Document k9nEa8Q570GGnnvKn2gr2QJaD
Interoffice Communication
To : C. R. Miller From : P. E. Markey Date : January 3, 1983
subject : 1982 VINYL AREA SAFETY AUDIT
Attached is the 1982 Vinyl Area Safety Audit. I will keep you appraised of our progress. Me have alot of work ahead of us.
P. E. Markey Vinyl Operations Superintendent rah attachment c: DJM, CRS,
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VAB.0001074574
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INYL SAFETY AUDIT DRYERS
A. V Silo Area 10/18/82 - MPB
I
l.\ Need a safety gate at top of ladder going up the side of 282,
Replace missing non-skid tape on silos 680, 688, 676, 675, 681, 682, 683 , and 684.
Bolts missing on level teck cover for all silos in 600 series (except 689-691).
Tighten light on 680 silo (top) so that it lights the top of silo.
Remove conduit box on 679- so that the vacuum/pressure lid will fall back when opened.
6. I Reposition light on top of 679.
7. Properly support air piping on top of 686 instead of using rope.
,8 Pressure vacuum lid on top of 688 is located in a position causing
several hand traps. Turn it to allow opening from southwest to north--
and position ladder to dust collector (if needed) such that it does not hinder opening the lid. Also, lid must be able to open fully Same on silo 686 and 684.
Turn
Remove hose running across top of silos.
Sweep resin off of non-skid tape on top of silos.
Repair jagged, broken handle on 677 vac/pressure lid, also on 675.
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* >4 _
Reposition direction of light on 677.
Reroute transfer lines to 681 and 682 out of walkway to 675 silo or paint with safety paint.
Hundreds of wasps on top of silos are a safety hazard. Search out and destroy nests or otherwise trap and kill them.
Resupport and repair light on 675 (top).
Remove socks from 690 that are piled on top of 690/691, also ladder, dust mask, and safety harness.
Put non-skid tape on top of 281/282 in walkway areas.
Clear walking areas on top of 281/282 of pipes, supports, air hoses, and tubing or paint with safety paint.
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VAB.0001074575
V-ll Silo Area (Cont'd)
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20. Remove old light, top of 282.
21. Paint with safety paint or cover the bolts on edge of silo 282 at top of steps from walkway from 600 series silos - Tripping hazard.
22. Glass broken on aeration air rotameter for 676.
O
CM
Remove debris around bottom of silos 675, 685, 687, 688, 678, 679, 680, and 689.
24. Remove piping, tubing and conduit around 686 and 687 manual" valve handles (hand traps)
25. Remove uncoupled transfer hose at 600 series.
26. Replace chain guard 282 small star valve.
B. V-ll Dryer Building 10/18/82 MPB *
p
1. Bend wall supporting brackets between 647 and west V-ll wall to that the sharp edges won't catch someone walking past.
2. Flag, paint, or remove drain plug southwest of 647 pump that is a tripping hazard.
3. Clean algae spot near 647 pump.
4. Remove one of cone supports around bottom valves for 646/647 (hand traps).
5. Remove bolts from bleed valves at 747 and 502 pump over lines from small blend tanks.
6. Install blind flange on 648 pump recirculation line where pipe is
open.
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7. Remove sharp edges of insulation on line from 648/9 pumps to #5 Bird, 5* above grade east of pump, also from 654/5 to #8 Bird.
8. Rope off or remove fire hose under blend tanks used for pump over (tripping hazard and burn hazard if line bursts.)
9. Repair water leaks under blend tanks to eliminate slipping hazard of standing water.
10. Reinstall gratings that are not flush with grade between 652 and 654 and between 653 and 655.
11. Blind flange open nozzle east of 407 south slurry pump, also nozzle on pump over line to 407 at 654.
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VAB.
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B. V-ll Dryer Building (Cont'd)
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12. Remove and replace sign at breathing air station between #7 and #8 and blend tanks, also between*-#4 and 5 outlets', and between #4 and 5 inlets.
13. Replace missing grating over sewer drain under #6 inlet. 14. Properly support glycerin piping to #4.
15. Repair trunion roller guard southeast side of #4.
16. Reinstall ground wire for #5 southwest trunion roller.
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17. Paint air piping between #6 and #7 activator with safety paint.
18. Reroute #8 recycle hopper line back to dryer so that it is not a tripping hazard just inside the door.
19. Reroute extension cord coming out of rest room so that it is not a tripping hazard.
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20. Repair phone booth in east end of building (jagged edges).
21. Need rack for air hose on Sweco deck, also safety nozzle. 22. Repair roof.
23. Support conduit around each antichatter device on all birds. Include
rerouting or shortening of wire on torque readouts to remove tripping hazard.
24. Remove pipe supports from walkway between blend tanks, 2nd level (tripping hazards).
25. Close breaker panel (tighten screws) above 501 north slurry pump breaker in breaker room above chiller building.
26. Paint top step going up to blend t^nks from Bird deck, S.W. side of building. Step height changes.
27. Remove plant growth from top of building, around blend tanks, dryer inlets, and on east end of building.
28. Remove hose from walkway above 652/653 (top).
29. Reinstall stack support wire for small blend tank exhauster, north side. Paint wire supporting stack from east with safety paint.
30. Remove or roll up hoses around 646, 647, 648, 649 (top).
31. Repair grating where broken on walkway between 646, 648, top of tanks.
32. Paint conduit and piping across walkways between dryer inlets with safety paint.
VAB.0001074577
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* B. V-ll Dryer Building (Cont'd)
33. Top of V-ll building is a. housekeeping disaster. Clean up resin, socks, hoses, wire, ropes, 4nasks, etc. Also dust collector deck is full of debris.
34. Remove scaffolding near #5 dust collector.
35. Repair hole in grating northwest of #6 dust collector near comer of railing.
36. Repair ladder to top of #8 dust collector.
37. Turn or pipe safety valves on pulsairs piping away from areas where personnel might be.
38. Gates missing on ladders to top of all dust collectors.
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39. Repair insulation covering on small blend tank dump header where you
cross over it to go to top of 501. Covering is sharp and jagged.
40. Gate missing at top of ladder between south steps to Sweco deck and
#8 dust collector.
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C. Large Blend Tank Area 10/18/82 - MPB
1. Remove hoses, rope, face masks, and buckets from top of tanks. 2. Resupport seal flush line to south 501 pump.
3. Remove 6" pipe by 407 on ground.
4. Repair busted cement northwest of south door coming into chiller building and west of the east entrance along drop off in floor.
D. V-10 Silo Area 10/19/82 - MPB
1. Clean resin and debris out of pit.
2. Remove and destroy condemned ladder from pit.
3. Dispose of paint thinner and buckets in bagging machine shed.
4. ooth down the jagged edges on walkway rai between V-10 silos and V-10 hookup station.
steps going
5. Repair grating on walkway between V-10 hookup station and V-10 silos
where edges of grating don't match up (tripping hazard) - About 30* north of silos.
6. Locking ear off of #2 dryer line to V-10 silos at silo hookup station.
7. Reroute air piping and revise supports in V-10 silo hookup station
area. When concentrating on stepping over hookup lines, the supports and piping could catch a man, causing injury.
8. Resupport conduit under middle of silos, 2nd deck. 9. Clean up debris at silo hookup station.
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VAB.0001074578
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D. V-10 Silo Area (Cont'd)
10. Clean up debris on roof foi
hookup station
11. Replace missing bolts on level teck covers.
12. Sweep resin off of top of silos and remove all debris.
13. Repair spring on gate at top of ladder going up silo 576.
14. storage?).
mailbox on top of 576 (instrument materials
15. Reposition light over top of ladder coming up between the silos. 16. Clean up V-10 hookup station.
17. Replace frayed 3M hookup hose on new 470 line.
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E. V-10 Building 10/19/82 - MPB
1. Conduit is open at N.E. corner, 15' high.
2. Repair spring on gate going behind both ends of #2.
3. Remove air piping attached with rope to #2 overflow chute.
4. Tighten trunion guard at southeast roller on #2.
5. Remove or reconnect ground wire for 552 pump.
6. Clean up clutter under V-10 blend tanks.
7. Remove barrel strainer north of blend tanks. Properly clean out and store.
8. Clean off bird deck, including removal of sump pump.
9. Remove hoses from area, top of blend tanks.
10. Need a handle and lid bolted down on 550 blend tank.
551 blend tank needs a lid on top manway
12. Bolts missing on lids for 552 and 553.
13. Handles for pond resin transfer valves are inaccessible and are safety hand traps. Turn, reposition, or install chain handles on valves.
14. Repair grating at top of stairs, southeast comer of building. It is not even (tripping hazard).
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VAB.0001074579
V-10 Building (Cont'd) 15. dryer Inlet platform 16 dryer Inlet above dual maxon 17. Repair fan guard by #2 sifter. 18. Repair chain guard #2 sifter. 19. Clean up hoses and debris around #1 and 2 dust collectors at manway
level and at grating near exhausters. Also on roof north of dust collectors. 20. Repair guard on #2 air pulser timer sprocket 21. Properly support air piping to #1 pulsair. 400 Series Silos - 10/19/82 - MPB 1. Need a gate at top of ladder east of D. Blend control room. 2. Sweep resin off top of silos and off of non-skid tape. Replace nonskid tape where needed.
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3. Bolts missing on all level tecks. 4. Repair vac/pressure lid 475 - Hinge is broken. 5. Turn vac./pressure lid on 400 so it will fall back when open. Won't
open now but 3-4" - Hand Trap. 6. Remove or tie down loose fencing on top of 493 silo at railing. Fluid Bed Dryer
1. Plug bleeder off bottom of sight glass on chemical addition tank for water. Also plug drain valve for tank.
2. Properly support Foxboro D. P. cell by temperature control steam valve that is hanging by wire. *
3. Remove 110 V. lamp from atop plug flow burner.
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4. Conduit broken on TIC-508 on outlet of plug flow. 5. Properly support D.P. cell at stairs at top of 2nd flight. 6. Need hose rack on bird deck. 7. Remove studs from concrete west of south bird.
VAB.0001074580
r A. Old Unit (Cont'd)
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44. Remove 2-2" stubs out of concrete In old chem wash area.
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45. Resupport steam header to old jets, running under deck and up the side of recovery building.
46. Bleeder plugs missing on discharge of south filter pack and on suction of north seal water pump.
47. Resupport conduit for switch on stanchion N.W. of K.O. pumps.
48. Remove busted pressure gauge on collect tank pump discharge.
49. Repair or remove electric tracing around east collect tank pump, includ ing junction box.
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50. Remove chairs, bolts, nuts and debris from platform deck, collect tank.
51. Support for 2" pipe on feed back line to collect tank is separated from stanchion.
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52. Plug missing in bleeder on collect tank pump suction line.
53. Remove old 2" drain line to sewer from recirculation cooler.
54. Paint conduit going to collect tank pump motors with safety paint.
55. Remove old base for rinse pump or at least remove studs out of base.
56. Repair grating along drain coming from DOP pump containment area.
57. Remove rope and properly support 3" cold water line at N.E. corner of old control room. (Charge water temperature control water).
58. Pipe new safety shower drain to grade at top of south steps going up to vacuum pumps/compressors.
59. Remove conduit hanging in middle of area 6* east of A vacuum pump.
60. Need a rack for breathing air hose at A vacuum pump.
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61. Recovery area building seems to be shaking more than usual during
recovery.
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62. Clean up clutter and debris around vacuum pumps and compressors.
63. Repair or remove broken wiring to electrical device near the 6" line running east/west above compressors.
64. Reroute air tubing to "A" vacuum pump discharge valve.
65. Remove conduit and piping around "C" compressor that is not used.
VAB.0001074581
IP
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A. Old Unit (Cont'd)
66. Put walkboards on roof above places where roof is about to fall in 67. Remove or resupport conduit for old general monitor system running
above methocel chain hoist area over to seal water separators
.68 Permanently support
on water for E-701.
69. Shut junction box behind seal water separators.
70. Remove bubble gum wrapper and properly plug conduit at T-701 drain valve.
71. Repair grating west of breathing air.filter, 2nd deck.
72. Secure coupling guard on P-703 vacuum pump.
73. Replace fitting on breathing air line south of emission recovery com--
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74. Discard old piece of piping on rack on wall south of E.R.S. compressors.
75. Remove light switch north of 705 compressor and connected conduit and lighting. These all have exposed wires, appear to be currently out of use.
76. Repair the screen over the old unit bullseye coming into K.O. tanks. 77. Remove scaffolding from behind colloid tank.
78. Open conduit plug under the methocel charge pump dishcarge valve on 2nd deck.
79. Clean up debris around methocel tank/K.O. tank area.
80. Does spare methocel tank need to be anchored?
81. Remove pressure transmitter and conduit at safety shower south of K.O. tanks, 2nd deck.
82. Clean off platform around T-702 and T-703.
83. Properly support level tank conduit for T--703, remove wire holding conduit.
84. Repair fire line hanger east of T-703 on 6" header.
85. Install pressure gauge or plug pipe on discharge of south E.R.S. seal H_0 pump.
86. Remove rope and support conduit above south seal H^O cooler for E.R.S.
on old general monitor conduit.
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VAB.0001074582
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'A. Old Unit (Cont * d)
87. Repair grating north of charge water filter.
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88 Clean up shed where deluge valve are located at N.E. corner of unit-
hoses, metal, bolts, nuts.
89. Remove studs and pieces of iron sticking in concrete north of deluge valve shed.
90.
Resecure If
box
outside
of
deluge
valve
shed
that
says
"In
case
of
fire.
91. Remove old wall supports on stanchions west of chem wash preheater.
92. Repair chem wash leak on pressure gauge at south end of preheater.
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93. Repair leaking plugs on piping at south end of chem wash preheater.
94. Repair support on conduit for steam control valve on preheater above south manual block valve.
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95. Clean up under stairs north of dump Sweco area.
96. Clean out deluge valve shed at dump Sweco area.
97. Drain cover missing in old unit slurry pump pit.
98. Need a rack for water hose in Sweco area.
99.
.100 .101 .102
Clean out gutter over dump Sweco shed.
Repair handle on valve below Calcium Stearate addition funnel.
Remove white suit downstream of dump bullseye and properly repair pipe.
Properly support conduit for steam high pressure alarm and remove rope support
103.
downstream manual valve from steam stripping control valve for
personnel protection.
104. Remove old conduit for duraseal units that sat west of D-300.
105.
Remove pipe dump valve,
support CV-372.
in
walkway
southwest
of
D-300
close
to
D-400
slurrvy
106. Bolt down support for actuator on D--400 slurry dump valve, CV--372.
107. Repair or condemn 4--step ladder west of D--400 at seal flush rotometer.
108. Remove V stainless tubing from seal pot on top of D-400 that went to old pressure transmitter.
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VAB.0001074583 w
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A. Old Unit (Cont'd)
109.
no.
Remove angle iron from stanchion directly southwest of D-400 seal water flow meter.
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Remove wiring from around D-400 emergency kill pot from old conduit.
in. How can you tell if manual valves on VCM charge hdr. to D-300 and 400
or D--500 D--600 D--700 are open or closed?
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112. Paint and plug bleeder valve on slurry dump line from D-300/400 north or D-400 charge pot.
113. Repair old unit delumper. Parts are laying all around it.
114. Turn test connections on N.0. bottles for D-500/600 so that they don't project into walkway.
115. Re-attach ground wire for D-500 structure on southeast leg.
116. Conduit cover off above north N.0. bottle for D-500.
117. Conduit plug missing near stanchion above D-600 AMS Emergency kill pot.
118. Straighten conduit pipe rack support directly east of D-600 motor.
119. Properly support wire to D-700 duraseal unit high level probe. Remove wire. Also replace missing cover on conduit in same vicinity.
120. Northernmost piece of conduit near pipe rack support directly east of D--700 motor has a loose elbow on conduit.
121. Replace conduit that fell out of pipe rack running east/west north of the road in front of new cooling tower for new unit.
122. Getting excessive water (hot) out of big jet on startup. Separator prior to jet should take most of condensate out.
123. 124. 125.
Safety catch and safety latch on D-700 manway need repair.
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Conduit plug missing at condenser cooling water control valve.
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Safety latch on D-600 manway needs repairing, also 300, 400, and 500.
126. Need a swing type gate on D-600 condenser level ladder. Current gate will move over catch and allow gate to open.
127. Replace conduit to D-600 atm. vent valve.
128. Remove debris top reactor level and condenser level on all reactors.
129.
Lamp above D-400.
D-500
manway
is
full
of
H1o0
and
has
no
bulb
in
it.
Also
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VAB.0001074584
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A, Old Unit (Contfd)
130. Reroute tubing from D-500 to manometer so it goes under walkway.
131. Conduit plug missing on D-500 inert vent valve conduit.
132.
connection on D-400 Cond. deck north side needs resupporting.
133. Conduit is broken off of west side of condenser platform on D--400.
134. Conduit broken on D--300 condenser rinse valve.
135. Remove plant growth fro V-ll rec. building roof.
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136. Wasp nest in corner of structure at top of north stairway to top of V--11 needs to be decimated.
VAB.0001074585
VINYL SAFETY AUDIT
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B. New Reactor Unit 10/20/82 - MPB
1. Clean off seal change platform. It's full of clutter.
.2 Roll up hoses, top reactor deck.
3. Repair safety catch and manway lock on all reactors, except 743. 4. Pick up and clean up debris on each reactor condenser platform.
5. Steam clean around methocel makeup tank, 2nd deck. Area is slick when
wet.
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6 Repair hinge on methocel charge tank lid.
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7. Clean out floor drains, 2nd deck recovery area.
.8 Grinder Room - Staighten and clean out unnecessary items. Steam clean
floor.
9. Clean off 2nd deck of Reactor 745, including condenser cleaning chunks.
.10 Remove old actuator and piping for 744 AMS Auto Emergency Kill from
top reactor deck. Laying on grating.
.11 Clean condenser cleaning chunks from around top deck .12 Holes for chain hoists to be used on relief valves are too small, do not
allow proper fit. (745 Reactor)
13. Part of railing missing on top of 745 condenser, northeast part.
14. Cover pressure gauge on big jet line between 743/744 for personnel pro tection.
15. Repair grating directly north of 743 where there is a dent and hole in the grating.
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16. Plug on conduit to 743 pressure transmitter is missing.
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17. Steam trace tubing around condenser valve, 743, is cut, has a jagged edge. Repair or remove.
18. Conduit plug missing, reed switch for CV-848 on small jet.
19. Bleeder plug missing on pressure gauge, top of 743 condenser.
.20 Remove or plug sample connection on bleeder valve on 742 inert vent
piping.
.21 Pressure transmitter on 742 is supported with wire. Properly support.
VAB.0001074586
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A
B. New Reactor Unit (Cont'd)
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22. Conduit broken on 742 condenser"sprayhead valve and 742 atm. vent valve wiring.
23. Conduit plug missing on presure switch on 742, condenser level.
24. Manometer bleeders are not plugged. Should be installed on downstream side of valve to manometer.
25. Remove debris from top of chem wash tank.
26. Disconnect and blind old 1" inert piping that is plugged, top of 741.
27. Remove and properly store step ladder on 2nd reactor deck by 741. Also one between 743 and 744.
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28. Clean up second reactor deck - wire, bolts, nuts, insulation, condenser cleanings and all other debris.
30. Remove and properly store 101 straight ladder 2nd deck, east side of 741.
31. Remove old wire supported conduit under 744, south side, that is attached to 3" deluge piping.
32. Thoroughly clean up 2nd and top receiver deck -- gloves, gauges, chunks, insulation, etc.
33. Spring on gate at top of ladder going to 2nd receiver deck is broken.
34. Plug bleeder on bottom of sight glass, east RVCM receiver, 2nd deck level.
35. Remove broken electric tracing wire at level transmitter, fresh receiver.
36. Safety valve return line back into east receiver not locked open. (No lock)
37. Remove hose connection and plug 3/4** gate valve on top of safety valve return line, east receiver.
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38. Plug bleeder on seal pot for west RVCM receiver, top. (^M)
39. Machine down sharp edge on deluge piping support above ladder going to top of fresh receiver. Sharp edge could catch a man's face or
shoulder when ascending ladder.
40. One inch plug missing from bleeder on 2M vent line from top of fresh receiver.
41. Remove rope and properly support relief valve discharge piping from east RVCM condenser.
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VAB.0001074587
B. New Reactor Unit (Cont'd)
42. One bolt loose on 3/4" nozzl'e Tillnd flange, top of west RVCM receiver.
43. Plug missing on y bleeder at pressure gauge off of common vent line from recovered receivers.
44. Conduit broken and wiring exposed below north side of east receiver. Repair or remove.
45. Remove old broken sight glass from 3/4" piping west of west RVCM charge pump and plug piping.
46. Insulate or cover hot water preheater trap, personnel protection.
47. Reconnect ground wire for south fresh filter pack.
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-i .M
48. Re--route drain piping from charge water pumps out of main walk area around tank and pumps.
49. Flexible conduit broken to north blow down tank pump motor.
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50. Plugs missing on all bleeders at suction of both blowdown tank pumps.
51. Drain line from steam trap at stanchion south of methocel makeup water
filter is a tripping hazard. Reroute or paint safety yellow and run along ground, not 2" above ground.
52. H20 dripping from conduit between south HPSW and north MSPW pump.
53. Cover steam tracing at pressure gauge for MSPW. Personnel protection.
54. Need a rack near HPSW pumps for HPSW hose connected to pump.
55. Cover steam tracing in duraseal pump area and piping, personnel protec tion.
56. Remove unused N bottle from between duraseal units.
57. Cover broken off of 110 connection for catalyst freezer plug in.
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58. Cover 1 steam piping behind cat. freezer -- personnel protection.
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59. Cover steam tracing near HPSW pressure control valve to recovery system for personnel protection. Also at slurry pump sample point.
60. Chem wash pump pressure gauge bleeders need to be plugged.
61* Pipe chem wash pump causing drains to sewer. 62. Sweep out new unit MCC building.
63. Replace cover for air inlet duct inside MCC building.
s
* ** B. New Reactor .Unit (Cont'd)
* ' w,fe!"
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64. Conduit broken to low pressure switch on 741 AMS emergency kill pot.
65. One bottle of N.O. on 742 does not have a seal, also one on 744.
66. Remove unused hu copper tubing running from behind 742 catalyst valve
switch to the sewer.
67. Tighten coupling guards on reactor agitators for 741, 742, 743, 744.
68. Conduit plug missing on conduit coming into north side of junction box by 743 emergency kill pot.
b>
69. Need a funnel on 745 cat bomb like on other reactors. Funnel now in use makes spillage of raw materials likely due to bad angle. !
70. Remove enter with caution tape around juction box and sewer between 742 and 743.
71. Re-attach coupling guard .to hose on north K.O. pump.
72. Plug missing from bleed valve under the east seal water subcooler.
73. Consolidate methocel skids so that there is only one skid rather than four in the area.
74. Plug bleeder on bottom of north recovery seal water filter.
75. Remove chain from foot pedal on safety eyewash by methocel charge pumps.
76. Properly support and hook up or remove conduit and wire hanging out of pipe rack north of methocel charge pump.
77. Tighten coupling guard on east methocel transfer pump, also west pump.
78. Tighten coupling guard on methocel charge pump, and on south recovery seal water pump.
79. Clean up debris, 2nd recovery deck.
Plugs missing from bleeders on inlet lines to both K.O. 'tanks and on pressure gauge on top of level well dn south tank.
81. Cover steam tracing around sight glasses and flush valves on both K.O. tanks for personnel protection.
82. Conduit plug missing on conduit at 6"equalization valve west of 903 compressor.
83. Tighten cover on conduit fitting on 903 discharge valve. 84. Conduit broken on wiring to 904 discharge valve.
A
VAB.0001074589
