible link systems in good condition to allow closing? (Observe Door Operation) Comments: AV'4
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DO A 037014 CONFIDENTIAL
PROCESS SAFETY AND LOSS PREVENTION AUDIT PageX
E. ELECTRICAL SYSTEMS
1, Yes [X] No [] Are electrical enclosures in classified areas properly assembled? (Field Observation)
2. Yes [] No [X] Are there major cable trays routed through areas where flammable liquids can pool? (Field Observation)
3. Yes [] No [X] Are cable wall penetrations adequately sealed? (Observe Penetrations in Control Room and Switchgear Room)
Comments:
F. FIRE PROTECTION SYSTEMS
1. Yes [X] No [] Are fire protection systems in good condition? (Field Observation)
2. Yes [] No [X] Is structural steel and tank supports protected with deluge protection or fire proofing? (Field Observation)
3. Yes [X] NO []Is pipe insulation on hot lines in good condition? (Field Observation)
Comments: 2. */*
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00 A 037015 OONFTDFNTTAL
PROCESS SAFETY AND LOSS PREVENTION AUDIT
Page XI
__________
G. FIRED EQUIPMENT
1. Yes [] No [X] Is fired equipment adequately separated from the other process hazards (LPP 2.2.6)? (Field Observation)
Comments:
H. EMERGENCY BLOCK VALVES
1. Yes [X]
No [] Are all incoming and outgoing headers handling flammable or toxic materials fitted with EBV's? (Field Observation, Ask Operators)
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
DO A 037016 CONFTDFNTTAl
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XII
2. Yes []
No [X] Are all vessels handling flammables or combustibles with a flashpoint below 140F fitted with an EBV on the bottom of the tank (within 4 feet)? (Field Observation, Operator Interview) (Fire Rated Valve)
Comments:
I. TANK FARMS
1. Yes [X] No [] Is water routinely able to get between the tank foundation and bottom of tank? (Field Observation)
2. Yes [] No [X] Is soil in contact with the tank exterior shell? (Field Observation)
3. Yes [X] No [] Are tank grounds in place? (Field Observation)
J. PRESSURE VESSELS AND RELIEF DEVICES
1. Yes [X]
No [] Do file folder(s) on each pressure vessel (Pressure Containing Equipment) have the registration form, calculations, inspection and status change reports, spec sheets, record prints, U-l forms, mill tests, and visual inspections? (Examine a random 5% sample ofpressure vessel folders for complete records.)
2. Yes [X]
No [] Are design calculations on all pressure relief devices done? (Examine a random 5% sample of folders for calculations, specifications and piping isometric sketch.)
3. Yes [X]
No (] Are glass devices and expansion joints in potentially hazardous service registered and routinely inspected? (Examine a sample of documentation folders for registration and inspection frequency.)
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
DO A 037017
oonftofnttai
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XIII
K. CRITICAL INSTRUMENTS
1. Yes [X] No [] Do written test procedures exist? (Examine Several Examples) Yes [X] No [] Are they being used?
2. Yes [X] No [] Is testing documentation current? (Examine Testing Schedule vs. Completion)
3. Yes [X]
No [] Do test procedures test from the initiating device through final control element? (Have one of the I&E technicians who does the testing explain a procedure.)
L. TANK INSTRUMENTATION
1. Yes [X] No [] Are storage tanks protected with redundant level indicating devices?
Yes [X]
No [] Are storage tank level indicators on separate computer boards? (Verify by having I&E technician show audit example of redundant devices on storage tanks.)
2. Yes [] No [X] Are automatic actions taken from these high level devices? (Have I&E technician explain another operation.)
(Revised 02/18/94; cmk) 1/3/97; LAD-.bwb
DO A 007018 OONFTDFNT T AL
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page XIV
APPENDIX C Process Safety and Loss Prevention Resource Materials
Guidelines for Burner Management Systems for Boilers & Process Furnaces
June 1993
Guidelines for Safety, Loss Prevention and Security Audits
November 1989
Guidelines for Emergency Planning
September 1985
Guidelines for a Motor Vehicle Accident Prevention Program
May 1992
Guidelines for Accident Investigation
November 1985
Fire and Explosion Index, 7th Edition
(At Printer)1994
Guidelines for Public Warehouse Rating and Risk Analysis
January 1990
Guidelines for Determining Dust Hazard Potential
October 1989
Guidelines for A Reactive Chemicals Program, 2nd Edition
Reprinted
November 1990
Guidelines for Business Data & Process Control Computer Systems
March 1982
U.S.A.-2 Safety Standard Management of Change
February 1992
Operating Discipline Standard for Operating Units of Dow U.S.A.
January 1992
Minimum Requirements
June 1989
Chemical Hazard Engineering Guideline Distribution Emergency Response Process
1993 ?
Process Risk Management Guidelines for Facilities and Distribution
1994
Loss Prevention Principles
1991
Chemical Exposure Index
September 1993
NFPA Codes
Continuous
Site Specific Reactive Chemicals Manual - Hazard Evaluation Procedure Manu il September 1993
(Texas Operations Only)
Site Specific Safety Standards and Safety References
Continuous
OSHA Process Safety Management of Highly Hazardous
1992
Chemicals, Explosives and Blasting Agents
Computer Security Policies & Procedures
February 1990
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
00 A 0370P0
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PROCESS SAFETY AND LOSS PREVENTION AUDIT Page VIII
RISKANAL YSIS PA CKA GE Reference: LPP 1.3.3
The Risk Analysis Package and the Loss Prevention Insurance Report will be sent to the insurance company broker and to Corporate Loss Prevention. Sufficient information should be given concerning the plant to allow the insurance companies to fully understand the process safety and loss prevention aspects of the plant. If there are any questions, contact Loss Prevention. The technology center can help ensure that no proprietary information is included.
The following should be the contents of the Risk Analysis Package:
1. Fire and Explosion Index (F&EI) calculation sheets for the highest F&EI, Maximum Probable Property Damage (MPPD) and Maximum Probable Days Outage (MPDO).
2. Loss Control Credit Factors that apply to the plant. (Back of F&EI Form) 3. Plant Risk Analysis Summary Sheet of F&EI calculations. 4. Block plot plan showing areas of exposure circles for the higher risk process unit
areas based on F&EI calculations.. 5. Simplified process flowsheet. (Include Emergency Block Valve Location) 6. Summary sheets covering the following information:
A. Raw materials used with source and means of receipt. B. Final product distribution means. C. Availability of critical equipment. D. Essential utilities and reliability. E. Replacement value of the plant. F. Interdependence with other Dow facilities.
A copy needs to be sent to your Loss Prevention Representative and it will be forwarded to Corporate Loss Prevention and the insurance company.
(Revised 02/18/94; cmk) 1/3/97; LAD:bwb
'jON
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page I
Block 36 - Chlor-Alkali 2 Process Summary
Raw material for the chlor-alkali plant is brine supplied by pipeline from salt domes.
The initial operation is an electrolytic reaction using diaphragm cells. Products of this reaction are chlorine gas, hydrogen, and weak caustic cell effluent. Two independent circuits of four cell series are used.
Cell power is supplied by two 45 megawatt Westinghouse W-501A gas turbine driven generators. Each gas turbine generator is coupled to a steam turbine for startup and power augmentation. Backup power is available through a division tie using two 27 MVA regulating transformers. The cell power turbines are not synchronized to the power grid. The wet chlorine gas from the cells from the cells is dried, purified, liquefied, and evaporated in a single train system to produce 100% gas and liquid chlorine. The plant produces 1.9> million pounds of chlorine per day. 100% chlorine gas is piped to the division distribution header, and liquid chlorine is sent to the chlorine plant for loading into tank cars.
Fifty six thousand pounds per day of hydrogen from the cells is scrubbed, compressed, and cooled in the hydrogen recovery area. The hydrogen is piped to the division header where the chlorine plant handles distribution to internal and external customers.
Cell effluent is processed in a multiple effect evaporator train to reach a concentration of 50% caustic and remove .alt. The caustic is then cooled and filtered to further reduce the salt concentration. 2.3 million pounds per day of caustic are transferred to the division caustic plant where it is shipped by tank truck, tank car, or marine carriers.
This plant typically runs at full capacity with load changes absorbed by the chlorine plant and caustic plant.
There are no automatic sprinklers at CA2, but monitor nozzles are located throughout the block to cover all potential fire hazards. A manual sprinkler exists on the chlorine compressor to combat a chlorine and iron fire if necessary.
Spare equipment is available for all major equipment. A gas turbine outage can be covered using backup power and steam from the division header until repairs are made. Caustic centrifuge has an installed spare. Rotating assemblies are stocked for the freon compressor and starter turbines. A spare rectifier transformer is stored in the Texas Division
(Revised 02/18/94; cmk) 1/8/97; LAD:bwb
PROCESS SAFETY AND LOSS PREVENTION AUDIT Page II
BUSINESS INTERRUPTION SUMMARY-CHLOR ALKALI 2
A. Raw Material Supply
Brine is supplied by pipeline from salt dome storage. Hydrochloric, and Sulfiuric acid are supplied by pipeline from other plants in the division.
B. Product Shipping
Chlorine production is delivered to Louisiana Division user plants by a pipeline distribution network, and tank cars are loaded at the chlorine plant for external customers. Caustic is pumped by pipeline to the caustic plant for distribution by tank truck, tank car and marine shipping. Hydrogen is sent by pipeline to the chlorine plant for distribution to internal and external customers.
C. Essential Utilities
Steam, Power, and Fuel Gas are all supplied by division network systems.
D. Critical Equipment
Spare equipment and parts are available in the Louisiana Division and other Dow locations,
i. Loss Control Systems
Fire Fighting water is supplied by the division system which includes nine diesel pumps, each capable of supplying 5000 GPM at 100 PSIG. These pumps start automaticaly on low pressure in the water header. Normal water supply is by electric pumps at the water treating plant that deliver a capacity of 3500 GPM.
F. Replacement Cost
$99 MM 1996
(Revised 02/18/94; cmk) 1/8/97; LAD:bwb
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CAUSTIC PLANT
PROCESS DESCRIPTION
The Caustic 1 plant is made up of an evaporation train, a salt removal area and a finishing area. The evaporators are used to concentrate the caustic to 50%. The salt removal area consists of salt columns, centrifuges, and salt settlers which are used to process. The finishing end of the plant cools the caustic with heat exchangers and removes salt to production specifications in the sparkler filters.
A caustic evaporator train is made up of four bodies configured as a triple-double evaporator system with a primary salt removal and a condensate collection system. The evaporator bodied are referred to as the fourth effect, third effect, second effect, and first effect.
After the evaporators, salt, and sulfate are removed at the centrifuges. Additional processes are l)cooling and 2)final filtration in the Sparkler filters.
The boiler grade condensate is returned to the Power plant for use in steam generation.
As the cell effluent is increased in concentration, solid salt drops out of solution in the evaporators because of reduced solubility. This salt is collected in a settling tank by use of cyclones. From here it is fed to a salt column. Caustic concentration in the salt slurry from the bottoms of the salt column is monitored and controlled by the addition of condensate. Salt slurry is sent to the Chlorine plant where it is fed back to the chlorine cells.
The product from the evaporator train is fed to a salt settling tank. The overflow is fed to a forwarding tank and the bottoms is fed to the centrifuges. The function of the centrifuge is to remove the salt and the sulfate. The product from the centrifuge goes to the forwarding tank and the slurry is sent to the sulfate salt column. This column removes the caustic from the salt with condensate spargers. Salt is sent to the Chlorine plant and caustic is sent to the user feed tank.
Caustic leaving the centrifuges goes through two precoolers before entering the caustic cooling tank. The precoolers are used to cool the 50% caustic and preheat the cell effluent feed to the evaporators. Caustic is pumped through a set of heat exchangers with chilled water as the cooling media and into the sparkler feed tank. The sparkler filter operation is made up of six filters. After the sparkler filter operation the finished caustic is stored in the finished 50% storage tanks.
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PROCESS SAFETY AND LOSS PREVENTION AUDIT PageX____________________________________________
BLOCK 29--CAUSTIC
This is a production block.
RAW MATERIALS
Cell Effluent from Chlorine (Block 26) and from Chlor-Alkali II (Block 36) is received here via pipeline, and by typical evaporation processes, concentrated.
FINISHED PRODUCT
288.75 MM lbs/quarter of 50% regular grade caustic are produced here.
LOADING & SHIPPING
50% caustic and cell effluent are distributed to division users via pipeline. 50% regular grade caustic is shipped to customers by tank truck, tank car, barge, and ship.
UTILITIES
Steam is supplied by the division Power Plant. Electrical power is supplied by two independent power feeder lines, also from the division Power Plants. Process water is supplied from the division Water Treating Plant. River water and compressed air are supplied from Caustic owned equipment. Caustic supplies compressed air to the division air network. This network serves as Caustic's source of backup air when needed. Caustic also supplies river water to Chlorine(Block 26). Hydrochloric acid for pH control is supplied via pipeline from the Solvents Plant(Block 16).
CRITICAL EQUIPMENT
Non-spared critical equipment includes the first, second, and fourth effect evaporator recirculation pumps.
LOSS CONTROL SYSTEMS
The probability of fire in this block is very low. Besides fire extinguishers, the only fire prevention/control system in the block is smoke detectors in the control room, motor control centers, and computer room. The computer room has a Halon fire protection system. The block is completely contained. All spills and runoff drain to a trench system with sump pumps that transfer the liquid to a holding tank.
(Revised 02/18/94; cmk) 1/13/97; LADibwb
DO A 037030 CONFTDFNTTAl
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Cal Effluent (incoming}
X Sample Pt.
Evaporation
Sulfate Removd ^ X
Salt
Salt Removal
Distribution
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