Document oDnkZdoRxLpwz6mzr7LjpRzD

ABD00036966 Process Safety Management Georgia Gulf Corporation, Aberdeen Plant Old Module Hazard and Operability Study Start Date: End Date: Issue Date: March 15, 2000 April 13, 2000 July 26, 2000 Distribution: PSM Steering Team ABD00036967 Georgia Gulf Corporation Memo To: PSM Steering Team From: Kelly Wood Date: 07/13/00 Re: Old Module Hazop Report Enclosed is the completed Old Module Hazop report. This is the 2nd Hazop to be performed on the Old Module. Performing a 2nd Hazop was preferred rather than a revalidation of the 1 * Hazop because: 1. Significant changes to the Old Module area since the previous Hazop, due mainly to the EXPRESS project. 2. Hazop software (PHAPRO 3.0) was available. The software helps facilitate Hazop thoroughness and improved hazard documentation. The software is expected to provide the same benefits for future revalidations. A list of hazards identified can be found in Section VIII. Hazards were identified during the preliminary hazard review, the human factors review, and the P&ID/Operating procedure review. Preliminary Hazard Review. Section VIII.A. Ten items were identified. Although the identified items do not receive a risk ranking, they do have to be reviewed and their resolution has to be documented. Human Factors Review. Section VIII.C. Five items were identified. Although the identified items do not receive a risk ranking, they do have to be reviewed and their resolution has to be documented. P&ID/Qperating Procedure Review Section VIII.D. In this section, hazards (also called consequences) are risk ranked. No hazards were found to have risk rankings of 1,2, or 3. Six hazards were found having a risk ranking of 4. A risk ranking of 4 requires the hazard be evaluated. If the evaluation determines no mitigation is required, documentation of the reasons why is needed. Otherwise, mitigation is required. All other hazards had risk rankings of 5 and require no mitigation. Explanation of risk ranking and required mitigation can be found in Appendix D of the Condea Vista Corporate Safety and Health Standard. Condea Vista's Corporate Safety and Health Standard can be found in Appendix G of this document. List of Recommendations. Section IX. The list of recommendations are listed by category similar to the list of hazards identified. Recommendations resulting from the P&ID/Operating procedure review are referenced to a study node. Recommendations are to be handled as described in Appendix E of the Condea Vista Corporate Safety and Health Standard. Post Hazop Communications See section 8.3 of the Condea Vista Corporate Safety and Health Standard. ABD00036968 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP I. II. III. IV. V. A. B. C. D. E. F. G. VI. VII. A. B. C. D. E. F. G. H. I. VIII. A. B. C. D. IX. X. TABLE OF CONTENTS Purpose Rationale for Selecting Hazop for the Project PHA Scope Team Members & Qualifications Team Orientation Methodology Risk Ranking Hazop Execution Plan Human Factors Checklist Previous Recommendations and Status of Actions Orientation Meeting Review Checklist Attendance Records Description of Covered Processes Hazards Analysis Hazards of the Process Potential Safety & Health Effects Engineering & Administrative Controls Consequence of Failure of Controls Reactor Operation Past Incidents Facility Siting Human Factors General Deviations List of Hazards Identified Preliminary Hazard Review Past Incidents Review Human Factors Review P&ID/Operating Procedure Review List of Recommendations List of Items Needing Further Review 1 Page 1 1 2 5 6 13 14 17 631 634 ABD00036969 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP TABLE OF CONTENTS APPENDICES A. Marked up P&Ids (Kept in separate 11x17 binder) B. Employee Participation Documentation C. List of Pre-Work Materials Used D. List of Past Incidents E. List of Updates and Revalidations F. Team Leader Training Documentation G. Condea Vista Company, Corporate Safety & Health Standard, Process Hazard Analysis, PSM-004 ABD00036970 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP I. Purpose The Old Module Hazop was conducted for the following purposes: Provide Management and Operations personal with the knowledge of where potential hazards exist. Provide safe operation documentation for the system. Provide a quantitative assessment of the risks involved with the operation of the system. Provide documentation that risk management is taking place at the Aberdeen Plant. Provide training on Hazop methodology and techniques for Vista personal. Make recommendations, which the team feels should reduce the risks identified. Comply with the Process Hazard Analysis requirements , paragraph (e), of the OSHA Process Safety Management of Highly Hazardous Chemicals regulation, 29 CFR 1910.119. Performing a Hazop study is generally an assurance that if procedural and/or engineering modifications are implemented to mitigate risk, the area will then operate under some lower risk. It is not, however, a guarantee that hazardous events or operating problems will not be encountered. II. Rationale Hazop was chosen to fulfill OSHA's 29 CFR 1910.119 PHA revalidation requirement because of the size and complexity of the revisions made to the Old Module during the EXPRESS project. In addition, it was desirable to have the Hazop documented on a PHA facilitating computer software program to benefit subsequent revalidations. 1 ABD00036971 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN OLD MODULE HAZOP III. Scope Th e scope of this PHA covers the part of the Aberdeen Plant known as the Old Module. The Old Module Hazop study comprises all colored lines on the P&lD's in appendix A, as well as applicable associated operating procedures listed in the table below. The following P&ID's and Operating Procedures were examined during the Hazop study. P&ID Number , OM-090100-PID-D OM-090101 -PI D-D OM-090102-PI D-D OM-090103-PI D-D OM-090104-PI D-D OM-090105-PID-D OM-090106-PI D-D OM-090107-PID-D OM-090108-PID-D OM-090109-PID-D OM-090109A-PID-D OM-090110-PID-D OM-090111-PID-D OM-090112-PID-D OM-090113-PID-D OM-090114-P1D-D OM-090115-PID-D OM-090116-PID-D OM-090117-PID-D OM-090118-PID-D OM-090119-PID-D OM-090120-PI D-D OM-090121 -PI D-D OM-090122-PID-D OM-090123-PID-D OM-090124-PID-D OM-090125-PID-D OM-090126-PI D-D OM-090127-PID-D OM-090128-PID-D OM-090129-PID-D OM-090130-PID-D Revision c i,,: P&ID Title . i 4 FVCM RECEIVER HOT WATER CHARGE & RINSE 4 REACTOR RX-300 4 REACTOR RX-400 4 REACTOR RX-500 3 REACTOR RX-600 3 REACTOR RX-700, 1 OF 2 BME METERING POTS 3 RECOVERY KNOCKOUT DRUMS 6 RECOVERY COMPRESSORS & VACUUM PUMPS 2 RECOVERY COMPRESSORS 506/111 6 SEAL WATER SEPARATORS & COOLERS 6 RECOVERED VCM CONDENSERS 4 RVCM RECEIVERS 5 EMISSION RECOVERY SYSTEM, 1 OF 3 4 EMISSION RECOVERY SYSTEM, 2 OF 3 3 EMISSION RECOVERY SYSTEM, 3 OF 3 0 OLD SLURRY DUMP SYSTEM 0 WET CALCIUM STEARATE 2 LOW MOLE SLURRY DUMP SYSTEM 6 BATCH WATER STRIPPING 2 MSPW & HPSW SYSTEMS, 1 OF 2 1 EMERGENCY KILL SYSTEMS 1 STEAM & REACTOR EVAC. SYSTEM 0 BRINE TANKS 1 SEAL OIL SYSTEM 1 REFRIGERATION SYSTEM FOR RVCM RECEIVER'S KNOCKBACK CONDENSERS REMOVED FROM SERVICE 0 MSPW & HPSW SYSTEMS, 2 OF 2 0 NORMAL KILL SYSTEMS 2 CLEAN WALL SUPPLY SYSTEMS 4 REACTOR RX-700, 2 OF 2 2 ABD00036972 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN OLD MODULE HAZOP 1: P&IDNumber - OM-090132-PID-D OM-090134-PID-D OM-090135-PID-D OM-090136-PID-D OM-090137-PID-D DY-090119-P1D-D DY-090133-PID-D DY-09013 5-PID-D DY-090136-PI D-D Revision 2 2 2 4 1 3 5 1 1 P&ID Title HIGH MOLE SLURRY STRIPPER DUMP PUMPS & STRAINERS HIGH MOLE DUMP TANK HIGH MOLE STRIPPER FEED TANK RECYCLED CENTRATE DISTRIBUTION CENTRATE SYSTEM INCINERATOR FLAME ARRESTOR SYSTEM EAST INCINERATOR WEST INCINERATOR Procedure Number 4 VINYL-RM-SD003 VINYL-RM-SD004 VINYL-RM-ESD006 VINYL-OM-EOOl VINYL-OM-E002 VINYL-OM-E003 VINYL-OM-E004 VINYL-OM-E006 VINYL-OM-E007 VINYL-OM-E008 VINYL-OM-E009 VINYL-OM-SDOOl VINYL-OM-SD002 VINYL-OM-SD005 VINYL-OM-ESUOO1 VINYL-OM-SUOO1 VINYL-OM-NSU002 ,.C. ' - 1 'P^ocedureTitle 4..^-, > 7 -l- Prepare The Charge Water Tank For Entry and Put Back In Service 2 Prepare the Decal Charge Water Tank For Changing Out Resin & Coal Beds Operation of Module emergency Shutdown Switch 0 Split One Reactor Into Another Due To VCM Escaping from the Top of the Reactor to the Atmosphere 0 VCM Leak/Release on the Bottom of Reactor Due to Gasket or Seal Failure 0 Steps Taken In the Event of a Power Failure 0 Operation of Automatic Shutdown/Isolation System 1 Operation of the Halon System in the Vinyl Control Room 1 Operation of the Emergency Generator for Vinyl Control Room 0 Operation of Deluge Water to Emergency Cooling Water System 0 Operation of Reactor Agitator On/Off/Auto Switch 2 Prepare a Batch Water Stripper for Entry 2 Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket 0 Schedule Shutdown/Tumaround 0 Start-Up of Old Module After an Emergency Shutdown 0 How to Start-Up After Scheduled Shutdown/Turnaround 0 How to Pressure Check Entire Recovery System and Put Back in Service 3 ABD00036973 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN OLD MODULE HAZOP The Hazop study focused on the following potential hazards: Fire Explosion Toxic Exposure Chemical Contact Thermal Bums Asphyxiation Impact Injury Fire * Explosion Corrosion Misoperation Overpressure Overheating Freezing Equipment Damage Power Failure Maintenance Turnarounds Equipment Failure Instrument Failure Misoperation Human Factors Past Incidents Facility Siting Failure of Engineering and Administrative Controls Spills Vapor Releases Emissions Fire Explosion 4 ABD00036974 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP IV. Team Members and Qualifications Selection of the Hazop team is consistant with OSHA requirements and the requirements outlined in the Condea Vista Company, Corporate Safety & Health Standard, PSM-004, " Process Hazard Analysis", section 4.7.2, July 30, 1998. Name Kelly Wood Title Facilitator David Covington Ed Mize Rusty Prillhart Vinyl Operations Supervisor "A" Mechanic Mechanic Shea Sargent Bob Newman David Nolen Charlie Peden Jeff Shields Nathaniel Wilson Milton Threadgill Plant Hygienist Vinyl Lead Operator Instrument Technician Instrument Technician Vinyl Shift Supervisor Chief Lead Operator Mechanic Craig English Engineer Expertise Engineering & Operations Vinyl Operations Qualifications Kelly has six years experience in the Aberdeen Plant and has performed two previous Hazop studies. Kelly has had formal Hazop team leader training. David has 18 years experience in vinyl unit operations. Maintenance Vinyl Operations Plant Hygiene Vinyl Operations Maintenance Maintenance Vinyl Operations Vinyl Operations Maintenance Engineering & Maintenance Ed has 25 years experience at the Aberdeen Plant Rusty has 14 years experience in Plant operations, 11 of which have been in the vinyl dept. Shea has 1 year experience at the Aberdeen Plant. Bob has 28 years experience in vinyl operations. David has 30 years experience in maintenance at the Aberdeen Plant. Charlie has 29 years experience in maintenance at the Aberdeen Plant. Jeff has 20 years experience in vinyl unit operations. Nate has 27 years experience in vinyl unit operations. Milton has 30 years experience at the Aberdeen Plant, 4 of which have been in the maintenance dept. Craig has 12 years experience in the Aberdeen Plant. 5 ABD00036975 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP V. Team Orientation A. Methodology The methodology used to perform the Hazop study is outlined in the Condea Vista Company, Corporate Safety & Health Standard, PSM-004, " Process Hazard Analysis", section 5, July 30, 1998. B. Risk Ranking Tables Risk Ranking of identified process hazards was completed per the instructions and information provided in the Condea Vista Company, Corporate Safety & Health Standard, PSM-004, " Process Hazard Analysis", Appendix D, July 30, 1998. ABD00036976 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP C. Hazop Execution Plan Gather required pre-work material (Appendix D). Select appropriate team members Post memo to all employees stating that a Hazop study will be done. Memo includes what area or process the Hazop will focus on, team members, meeting place, and meeting times. Hold Team Orientation Meeting. The orientation meeting is used to set the tone for the Hazop. It includes a review of the following: Purpose and Scope of the Hazop Rationale for choosing Hazop for the PHA Hazop Execution Plan Methodology Process Description Pre-work material Site Specific Hazards of the Process Previous Incidents Human Factors Facility Siting Perform line by line analysis of process nodes. Includes P&ID's and operating procedures. Identify Hazards of the Process Rank Hazards By How Much Risk They Exhibit Recommend Actions to Mitigate Risks Compile all team findings during Hazop into a report. 7 ABD00036977 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP D. Human Factors Checklist Equipment Labeling Access Operability Layout Uniqueness - +.< , 1 , '-a i 'rW . r 4.1, h io*t' equipment clearly labeled immediately at hand power assisted operation well-planned, logical arrangement only component of its kind in area mislabeled or not labeled hard to reach or access difficult to operate/change confusing/inconsistant arrangement several components look similar Observed Practice Controls ^ Labeling Mode Involvement Displays Dispays 4h4H* .+ * ,.,11 controls clearly labeled; uniform coding fully automatic; well-tuned operator continually involved clear, simple, representational immediant, unambiguous mislabeled or not labeled Observed ,,,,,,^.Practice manual operation; many manual steps operator detached from process unclear, complex, nonrepresentational none or potentially misleading "ft-: Deviations? sirAlarms Coverage Time Preparedness Last-Resort " ` *' jjjit1 + mr ft * * first-out; safety critical alarms dual operator coverage at all times no time pressure for response periodic simulation exercises shutdown not discourage; fast access "Hasp, . 'Hjjarr ^1 1 many simultaneous or false alarms operator not always present inadequate time for response no drills or simulation of scenarios shutdown discouraged or unsafe Observed Practice Transient ^ Procedures Identifying Format Aids ik -- % , ft * ] complete, accurate, current, incomplete/too general/out of date verified ID, location of devices/actions ambiguous device/action given identification graphical identification aids confusing/inconsistant; difficult to read checklist or supervisory check task sequence done by memory Observed Practice "+" = FACTORS BEYOND STANDARD PRACTICE; MAY REDUCE HUMAN ERROR OR INADEQUATE RESPONSE LIKELIHOOD. 8 ABD00036978 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP = FACTORS that may tend to increase the likelihood of of human error or inadequate RESPONSE. Scheduling ,"s- , + . Overtime Consistency permanent shift assignments # of Tasks Task Frequency Intensity tasks, work force, and skills matched routine tasks regular tasks at normal pace extreme enough to affect performance inconsistent shift rotations/schedules tasked required exceed time available very infrequent; no expertise base differing tasks in rapid succession Observed Practice Communicate Shift Changes Field/Control Supervision Emergency status communicated verbally, plus turnover sheet used constant communication with field operator frequent supervisory communication rapid, unambiguous plant alarm system inadequate communication of plant status between shifts no communication with field operator little or no supervisory checks Observed " ' Practice no distiction between area/type Environn^ Noise Level office environment noise level Climate indoors, climate controlled Visibility Lighting visibility enhancement of some kind area where hearing protection required temperature/humidity/ precipitation/wind extremes visibility limitation of some kind Observed SU.. inadequate lighing for task "+" = FACTORS BEYOND STANDARD PRACTICE; MAY REDUCE HUMAN ERROR OR INADEQUATE RESPONSE LIKELIHOOD. = FACTORS THAT MAY TEND TO INCREASE THE LIKELIHOOD OF OF HUMAN ERROR OR INADEQUATE RESPONSE. 9 ABD00036979 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP E. Team Orientation Meeting Review Checklist ^Reviewed X 1. Purpose of Hazop X 2. Rationale for choosing Hazop for the PHA X 3. Scope of Hazop X 4. Hazop Execution Plan X 5. Methodology X 6. Process Description X 7. Pre-work material X 8. Site Specific Hazards ofthe Process X 9. Previous Incidents X 10. Human Factors X 11. Facility Siting (Refer to Plant Facility Siting Study) 10 F. Attendance Records ABD00036980 Old Module Hazop English, Craig Shields, Jeff Threadgill, Milton Wilson, Nathaniel Wood, Kelly ------ - - - - - - nr:- - -- l Georgia Gulf Corp 11 F. Attendance Records ABD00036981 Old Module Hazop Covington, David English, Craig Mize, Ed Newman, Bob Nolen, David Peden, Charlie Prillhart, Rusty Sargent, Shea Shields, Jeff Threadgill, Milton Wilson , Nathaniel Wood, Kelly ^ --- /X& ------- ----------- Georgia Gulf Corp 12 ABD00036982 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP VI. General Process Description The polymerization reaction of vinyl chloride monomer (VCM) to form polyvinyl chloride (PVC) resin is a batch suspension process in which VCM, water, suspension agents, and reaction initiator are the primary constituents. The exothermic reaction takes place under pressure and is held at a constant temperature throughout the reaction. The mixture is kept in suspension by mechanical agitation. At the conclusion of the reaction, unused VCM is drawn off, compressed, condensed, and stored for reuse. The slurry is steam stripper to decrease the amount of residual VCM. Modifying reaction temperature, suspending agents, initiators, and recovery pressure can vary resin properties. 13 ABD00036983 VII. HAZARDS ANALYSIS A. Hazards of the Process The hazards associated with the process are the usual ones, i.e.: Loss of containment of a potentially hazardous chemical, with consequent exposure of personnel. Loss of containment of a flammable and/or explosive chemicals, with consequent fire and/or explosion. Loss of containment of an environmentally hazardous chemical, with the consequent environmental impact. There are a number of chemicals, part of the process, which were identified as potentially hazardous from a safety and/or environmental point of view. The hazards associated with each of these chemicals are summarized in the next section. The potential scenarios leading to the hazards shown above were extensively analyzed during the formal HAZOP sessions, and their causes and consequences are shown in the HAZOP table, Section VIII, E. B. Potential Safety and Health Effects In estimating the effects of the potential hazards, the properties of the chemicals involved were considered. These properties are shown in the Material Safety Data Sheets. See Appendix C (Pre-work Materials) for location of MSDS's. The effects of inadvertent mixing of the chemicals have also been analyzed, but no hazards were identified. C. Engineering and Administrative Controls The following engineering controls were identified as relevant: Instrumentation, controls, alarms, interlocks Area detection an analyzer devices Emergency shutdown system of the generating facility to a safe condition Emergency shutdown button Relief system to safe header (in some places) Ventilation system in control room 14 ABD00036984 Fire fighting equipment (both within the plant and from the local fire department) HAZMAT gear Dikes on storage area Explosion hatches on the storage tanks, baghouses Overflow lines on storage tanks Vent lines to safe location Deluge systems Backup emergency power system Breathing equipment throughout the plant Backup cooling water (firewater) A number of administrative controls intended to provide a safe work place were identified, such as: Safe work practices (lockout/tagout), hot work permit, use of respirators in hazardous areas, use of personal detection badges, etc.) Emergency response plan/team Preventive/predictive/proactive maintenance program and procedures Operating procedures Maintenance procedures Training program for operators, maintenance personnel, contractors, firefighting activities, emergency personnel, etc. Restricted access to hazardous areas, thus reducing potential exposure HAZMAT training and procedures Management of change system Evacuation procedures after maintenance Color coding of utilities lines Use of generally accepted standards (for engineering, piping, painting, etc.) Company standards, based on years of experience in working with the chemicals involved in this process, for its safe handling, storage, and processing Use of hand-held detection devices Periodic noise surveys During the PHA meetings, credit was taken for the safeguards provided by specific and generic controls, as shown in the HAZOP table, Section VIII, E. D. Consequence of Failure of Controls The potentially hazardous conditions which could lead to the hazards identified in section A are systematically addressed in the formal HAZOP processes, and listed in the Hazop tables. Section VIII, E. The 15 ABD00036985 consequences listed in this table assume failure of controls, which are then listed as safeguards for either reducing the probability of the event or mitigating its consequences. Whenever these safeguards were deemed sufficient by the team members, action items were included to further improve the safety of the system. Refer to the enclosed HAZOP table for specific scenarios of potential hazards, the risks associated with them, and the engineering and administrative control listed under safeguards, which reduce the associated risk. E. Previous Relevant Incidents A list of previous relevant incidents is enclosed in Appendices of this report. The recommendations arising from the analysis of the previous incidents are included in the List of Recommendations. F. Facility Siting The possible safety considerations associated with layout and siting are addressed by the Aberdeen Plant's Facility Siting Report dated Dec., 1998. Therefore the team chose not consider Facility Siting issues in the Hazop report. See Appendix C for information regarding the location of the Facility Siting report. G. Human Factors Human factors and their impact on the safe operation and maintenance of the process were addressed at all stages of the analysis. To insure more complete coverage of this important issue, a human factors checklist was used to establish the team's mindset in considering human factors and is shown in the Team Orientation section of this report. Recommendations arising from the analysis of this checklist is included in the List of Recommendations section. H. General Deviations In addition to the deviations listed in the HAZOP table, Section VIII, E. Some deviations of a general nature were also considered, i.e., compatibility of vent streams, external leak and rupture, contamination, external fire, external events, effects of emergency operation, shutdown, etc. Recommendations arising from the teams' discussion can be found in the List of Recommendations section. ABD00036986 LIST OF HAZARDS ABD00036987 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP VIII. List of Hazards Identified A. Preliminary Hazard Review 1. Location of Rust trailer relative to the VCM tankfarm. The trailor is not explosion proof. 2. Deluge house by open dump system, north of stripper, and in NE comer of recovery building have seemingly light protection. Also, the two older deluge valves have manual valves that are hard to operate. 3. Crane outrigger placement points can be placed on sewers. 4. Setting up crane to work on stripper. 5. Not enough electrical outlets to avoid using long extension cords. 6. Relief valve discharge locations on catalyst charge pots. 7. Hot work permit does not address restarting vehicles in unit once they have been shut off for a significant amount of time. 8. Some equipment may need individual fire protection. 9. Plant alarm system is inadequate in some areas. 10. One exit exists for the OM recovery building addition. B. Human Factors Review 1. Equipment and line labeling poor. 2. Rx-700 cooling water supply and return valves are in a hard to access location. 3. Some controls are local and not on the DCS. 4. Changing VCM filters while charging a reactor. 5. Lighting is poor under the reactors, on top ofthe reactors, and at filter packs. C. Past Incidents Review No hazards identified. D. P&ID/Operating Procedure Review See PHAPRO output starting on next page. Hazards with risk rankings of 4 are: Nodes 1.1.2 1.2.3 1.4.2 1.5.2 8.4.4 9.4.1 17 ABD00036988 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 1. DM-013, FVCM Receiver Type: Vessel Drawing: OM-090100-PID-D Design Conditions/Parameters: MAWP: 150 psig; MOC CS Georgia Gulf Corp Dev Consequences 1.1 High Pressure CAT S L RR Safeguards Causes 1. Fire and explosion 2. Lift relief valve 3. Blow gasket 1.2 High Temperature S/E 3 D 5 1. Pressure transmitter, 81p746 S/E 3 C 4 2. relief valve S/E 4 C 5 3. Equalization line 1. Pump malfunction 2. Equalization line plugged 3. instrument failure 1. Fire and explosion 2. High pressure 3. Lift relief valve S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. relief valve S/E 3 C 4 3. Temperature gauge 1. Fire 2. Heat tracing on in warm weather 1.3 Low Temperature 1. Water freeze in receiver bottom 1.4 High Level S/E 4 C 5 1. Heat tracing 2. Operating procedures 3. Temperature gauge 1. Cold weather 2. Heat trace off or not enough heat trace 1. High pressure 2. Lift relief valve 1.5 Leak S/E 4 C S/E 3 C 5 1. relief valve 4 2. sight glass 3. level instrument, 811745/811749 1. Level transmitter failure 2. Pump malfunction 1. Fire and explosion 2. Personnel exposure S/E 3 D 5 1. Fixed point monitor 1. Pressure gauge failure S 3 C 4 2. general monitor 2. High pressure 3. Fire Protection System 3. Gasket failure 4. Engineering standard for 4. High level material compatibility 5. level/pressure indication, 811745/ 81p746 1.6 Start-up/Shutdown Hazards 1. Personel Exposure S 3 D 5 1. Maintenance & operating procedures 1. Not recovered sufficiently 2. Not pressure checked 3. Not blanked out properly 18 ABD00036989 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 2. FVCM Charge Pump Suction Line And Relief Valve/RV Discharge Line Type: Line Drawing: OM-090100-PID-D Design Conditions/Parameters: 800 GPM, Ambient temp, Pipe Spec A2-22 Georgia Gulf Corp Dev Consequences 2.1 High Pressure 1. Lift relief valve 2. Blow gasket 3. Valve packing leak 2.2 High Temperature 1. Fire and explosion 2. High pressure 3. Lift relief valve 4. Personnel exposure 2.3 Low Temperature 1. Line freeze CAT S L RR Safeguards S/E 4 C S/E 4 B S/E 4 A 5 1. relief valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor S/E 3 D 5 1. Fire Protection System S/E 4 C 5 S/E 4 C 5 S 4C 5 S/E 4 C 5 1. winter shelter Causes 1. External heat 2. Closed valve 3. Relief valve plugged 1. Fire 1. Cold weather 19 ABD00036990 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 3. FVCM Charge Pump Type: Centrifugal Pump Drawing: OM-090100-PID-D Design Conditions/Parameters: 3x6-13-10 7/8, Ductile Iron, 800 GPM @ 196 psi, Double Mechanical Seal Georgia Gulf Corp Dev Consequences 3.1 High Pressure 1. Seal failure 2. Blow gasket 3. Pump case failure 4. High temperature 3.2 Leak 1. Personal exposure 2. Fire/Explosion 3.3 High Temperature 1. Seal failure 2. Fire/explosion CAT S L RR Safeguards Causes S/E 4 B 5 1. recirculation line locked open S/E 4 C 5 S/E 3 D 5 S/E 4 D 5 1. Recirculation line closed/plugged 2. discharge blocked/plugged S 4B S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 1. Seal failure 2. Gasket failure 3. Pump casing failure S/E 4 C 5 1. Fire Protection System S/E 3 D 5 2. Equalization line 1. Discharge blocked 2. recirculation line blocked 3. plugged filter 4. External heat 20 ABD00036991 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 4. FVCM Charge Pump Discharge Line To FVCM Filters Type: Line Drawing: OM-090100-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 4.1 High Pressure 1. Lift relief valve 2. Blow gasket 3. Valve packing leak 4.2 High Temperature 1. High pressure 2. Lift relief valve 4.3 Low Temperature 1. Frozen Line 4.4 Low/No Flow 1. High pressure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 B 5 1. relief valve 1. Plugged filter pack 5 2. DCS interlocks, valve 81hv706/ 2. Plugged relief valve 5 707 3. external heat 3. Operating procedures 4. Valve blocked in/closed S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. relief valve 1. External heat S/E 4 C 5 1. Winterization 1. Cold weather S/E 4 C 5 1. Operating procedures 1. Plugged filter 2. Recovery Line Open 3. Plugged Line 21 ABD00036992 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 5 FVCM Filters and Relief Valve/Relief Valve Discharge Line Type. Vessel Drawing: OM-090100-PID-D Design Conditions/Parameters: MAWP 300 psig @ 150 F, 316 ss Georgia Gulf Corp Dev Consequences 5.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Blown O-Ring 5.2 High Temperature 1. Fire and explosion 2. High pressure 3. Lift relief valve 4. Personnel exposure 5.3 Low Temperature 1. Frozen Line 2. No flow 3. High pressure 5.4 Start-up/Shutdown Hazards 1. Personal exposure 2. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Equalization line S/E 4 B 5 2. Operating procedures S 4 C 5 3. relief valve S/E 4 C 5 4. Pressure Gauge 1. Plugged Filter 2. Equalization Line Plugged 3. Closed Outlet Valve 4. External Heat S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Operating procedures S/E 4 B 5 3. relief valve S 4C 5 1. External heat S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Heat tracing on recovery line S/E 4 C 5 1. Cold weather S 4C S/E 3 D 5 1. Personal Protective Equipment 5 2. Operating procedures 3. Operator training 1. Operator error 2. O-ring not installed 3. Lid bolts not tight 22 ABD00036993 VIIID. Hazards Identified - P&ID/Operating Procedures Review Node: 6. FVCM Filter Outlet Line To Reactors Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 6.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 6.2 High Temperature 1. Fire and explosion 2. High pressure 3. Lift relief valve 4. Personal exposure 5 VCM release 6.3 Low Temperature 1. Line freeze 6.4 Reverse/Misdirected Flow 1. Overpressure batchwater stripper 2. Lift relief valve CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 3 D 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. relief valve 1. Line plugged 2. Valve closed 3. External heat S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor S/E 4 B 5 3. general monitor S 4 C 5 4. Personal Protective Equipment S/E 3 D 5 5. relief valve 6. Temperature gauge 7. Temperature transmitter, 81t748 S/E 4 C 5 1. Operating procedures 1. Cold weather S/E 3 D 5 1. Equipment Preventive Maintenance Program S/E 4 C 5 1. Faulty relief valve 23 ABD00036994 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 7. DM-013, FVCM Receiver Equalization Line Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 7.1 High Pressure 1. Personal exposure 2. VCM release 3. Valve packing leaking 4. Gasket failure 7.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM release 7.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards Causes S 4C S/E 3 D S/E 4 B S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. DCS interlock, valve 81xv708 1. Line plugged 2. Valve closed 3. External heat S/E 3 D S/E 4 C S/E 4 C S 4c S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat S/E 4 C 5 1. Pipe routing prevents standing water 1. Cold weather 24 ABD00036995 VIII.D Hazards Identified - P&ID/Operating Procedures Review Node: 8. DM-013, FVCM Receiver Drain Line Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 8.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 8.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 8.3 Low Temperature 1. Frozen Line 8.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 B 5 2. Fixed point monitor S/E 4 B 5 3. general monitor S/E 3 D 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat S/E 4 C 5 1. Heat tracing 2. Operating procedures 3. Operator training 1. Cold weather S/E 3 D S/E 4 C S/E 3 D S/E 3 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 4 5. Operator training 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 25 ABD00036996 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 9. FVCM Charge System Bypass Line Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 9.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 9.2 High Temperature 1. Fire and explosion 2. High pressure 3. Personal exposure 4. VCM release 9.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 4. VCM release 9.4 Reverse/Misdirected Flow 1. If valve is left open and vcm transfer pumps are running , can't isolate unit. CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Line plugged 3. Valve closed 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 1. External heat S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Cold weather S/E 3 C 4 1. Operating procedures 2. Operator training 1. Operator error 26 ABD00036997 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 10. DM-013 Fill Line From FVCM Transfer Pumps Type: Line Drawing: OM-090100-PID-D Design Conditions/Parameters: Pipe Spec A2-22 Georgia Gulf Corp Dev Consequences 10.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 10.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. VCM release 10.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 B S/E 3 D 5 1. DCS interlock, valve 81 hv701 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 3 D 5 1. DCS interlock 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 1. External heat S/E 3 D 5 1. DCS interlock S/E 4 C 5 2. Fire Protection System S/E 4 C 5 3. Fixed point monitor S/E 3 D 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 27 J ABD00036998 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 11. FVCM Charge Pump Recirculation Line Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 11.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 11.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. VCM release 11.3 Low Temperature 1. Frozen Line 2. High pressure 3. Fire and explosion 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. External heat S/E 4 D 5 1. Operating procedures S/E 4 C 5 2. Fire Protection System S/E 3 D 5 3. Fixed point monitor S/E 4 C 5 4. general monitor S/E 3 D 5 5. Personal Protective Equipment 1. Cold weather 28 ABD00036999 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 12. MSPW Line To FVCM Charge Pumps Type: Line Design Conditions/Parameters: Pipe SpecA2-3 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 12.1 High Temperature 1. Seal failure 12 2 Low Pressure 1. Seal failure 2. VCM Leak 12.3 Low Temperature 1. Frozen Line 2. No flow 3. Seal failure 4. VCM Leak 12.4 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak CAT S L RR Safeguards Causes S/E 4 D 5 1. Fire Protection System S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Equipment Preventive Maintenance Program 3. Fixed point monitor 4. Operating procedures 5. Operator training 6. Pressure Gauge 1 External heat 1. Line plugged 2. Operator error 3. Valve closed 4. Valve failure 5. Filter plugged 6. Power Failure S/E 4 C 5 1. Heat tracing S/E 4 D 5 2. Fixed point monitor S/E 4 C 5 S/E 4 C 5 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Valve closed 4. Valve failure 5. Regulator failure 29 ABD00037000 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 13. FVCM Charge Pump Recovery Line Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 13.1 High Pressure 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM Leak 13.2 Low Temperature 1. Frozen Line 13.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. High pressure in batch water stripper S/E 4 c 5 1. Heat tracing 1. Cold weather S/E 3 D 5 1. Equipment Preventive S/E 3 D 5 Maintenance Program 2. Operating procedures S/E 4 C 5 3. Operator training S/E 4 C 5 1. Operator error 2. Valve failure 30 ABD00037001 VIIID Hazards Identified - P&ID/Operating Procedures Review Node: 14. Recirculation Line Off FVCM Charge Filters Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PID-D Georgia Gulf Corp Dev Consequences 14.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 14.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. VCM release 14.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. High pressure 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure S/E 3 D S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. External heat S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Cold weather 31 ABD00037002 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 15. Relief Valve and RV discharge line off RVCM charge pump discharge line Type: Line Drawing: OM-090100-PID-D Design Conditions/Parameters: Pipe Spec A2-22 Georgia Gulf Corp Dev Consequences 15.1 High Pressure 1. Create heat in RVCM pump 2. Blow seal in RVCM pump 3. Fire and explosion 4. VCM Leak 15.2 High Temperature 1. Fire and explosion 2. High pressure 3. Personal exposure 4. VCM release 15.3 Low Temperature 1. Frozen Line 2. No flow 3. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor 2. High pressure in batch water S/E 3 D 5 3. general monitor stripper S/E 4 C 5 4. Personal Protective Equipment 3. Line plugged 5. relief valve 4. Valve closed 6. Locking devices on relief valves 7. Operating procedures S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 1. External heat S/E 4 C S/E 4 C S/E 3 D 5 1. none 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Personal Protective Equipment 1. Cold weather 32 ABOT0037003 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 16. Recirculation header from VCM charge equipment to DM-013 Type: Line Drawing: OM-090100-PID-D Design Conditions/Parameters: Pipe Spec A2-22 Georgia Gulf Corp Dev Consequences 16.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM release 16.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM Leak 16.3 Low Temperature 1. Fire and explosion 2. High pressure 3. No flow 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 1. High pressure in batch water 5 2. Fixed point monitor stripper 5 3. general monitor 2. Line plugged 5 4. Locking devices on relief valves 3. Valve closed 5 5. Personal Protective Equipment 6. relief valve 7. DCS interlock, valve 81xv709 S/E 3 D S/E 4 C S/E 4 C S/E 3 D S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Personal Protective Equipment 5 5. relief valve 5 1. External heat S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 5 1. Cold weather 33 ABD00037004 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 17. RVCM Charge Pump Discharge Line to FVCM Charge Pump Suction Type: Line Drawing: OM-090100-PID-D Design Conditions/Parameters; Pipe SpecA2-22 Georgia Gulf Corp Dev Consequences 17.1 High Pressure 1. Blow gasket 2. Lift relief valve 3. Valve packing leak 17.2 High Temperature 1. High pressure 2. Lift relief valve 3. Fire and explosion 4. Personal exposure 17.3 Low Temperature 1. Frozen Line 2. Fire and explosion 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. DCS interlocks, valve 81 hv703 S/E 4 c 5 2. Operating procedures S/E 4 c 5 3. relief valve 1. external heat 2. Plugged filter pack 3. Plugged relief valve 4. Valve blocked in/closed S/E 4 c 5 1. Fire Protection System S/E 4 c 5 2. relief valve S/E 3 D 5 3. Fixed point monitor S/E 3 D 5 4. general monitor 5. Personal Protective Equipment 1. External heat S/E 4 C S/E 3 D S/E 3 D S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 1. Cold weather 34 ABD00037005 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 18. Recovery Line Off FVCM Charge Filters Type: Line Design Conditions/Parameters: Pipe Spec A2-22 Old Module Hazop Drawing: OM-090100-PI D-D Georgia Gulf Corp Dev Consequences 18.1 High Pressure 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM Leak 18.2 Low Temperature 1. Frozen Line 18.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM release 5. Send VCM to recovery system CAT S L RR Safeguards Causes S/E 3 D S/E 4 B S/E 4 C S/E 4 B 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. High pressure in batch water stripper 3. Line plugged 4. Operator error 5. Valve closed S/E 4 B 5 1. Heat tracing 1. Cold weather 2. Valve leaking through 3. Heat tracing failure S/E 3 D 5 1. Equipment Preventive S/E 4 B 5 Maintenance Program 2. Operating procedures S/E 4 C 5 3. Operator training S/E 3 D 5 4. Fire Protection System S/E 4 B 5 5. Fixed point monitor 6. general monitor 7. Personal Protective Equipment 1. Operator error 2. Valve failure 35 ABD00037006 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 19. Steam Supply Line to charge water pick heater Type: Line Drawing: OM-090101-PID-D Design Conditions/Parameters: pipe spec a2-3 Georgia Gulf Corp Dev Consequences CAT s L RR Safeguards 19.1 High Pressure 1. Gasket failure 2. Valve packing leaking 3. Line rupture 4. Scald hazard S 4 B 5 1. Operating procedures S 4 B 5 2. Operator training s 4 B 5 3. Pressure Gauge s 4 B 5 4. Line insulation 19.2 Low Pressure 1. Reverse flow of water into steam s 4 B 5 1. Pressure Gauge line resulting in water hammer and line rupture 19.3 Low Temperature 1. Frozen Line s 4 B 5 1. Equipment Preventive Maintenance Program 2. Operator training Causes 1. Line plugged 2. Valve failure 3. Valve leaking through 1. Cold weather 2. Operator error 3. Valve closed 4. Control Valve failure 1. Cold weather 36 ABD00037007 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 20. Charge water supply line to charge tank and process water filter Type: Line + Vessel Drawing: OM-090101-PID-D Design Conditions/Parameters: Pipe Spec a2-3; Filter MAWP 300 psig @ 200 F Georgia Gulf Corp Dev Consequences CAT S L RR Safeguards 20.1 High Pressure 1. Gasket failure 2. Lift relief valve 3. Overpressure filter pack S 4 C 5 1. relief valve S 4 B 5 2. Operating procedures S 4 C 5 3. Operator training 20.2 Low Pressure 1. Reverse flow of steam into water line resulting in water hammer and line rupture S 4C 5 1. Operating procedures 2. Operator training 3. Pressure Gauge 20.3 High Temperature 1. Line rupture S 4 C 5 1. Operator training 2. relief valve 20.4 Low Temperature 1. Frozen Line 2. Gasket failure 3. Line rupture 4. No flow S 4 C 5 1. Line insulation S 4 C 5 2. Operating procedures S 4 C 5 3. Operator training S 4B 5 Causes 1. Line blocked in with external heat (thermal expansion) 1. Valve closed 2. Line plugged 1. Line blocked in with external heat (thermal expansion) 1. Cold weather 37 ABD00037008 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 21. Charge water pick heater and outlet line to charge tank TK-023 Type: Heat Exchanger + Line Drawing: OM-090101-PID-D Design Conditions/Parameters: Pipe Spec a13-1 Georgia Gulf Corp Dev Consequences 21.1 High Pressure 1. Line rupture 2. Valve packing leaking 3. Make hot water tank vibrate 21.2 High Temperature 1. Gasket failure 2. High pressure 3. Line rupture 4. Overpressure filter pack 5. Valve packing leaking 21.3 Low Temperature 1. Frozen Line CAT s L RR Safeguards Causes S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 c 5 1. Line blocked in with external heat (thermal expansion) 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure 6. Valve leaking through S 4 B 5 1. Operating procedures 1. External heat S 4 B 5 2. Temperature Indication 81T026 2. Line blocked in with external s 4C 5 heat (thermal expansion) s 4C 5 3. Line plugged s 4B 5 4. Operator error 5. Valve closed 6. Valve leaking through s 4 C 5 1. Line insulation 1. Cold weather 38 r ABD00037009 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 22. Hot water supply line to Brine Tank, TK-313 Type: Line Design Conditions/Parameters: Pipe Speca13-1, ss Old Module Hazop Drawing: OM-090101-PID-D Georgia Gulf Corp Dev Consequences 22.1 High Pressure 1. Gasket failure 2. Line rupture 22.2 High Temperature 1. Gasket failure 2. Line rupture 22.3 Low Temperature 1. Frozen Line CAT s L RR Safeguards S 4 C 5 1. Operating procedures S 4C 5 s 4 C 5 1. Operating procedures s 4C 5 s 4 c 5 1. Line insulation Causes 1. External heat 1. External heat 1. Cold weather 39 ABD00037010 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 22. Hot water supply line to Brine Tank, TK-313 Type: Line Design Conditions/Parameters: Pipe Spec a13-1, ss Old Module Hazop Drawing: OM-090101-PID-D Georgia Gulf Corp Dev Consequences 22.1 High Pressure 1. Gasket failure 2. Line rupture 22.2 High Temperature 1. Gasket failure 2 Line rupture 22.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4C 5 S 4 C 5 1. Operating procedures S 4C 5 S 4 C 5 1. Line insulation Causes 1. External heat 1. External heat 1. Cold weather 39 ABU00037011 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 23. Hot water charge tank, TK-023 Type: Tank Drawing: OM-090101-PID-D Design Conditions/Parameters: 35,000 Gallon Atmos.Tank, Insulated Georgia Gulf Corp Dev Consequences 23.1 High Pressure 1. Tank rupture 23.2 High Temperature 1. Tank rupture CAT s L RR Safeguards Causes S 4 C 5 1. Operating procedures 2. sight glass 3. Vents 4. Overflows 5. Temperature Indicator 81T008 6. Level Indicator 81L006 1. Overflow plugged 2. vent plugged 3. External heat S 4 C 5 1. Temperature Indicator 81T008 2. sight glass 3. Tank insulation 1. External heat 2. Valve failure 3. Water addition valve failure- 81 H007 40 ABD00037012 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 24. Hot water supply line to rinse pump Type: Line Design Conditions/Parameters: Pipe Spec a2-3 Old Module Hazop Drawing: OM-090101-PID-D Georgia Gulf Corp Dev Consequences 24.1 High Pressure 1 Gasket failure 2. Line rupture 3. Valve packing leaking 24.2 High Temperature 1. Gasket failure 2. Line rupture 3. Valve packing leaking 24.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4D 5 S 4C 5 S 4 C 5 1. Operating procedures S 4D 5 S 4C 5 S 4 C 5 1. Heat tracing 2. Operator training Causes 1. Line plugged 2. Valve closed 3. Valve failure 4. Valve leaking through 1. External heat 1. Cold weather 41 ABD00037013 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 25. Hot water charge line from charge tank through charge pumps and charge filters Type: Centrifugal Pump + Line + Vessel Drawing: OM-090101-PID-D Design Conditions/Parameters: Pipe spec a 13-1; Pumps 3x4-13-11,450 GPM @ 150 psig; Filter MAWP 300 psig @ 190 F. Dev Consequences 25.1 High Pressure 1. Gasket failure 2. Lift relief valve 3. Line rupture 4. Overpressure filter pack 5. Seal failure 6. Valve packing leaking 25.2 High Temperature 1. Gasket failure 2. Lift relief valve 3. Line rupture 4. Seal failure 5. Valve packing leaking 25.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards Causes S 4 C 5 1. Operating procedures S 4 A 5 2. Pressure Gauge S 4 D 5 3. relief valve S 4C 5 S 4c 5 S 4c 5 1. External heat 2. Line plugged 3. Valve closed 4. Valve failure 5. Filter plugged S 4 c 5 1. Operating procedures S 4 B 5 2. relief valve S 4 D 5 3. Temperature Indicator 81T020 S 4C 5 S 4C 5 1. External heat S 4 C 5 1. Line insulation 1. Cold weather 42 ABTO0O37O14 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 26. Decal System; includes fitters, decal tank, and piping Type: Line + Vessel Drawing: OM-090101-PID-D Design Conditions/Parameters: filters MAWP 300 psig @ 190 F, Decal tank MAWP 250 psig, pipe spec a13-1 Georgia Gulf Corp Dev Consequences 26.1 High Pressure 1. Gasket failure 2. Lift relief valve 3. Line rupture 4. Tank rupture 26.2 High Temperature 1. Gasket failure 2. High pressure 3. Lift relief valve 4. Line rupture 5. Seal failure 6. Tank rupture 26.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4 B 5 2. relief valve S 4D 5 S 4D 5 S 4 C 5 1. Line insulation S 4 C 5 2. Operating procedures S 4 B 5 3. Operator training S 4 C 5 4. Pressure Gauge S 4 C 5 5. relief valve S 4 C 5 6. Tank insulation 7. Temperature gauge S 4 C 5 1. Heat tracing 2. Line insulation 3. Tank insulation Causes 1. External heat 2. Filter Plugged 3. Line plugged 4. Valve closed 5. Valve failure 6. Valve leaking through 1. External heat 2. Filter Plugged 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure 7. Valve leaking through 1. Cold weather 43 ABD00037015 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 27. Cold water Supply to charge water pumps. Also supplies wet calcium stearate and brine tank. Type: Line Drawing: OM-090101-PID-D Design Conditions/Parameters: Pipe spec a2-3 Georgia Gulf Corp Dev Consequences 27.1 High Pressure 1. Gasket failure 2. Line rupture 3. Valve packing leaking 27.2 High Temperature 1. Gasket failure 2. Line rupture 3. Seal failure 4. Valve packing leaking 27.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4D 5 S 4C 5 S 4 c 5 1. Line insulation S 4 D 5 2. Operating procedures S 4C 5 S 4C 5 S 4 C 5 1. Heat tracing 2. Line insulation Causes 1. Control Valve failure 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure 6. Valve leaking through 1. Control Valve failure 2. External heat 3. Line plugged 4. Valve closed 5. Valve failure 1. Cold weather 44 ABD00037016 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 28. Hot water make-up from centrate heat recovery system to hot water charge tank. Type: Line + Vessel Drawing: OM-090101-PID-D Design Conditions/Parameters: 250 GPM, 200 Deg F, Pipe spec A2-3 to FL-102, A13-1 from FL-102. FL-102, MAWP 150 psig @ 500 F. MOCCS. Dev Consequences 28.1 High Pressure 1. Gasket failure 2. Lift relief valve 3. Line rupture 28.2 High Temperature 1. Gasket failure 2. High pressure 3. Lift relief valve 4. Overpressure filter pack 28.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4 B 5 2. relief valve S 4C 5 S 4 c 5 1. Operating procedures S 4 c 5 2. relief valve S 4B 5 S 4C 5 S 4 C 5 1. Line insulation Causes 1. External heat 2. Filter Plugged 3. Valve closed 4. Relief Valve failure 1. External heat 1. Cold weather 45 ABD00037017 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 29. Process water supply to charge pumps. Intent is a back-up water source. Type: Line Drawing: OM-090101-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 29.1 High Pressure 1. Line rupture 29.2 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4 C 5 1. Line insulation Causes 1. External heat 2. Line plugged 1. Cold weather 46 ABD00037018 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 30. Decal water supply line to rinse tank. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Drawing: OM-090101-PID-D Georgia Gulf Corp Dev Consequences 30.1 High Pressure 1. Gasket failure 2. Line rupture 3. Valve packing leaking 30.2 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Operating procedures S 4 D 5 2. Pressure Gauge S 4C 5 S 4 C 5 1. Line insulation Causes 1. External heat 2. Filter Plugged 3. Line plugged 4. Valve closed 5. Valve failure 6. Valve leaking through 1. Cold weather 47 ABD00037019 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 31. Decal Tank drain line from rinse tank. Type: Line Design Conditions/Parameters: Pipe spec A2-3 Old Module Hazop Drawing: OM-090101-PID-D Georgia Gulf Corp Dev Consequences 31.1 High Pressure 1. no consequences 31.2 Low Temperature 1. Frozen Line CAT S L RR Safeguards S 4 C 5 1. Line insulation Causes 1. Cold weather 48 ABD00037020 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 32. Brine supply line to Decal tank from brine make-up Type: Line Drawing: OM-090101-PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 32.1 Low/No Flow 1. no consequences 32 2 Reverse/Misdirected Flow 1. No consequences 32.3 High Pressure 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 49 ABD00037021 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 33. Old Module reactors: 300,400,500,600,700. Type: Reactor Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: RX-300-600, MAWP 200 psig @ 200 F; RX-700 25 psig @ 250 F Dev Consequences 33.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Seal failure 6. Valve packing leaking 7. Vessel rupture 8. O-Ring failure 9. Valve failure 10. Condenser Tube failure 33.2 High Temperature 1. See High Pressure 33.3 Low Pressure 1. none 33.4 Low Temperature 1. High pressure 2. High temperature 3. Fire and explosion 4. Personal exposure 5. Vessel rupture 6. Lift relief valve 33.5 High Level 1. Fire and explosion 2. High pressure 3. High temperature 4. Lift relief valve 5. O-Ring failure 6. Personal exposure 7. Seal failure 8. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Equipment Preventive 2. Operator error S/E 4 C 5 Maintenance Program 3. Relief Valve failure S 4 C 5 3. Fixed point monitor s 4 D 5 4. general monitor s 4 B 5 5. Maintenance & operating 4. Valve closed 5. Valve failure 6. Valve leaking through S/E 3 D 5 procedures 7. Instrument failure S/E 4 C 5 6. Operator training 8. Agitator failure S/E 4 C 5 7. Personal Protective Equipment 9. Power failure S/E 4 C 5 8. Pressure Gauge 10. Steam Control Valve failure 9. multiple relief valves 11. Cooling Water Control Valve 10. Temperature gauge failure 11. Temperature Indication 81T164 12. Catalyst water addition valve 12. Temperature Indication 81T161 left on 13. Temperature Indication 13. Too much catalyst 81T156A 14. Charging System Malfunction 14. Pressure Indication 81P162 15. Too many inerts 15. Pressure Indication 81P163 16. Too much lip seal water 16. Agitator Run Indication 81H170 17. Too much spray head flow 17. Amp Indication 811172 18. Recovery line plugged 18. Auto Kill Program- activates on 19. Inert Vent line plugged high pressure 19. Emergency Manual Kill Procedure 1. See High Pressure 1, See High Pressure 1. none 1.none S/E 4 B S/E 4 B S/E 3 D S 4C S/E 3 D S/E 4 C 5 1. Operating procedures 1. Possible batch separation 5 2. Operator training 5 3. Temperature Indication 81T164 5 4. Temperature Indication 81T156A 5 5. Agitator Amp indication 811172 5 S/E 3 D S/E 4 C S/E 4 C S/E 3 D S/E 4 C S 4C S/E 4 D S/E 4 C 5 1. Redundant charge meters 5 2. Operating procedures 5 3. Dump line bulls-eye 5 5 5 5 5 50 1. Operator error 2. Charge meter failure 3. Too much flush water 4. Incomplete dump ABD00037022 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 33. Old Module reactors: 300,400,500,600,700. Type: Reactor Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: RX-300-600, MAWP 200 psig @ 200 F; RX-700 25 psig @ 250 F Dev Consequences 33.5 cont'd 9. VCM release 10. Vessel rupture 11. Condenser plugged CAT S L RR S/E 3 D S/E 3 D S/E 4 C 5 5 5 Safeguards Causes 51 ABD00037023 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 34. VCM Charge line to RX-300,400,500.600,700 Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Georgia Gulf Corp Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Dev Consequences 34.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 34.2 High Temperature 1. Fire and explosion 2. Gasket failure 3 High pressure 4. O-Ring failure 5. Personal exposure 6. VCM Leak 34.3 Low Temperature 1. Frozen Line 2. VCM Leak 34.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. DCS interlock-abort charge on high reactor pressure 1. External heat 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. High Pressure in Reactor S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3 general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. DCS interlock - vcm charge valves cannot be open at the same time as dump and rinse valves. 7. Low flow shutdown 8. DCS interlock - abort vcm charge on low flow. 1. High Pressure in Reactor 2. Instrument failure 3. Operator error 4. Valve failure 5. Pump failure 52 ABD00037024 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 35. Water charge line to RX-300,400,500,600.700 Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 35.1 High Pressure 1. Gasket failure 2. Fire and explosion 3. VCM Leak 35.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. O-Ring failure 5. Personal exposure 6. VCM Leak 35.3 Low Temperature 1. Frozen Line 2. High pressure 35.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3 VCM Leak CAT S L RR Safeguards Causes S/E 4 C S/E 3 D S/E 4 C 5 1. DCS interlock- charge program 5 shutdown on high reactor 5 pressure 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Pump failure 5. Valve closed 6. Valve failure 7. Check valve failure 8. High Pressure in Reactor S/E 3 D S/E 4 C S/E 4 C S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 4 c 5 1. Line insulation S/E 4 c 5 1. Cold weather S/E 3 D S/E 4 C S/E 4 D 5 1. DCS interlock- charge water 5 valve can only open during 5 charge and open dump mode. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Low flow shutdown 6. Maintenance & operating procedures 7. Personal Protective Equipment 8. DCS interlock- abort water charge on low flow. 1. High Pressure in Reactor 2. Instrument failure 3. Operator error 4. Pump failure 5. Valve failure 53 ABD00037025 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 36. Rinse water line to RX condenser, shell, and dump header. RX-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A2-3.A13-2 Dev Consequences 36.1 High Pressure 1. Gasket failure 2. Line rupture 3. Valve packing leaking 36.2 High Temperature 1. High pressure 2. Line rupture 36.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Valve failure 36.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures 1. External heat S/E 4 C S/E 4 c 5 2. Operator training 2. High Pressure in Reactor 5 3. Recycle line on rinse pump, pp- 3. Line plugged 229, thru valve, 81 h018. 4. Valve closed 5. Valve leaking through S/E 4 c 5 1. Fire Protection System S/E 4 c 5 2. Operating procedures 3. Operator training 1. External heat S/E 4 c 5 1. Line insulation S/E 4 c 5 2. Operating procedures S/E 4 c 5 3. Operator training 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock valve 81h145 will 1. High Pressure in Reactor 5 open if RX pressure < 120 psig 2. Operator error 5 and all other reactor flush 3. Power failure 5 header valves are closed. 4. Pump failure 5 2. DCS interlock - valve 81 hvl 38. 5. Valve failure Won't open unless RX in dump 6. Valve leaking through and all other RX rinse valves closed 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operator training 7. Personal Protective Equipment 8. Check valve 54 ABD00037026 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 37. F-50 charge line to RX-300,400,500,600,700. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Georgia Gulf Corp Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Dev Consequences 37.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 37.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 37.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 37.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Heat tracing 8. Line insulation 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Check valve 1. High Pressure in Reactor 5 2. DCS interlock - valve 81 hvl 10. 2. Operator error 5 Won't open unless RX in charge 3. Power failure 5 and all other RX F-50 valves 4. Pump failure closed 5. Valve failure 3. Fire Protection System 6. Valve leaking through 4. Fixed point monitor 5. general monitor 6. Operator training 7. Personal Protective Equipment 8. DCS interlock - abort F-50 charge on low flow 55 ABD00037027 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 38. Alcotex charge line to RX-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-Q90105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 38 1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 38.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 38.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 38.4 Reverse/Misdirected Flow 1. Fire and explosion 2 Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 c 5 4. Operating procedures S/E 4 c 5 5. Operator training S/E 4 c 5 6. Personal Protective Equipment S/E 4 c 5 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Check valve 1. High Pressure in Reactor 5 2. DCS interlock - valve 81 hvt 11. 2. Operator error 5 Won't open unless RX in charge 3. Power failure 5 or poly and all other RX Alcotex 4. Pump failure valves closed 5. Valve failure 3. Fire Protection System 6. Valve leaking through 4. Fixed point monitor 5. general monitor 6. Operator training 7. Personal Protective Equipment 8. DCS interlock - Abort alcotex charge on low flow. 56 ABD00037028 VIIID. Hazards Identified - P&ID/Operating Procedures Review Node: 39. Alcotex line to rinse header. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Drawing: OM-090102-PID-D Georgia Gulf Corp Dev Consequences 39.1 High Pressure 1. Gasket failure 2. Line rupture 3. Valve leaking 39.2 High Temperature 1. Gasket failure 2. High pressure 3. Line rupture 4. Valve packing leaking 39.3 Low Temperature 1. Frozen Line 2. Line rupture 3. No flow CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Valve closed S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Operating procedures 5 3. Operator training 5 4. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Operator error S/E 4 C 5 1. Heat tracing S/E 4 C 5 2. Line insulation S/E 4 C 5 3. Operating procedures 4. Operator training 1. Cold weather 57 ABD00037029 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 40. External Dump Line. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-P1D-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec B13-22 Dev Consequences 40.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 40.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 40.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. High Pressure in Reactor 3. Instrument failure 4. Line plugged 5. Operator error 6. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. DCS interlock Dump valve can 1. Instrument failure 5 only be open in closed dump 2. Operator error 5 mode. 3. Pump failure 2. Fire Protection System 4. Valve failure 3. Fixed point monitor 5. High pressure in dump tank 4. general monitor 5. Maintenance & operating procedures 6. Personal Protective Equipment 7. Dump line bullseye 8. Dump pump amp indication S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. External heat 2. Operator error 58 ABD00037030 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 41. Atmospheric Dump Line. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PI D-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-5 Dev Consequences 41.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 41.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor 2. High Pressure in Reactor S/E 4 C S/E 4 c S/E 4 c 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 3. Instrument failure 4. Line plugged 5. Operator error 6. DCS interlock Dump valve can 6. Valve closed only be open in atmospheric 7. Valve failure dump mode. 8. Valve leaking through 7. Pressure Gauge S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. External heat 2. Operator error 59 ABD00037031 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 42. Seal Oil supply and return lines to Rx-300,400,500,600,700 Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-2, J16-1 Dev Consequences 42.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 42.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 42.3 Low Pressure 1. Fire and explosion 2. No flow 3. Personal exposure 4. Reverse flow 5. Seal failure 6. Valve leaking 7. VCM Leak 42.4 Low Temperature 1. High pressure 2. Fire and explosion 3. Gasket failure 4. Line rupture 5. Personal exposure 6. Seal failure 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 B S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Pressure Gauge 8. relief valve 9. Pressure transmitter, 81P171 1. External heat 2. Filter Plugged 3. Heat tracing failure 4. Instrument failure 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5 5. Personal Protective Equipment 5 6. Pressure Gauge 5 7. Pressure transmitter, 81 PI 71 1. Operator error 2. Power failure 3. Pump failure 4. Seal failure 5. Valve closed 6. Valve leaking through 7. Line leak/rupture 8. Instrument failure S/E 4 c S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Pressure transmitter, 81P171 5 7. Heat tracing 8. Line insulation 1. Heat tracing failure 2. Instrument failure 3. Cold weather 60 ABD00037032 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 43. Cooling Water supply and return lines for RX condenser & jacket. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 43.1 High Temperature 1. Run away reaction 43.2 High Pressure 1. Gasket failure 2. Lift relief valve 3. Line rupture 4. Control valve failure 5. Damage condenser CAT S L RR Safeguards Causes 3D 5 1. Fire Protection System 2. general monitor 3. Auto/emergency kill system 4. Auto kill program 5. Flow indication, 81F156A/B 6. Temperature indication, 81T156B 7. Temperature gauge 1. Cooling Water Control Valve failure 2. External heat 3. Line plugged 4. Operator error 5. Power failure 6. Pump failure 7. Valve closed S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 3. relief valve S/E 4 C 5 S/E 4 C 5 1. Cooling Water Control Valve failure 2. External heat 3. Instrument failure 4. Line plugged 5. Operator error 6. Relief Valve failure 7. Valve closed 61 ABD00037033 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 44. MSPW flush line to Rx seal. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-1, J16-1 Dev Consequences 44.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak 44.2 High Temperature 1. High pressure 44.3 Low/No Flow 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fixed point monitor 5 2. general monitor 5 3. Operating procedures 5 4. Operator training 5 5. Personal Protective Equipment 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure S/E 4 C 5 1. Operating procedures 2. Operator training 1. External heat 2. Line blocked in with external heat (thermal expansion) S/E 3 D S 4C s 4C s 4C s 4C 5 1. Fixed point monitor 5 2. general monitor 5 3. Operating procedures 5 4. Operator training 5 5. Personal Protective Equipment 6. Flow meter 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure 62 ABD00037034 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 45. Clean wall supply line. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 45.1 High Pressure 1. Gasket failure 2. Line rupture 45.2 High Temperature 1. Gasket failure 2. High pressure 3. Line rupture 45.3 Low Temperature 1. Frozen Line 45.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Line rupture 5. Personal exposure 6. VCM Leak 7. No flow CAT S L RR Safeguards Causes S/E 4 C 5 1. Maintenance & operating S/E 4 C 5 procedures 2. Pressure Gauge at pump 3. relief valve at pump 1. Line plugged 2. Valve closed 3. Valve leaking through 4. RX nozzle plug 5. High Pressure in Reactor S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Pressure Gauge 5 1. External heat 2. Line leak/rupture 3. Line plugged 4. Operator error 5. RX nozzle plug 6. Valve closed 7. Valve leaking through S/E 4 C 5 1. Line insulation 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. Line leak/rupture 2. Line plugged 3. Operator error 4. Power failure 5. Pump failure 6. RX nozzle plug 7. Valve leaking through 63 ABD00037035 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 46. Auto Kill (Isonox) line to Rx. RX-300,400,500,600. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D Design Conditions/Parameters: Pipe Spec A13-1 Dev Consequences 46.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 46.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 46.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 46.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. High Pressure in Reactor 2. Line plugged 3. Operator error 4. Valve closed 5. RX nozzle plug 6. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock - Auto kill valve on 1. High Pressure in Reactor 5 other reactors must be closed to 2. Line leak/rupture 5 open 3. Operator error 5 2. Fire Protection System 4. Power failure 5 3. Fixed point monitor 5. Pump failure 4. general monitor 6. Valve failure 5. Operating procedures 7. Valve leaking through 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 64 ABD00037036 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 47. MSPW Flush line to rinse nozzle & slow vent. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 47.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5 VCM Leak 47.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. Hydro fill the reactor 5 VCM release 47.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High Pressure in Reactor 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Check valve 5 2. DCS interlock-AII RX slow vent 1. Line leak/rupture 2. Operator error 5 valves must be closed & 3. Valve leaking through 5 recovery system discharge 4. Pump failure 5 pressure is < 110 psig (81 p759) before slow vent flush valve will open. 3. Fire Protection System 4. Fixed point monitor 5. Flow meter 6. general monitor 7. Operating procedures 8. Operator training 9. Personal Protective Equipment S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 1. Cold weather 2. Valve leaking through 65 ABD00037037 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 48. Reactor recovery line including slow vent. Rx-300,400,500,600,700 Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe specA2-22 Dev Consequences 48.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 48.2 Low/No Flow 1. Overpressure reactor 48.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Line plugged 3. Valve closed 4. Valve leaking through 5. Operator error S/E 4 c 5 1. Operating procedures 2. Operator training 1. Line plugged 2. Operator error 3. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. DCS interlock vent valve won't 1. Operator error 5 open unless in poly (similar on 2. Valve leaking through 5 all rx's); main recovery valve, 81H131, won't open unless atmospheric vent closed and evac valve closed (similar on all rx); condenser recovery valve will not open unless similar valve on other rx's closed. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 66 ABD00037038 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 49. Atmospheric Vent. RX-300,400,500,600,700. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Georgia Gulf Corp Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Dev Consequences 49.1 Low/No Flow 1. Fire and explosion 2. Lift relief valve 3 Overpressure reactor 4 Personal exposure 5. VCM release 6. Can't completely dump reactor 49.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Line plugged S/E 3 D 5 2. Fixed point monitor 2. Valve failure S/E 3 D 5 3. general monitor S/E 4 C 5 4. Operator training S/E 4 D 5 5. Personal Protective Equipment S/E 4 C 5 6. relief valve 7. Abort charge on high pressure if reactor was not emptied 8. Agitator amps would indicate reactor not empty 9. Dump timer would indicate abnormally long dump S/E 3 D S/E 4 C S/E 3 D 6 1. DCS interlock-vent won't open 1. Operator error 5 unless rx pressure < 8 psig and 2. Valve failure 5 main recovery valve closed, 3. Valve leaking through 81H131. similar on all rx. 2. Fixed point monitor 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P162/163 67 ABD00037039 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 50. Rx evacuation line. Rx-300,400,500,600,700 Type: Line Design Conditions/Parameters: Pipe spec A2-1 Old Module Hazop Georgia Gulf Corp Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Dev Consequences 50.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 50.2 Low/No Flow 1. Can't evac reactor 2. High pressure during next charge 50.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. DCS interlock Won't open unless Evac header pressure less than 5 psig (81P080) and main recovery valve closed, 81H131. 1. Line plugged 2. Operator error 3. Valve failure 4. Valve leaking through S/E 4 C 5 1. Abort charge on high pressure if 1. Line plugged S/E 4 C 5 reactor was not emptied 2. Operator error 2. Operator training 3. Valve closed 4. Valve failure 5. Steam jets broke S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock - Won't open 1. Line plugged 5 unless Evac header pressure 2. Operator error 5 less than 5 psig (81P080) and 3. Valve failure 5 main recovery valve closed, 4. Valve leaking through 81H131. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve position indicator on valve stem 68 ABD00037040 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 51. Nitrogen line to emergency kill valves. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec B2-1 Dev Consequences 511 Low Pressure 1. Valves won't open 2. Fire and explosion 3. Lift relief valve 4. Overpressure reactor 5. Personal exposure 6. VCM release 51.2 Low Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure reactor 4. Personal exposure 5. VCM release 6. Solenoid failure 51.3 High Pressure 1. Line rupture 2. O-Ring failure 3. Actuator failure CAT S L RR Safeguards Causes S/E 3 D S/E 3 D S/E 4 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Valve indication 1. Instrument failure 2. Line leak/rupture 3. Line plugged 4. Valve failure 5. Nitrogen bottle empty 6. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment 7. Valve indication 1. Cold weather 2. Valve leaking through S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 1. External heat 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve failure 69 ABD00037041 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 52. Emergency kill (AMS) line to Rx-300,400,500,600,700. W/ nitrogen operated valves. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec B2-1 Dev Consequences 52.1 High Pressure 1. Line rupture 2. Valve failure 3. Fire and explosion 4. VCM Leak 5. AMS release 52 2 Low Pressure 1. No flow 2. Fire and explosion 3. Lift relief valve 4. Line rupture 5. Overpressure reactor 6. VCM release 52.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Lift relief valve 4. Overpressure reactor 5. Personal exposure 6. VCM release CAT S L RR Safeguards Causes S/E 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 c 5 3. general monitor S/E 4 c 5 4. Operating procedures S/E 4 c 5 5. Operator training 6. Pressure Gauge 7. HNU unit 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line leak/rupture 4. Valve failure 5. Operator error S/E 4 c S/E 3 D S/E 4 c S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Pressure Gauge 1. Line leak/rupture 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 S/E 4 C 5 S/E 4 C 5 S/E 4 C 5 1. Cold weather 2. Valve leaking through 70 ABD00037042 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 53. Emergency kill (AMS) line to Rx-300,400,500,600,700. W/ manual operated valves. Type: Line Design Conditions/Parameters: Pipe spec B2-1 Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Dev Consequences 53.1 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. No flow 5. Overpressure reactor 6. VCM release 53.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Lift relief valve 4. Overpressure reactor 5. Personal exposure 6. VCM release 53.3 High Pressure 1. AMS release 2. Fire and explosion 3. Line rupture 4. Valve failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. Line leak/rupture 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 S/E 3 D 5 S/E 4 C 5 S/E 4 C 5 1. Cold weather 2. Valve leaking through S/E 4 C S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. HNU unit 5 5. Operating procedures 6. Operator training 7. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line leak/rupture 4. Operator error 5. Valve failure 71 ABD00037043 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 54. Steam supply to Rx jacket on Rx-300,400,500,600. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 54.1 High Flow 1. No consequences 54.2 Low/No Flow 1. No consequences 54.3 Reverse/Misdirected Flow 1. No consequences CAT S L RR Safeguards Causes 72 ABD00037044 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 55. Stripping steam supply line to Rx-300,400,500,600.700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 55.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 5. Overpressure reactor 55.2 High Pressure 1. Line rupture 2. Reverse flow 3. Fire and explosion 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 3D 5 1. DCS interlock-steam supply 1. Line leak/rupture 5 valve will not open unless steam 2. Line plugged 5 pressure > 120 pslg and 5 recovery valves, 81 HI 30 & 3. Valve closed 4. Low steam pressure 5 81H131 are open 5. Valve leaking through 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Personal Protective Equipment S/E 4 C S/E 4 C S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Persona! Protective Equipment 7. Valve Indication 1. External heat 2. Line plugged 3. Valve failure 4. Valve leaking through 5. Operator error 73 ABD00037045 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 56. Catalyst charge line to Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec B13-3 Dev Consequences 56.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 56.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 56.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 56.4 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 3. Personal Protective Equipment S/E 4 C 5 4. Fire Protection System S/E 4 C 5 5. Fixed point monitor 6. general monitor 1. External heat 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Heat tracing 7. Line insulation 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Check valve 5 2. DCS interlock-Valve will only 1. High Pressure in Reactor 2. Line leak/rupture 5 open in poly mode, must have 3. Operator error 5 enable from lead operator, and 4. Power failure has timer to alert lead operator 5. Valve failure that charge valve has been open 6. Valve leaking through a long time. 7. Low HPSW pressure 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Ram valve 1. External heat 2. Line plugged 3. Operator error 4. Line blocked in with external heat (thermal expansion) 74 ABD00037046 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 57. Water line to reactor stripping steam line. Rx-500 Type: Line Drawing: OM-090104-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 57.1 No Items 1. Node found not to exist during Hazop analysis. CAT S L RR Safeguards Georgia Gulf Corp Causes 75 ABD00037047 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 58. Low Mole Sweco (atmospheric) dump line. Rx-600,700. Type: Line Drawings: OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A13-5 Dev Consequences 58.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 58.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock - Dump valve can 1. External heat 5 only be open in atmospheric 2. High Pressure in Reactor 5 dump mode. 3. Instrument failure 5 2. Fire Protection System 4. Line plugged 5 3. Fixed point monitor 5. Operator error 4. general monitor 6. Valve closed 5. Operating procedures 7. Valve failure 6. Personal Protective Equipment 8. Valve leaking through 7. Pressure Gauge S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error 76 ABD00037048 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 59. GH-20 charge line. Rx-600,700. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Georgia Gulf Corp Drawings: OM-090105-PID-D, OM-090106-PID-D Dev Consequences 59.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 59.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 59.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 59.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 c 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather S/E 3 D S 4C S/E 4 c S/E 4 c 5 1. Check valve 1. High Pressure in Reactor 5 2. DCS interlock - Abort GH-20 5 charge on low flow. 5 3. DCS interlock - valve 81hv412. 2. Operator error 3. Power failure 4. Pump failure Won't open unless RX in charge 5. Valve failure and all other RX GH-20 valves 6. Valve leaking through closed 4. Fire Protection System 5. Fixed point monitor 6. general monitor 7. Operator training 8. Personal Protective Equipment 77 ABD00037049 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 60. Branch cooling water line to Rx jacket from cooling water supply header. Rx-600,700. Type: Line Drawings: OM-090105-PID-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 60.1 High Pressure 1. Damage condenser 2. Gasket failure 3. Lift relief valve 4. Line rupture 60.2 High Temperature 1. Run away reaction CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 c S/E 4 c 5 3. relief valve 5 1. Cooling Water Control Valve failure 2. External heat 3. Instrument failure 4. Line plugged 5. Operator error 6. Relief Valve failure 7. Valve closed S/E 4 c 5 1. Auto kill program 2. Auto/emergency kill system 3. Fire Protection System 4. Flow indication, 81F456A 5. general monitor 6. Temperature gauge 1. Cooling Water Control Valve failure 2. External heat 3. Line plugged 4. Operator error 5. Power failure 6. Pump failure 7. Valve closed 78 ABD00037050 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 61. BME charge line to RX. Rx-600,700. Type: Line Design Conditions/Parameters: Pipe spec B16-1 Old Module Hazop Georgia Gulf Corp Drawings: OM-090105-PID-D, OM-090106-PID-D Dev Consequences 61.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 61.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 61.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 61.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Ram valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 c 5 5. Operator training 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. DCS interlock-Valve will only 5 open in poly mode, must have 5 enable from A operator, has timer to alert lead operator that charge valve has been open a long time, and has pressure switch enable to allow charge. 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication 1. High Pressure in Reactor 2 Line leak/rupture 3. Low HPSW pressure 4. Operator error 5. Power failure 6. Valve failure 7. Valve leaking through 79 ABD00037051 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 62. Polyvic charge line to Rx. Rx-600,700. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Georgia Gulf Corp Drawings: OM-090105-PID-D, OM-090106-PID-D Dev Consequences 62.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 62.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve packing leaking 62.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 62.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 c 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather S/E 3 D 5 1. Check valve 1. High Pressure in Reactor S/E 4 C 5 2. DCS interlock - abort polyvic 2. Operator error charge on low flow 3. Power failure 3. DCS interlock - valve 81hv418. 4. Pump failure Won't open unless RX in charge 5. Valve failure and all other RX polyvic valves 6. Valve leaking through closed 4. Fire Protection System 5. Fixed point monitor 6. general monitor 7. Operator training 8. Personal Protective Equipment 80 ABD00037052 VIIID. Hazards Identified - P&ID/Operating Procedures Review Node: 63. Auto Kill (Isonox) line to Rx. RX-700. Type: Line Design Conditions/Parameters: Pipe Spec A13-1 Old Module Hazop Drawing: OM-090106-PID-D Dev Consequences 63.1 High Pressure 1. SEE NODE 46 63.2 High Temperature 1. SEE NODE 46 63.3 Low Temperature 1. SEE NODE 46 63.4 Low/No Flow 1. SEE NODE 46 63.5 Reverse/Misdirected Flow 1. SEE NODE 46 CAT S L RR Safeguards Georgia Gulf Corp Causes 81 ABD00037053 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 64. Emergency kill line to isonox charge line. Rx-700 Type: Line Drawing: OM-090106-PID-D Design Conditions/Parameters: Pipe spec B13-3 Dev Consequences 64.1 High Pressure 1. SEE NODE 53 64.2 High Temperature 1. SEE NODE 53 64.3 Low Temperature 1. SEE NODE 53 64.4 Reverse/Misdirected Flow 1. SEE NODE 53 CAT S L RR Safeguards Georgia Gulf Corp Causes 82 ABD00037054 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 65. Steam supply to Rx jacket on Rx-700. Type: Line Design Conditions/Parameters: Pipe spec A2-3 Old Module Hazop Drawing: OM-090106-PID-D Dev Consequences 65.1 High Flow 1. SEE NODE 54 65.2 Low/No Flow 1. SEE NODE 54 65.3 Reverse/Misdirected Flow 1. SEE NODE 54 CAT S L RR Safeguards Georgia Gulf Corp Causes 83 ABD00037055 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 66. HPSW supply line to RX-600,700 BME charge pot Type: Line Drawing: OM-090107-PID-D Design Conditions/Parameters: Pipe spec A13-1 Georgia Gulf Corp Dev Consequences 66.1 Low Pressure 1. Lift relief valve 2. No flow 3. Personal exposure 4. Reverse flow 66.2 Low Temperature 1. Frozen Line 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Reverse flow 6. Fire and explosion 7. VCM Leak 66.3 High Pressure 1. Gasket failure 2. Line rupture 3. Valve leaking 66.4 High Temperature 1. Gasket failure 2. Line rupture 3. Personal exposure 4. Valve failure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. DCS interlock-Rx BME charge 5 valve won't open unless 5 adequate pressure 5 2. Pressure switch, 81P469/569 3. Check valve 4. Pressure Gauge 5. Flow indication, 81F565 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Instrument failure 2. Line leak/rupture 3. Line plugged 4. Operator error 5. Valve failure 6. Valve leaking through S/E 4 C 5 1. Heat tracing S/E 4 C 5 2. Line insulation S/E 4 C 5 S/E 4 C 5 S/E 4 C 5 S/E 3 D 5 S/E 4 D 5 1. Cold weather S/E 4 C 5 1. Pressure Gauge S/E 4 C 5 2. Pressure switch, 81P469/569 S/E 4 C 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Valve closed S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Operating procedures 5 3. Operator training 5 4. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Line blocked in with external heat (thermal expansion) 84 ABD00037056 VHI.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 67. BME supply line to BME charge pots. Rx-600,700. Type: Line Drawing: OM-090107-PID-D Design Conditions/Parameters: Pipe spec B16-1 Georgia Gulf Corp Dev Consequences 67.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 67.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 67.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure 67.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. High pressure switch - 81P467/ 5 568 5 2. Fire Protection System 5 3. general monitor 4. Operating procedures 5. Operator training 6. relief valve 7. Valve indication 1. External heat 2. Operator error 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Operating procedures 5 3. Operator training 4. Personal Protective Equipment 1. External heat 2. Operator error S/E 4 C 5 1. Heat tracing S/E 4 C 5 2. Line insulation S/E 4 c 5 3. Operating procedures 4. Operator training 1. Cold weather 2. Operator error 3. Heat tracing failure S/E 3 D 5 1. DCS interlock-BME addition 1. Line leak/rupture S/E 4 C 5 S/E 4 c 5 valve, 81X442, will not open 2. Operator error unless charge valves 81X421A/B 3. Valve failure are closed, 81H443 sewer valve 4. Valve leaking through is closed, and 81X442 hand switch is on. Similar on RX-700 charge pot supply line. 2. Fire Protection System 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 85 ABD00037057 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 68. BME charge pots for Rx-600,700. Includes relief valve. Type: Vessel Drawing: OM-090107-PID-D Design Conditions/Parameters: MAWP: 300 psig @ 425 F. MOC: 304SS Georgia Gulf Corp Dev Consequences 68.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 5. Vessel rupture 6. Lift relief valve 68.2 Maintenance Hazards 1. Personal exposure 68.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Vessel rupture 5. Lift relief valve 68.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. No flow 4. Personal exposure 5. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. general monitor 2. Line blocked in with external S 4 C 5 3. Operating procedures heat (thermal expansion) S/E 4 C S/E 4 C 5 4. Operator training 5 5. Personal Protective Equipment 3. Line plugged 4. Operator error S/E 4 C 5 6. Ram valve 5. Relief Valve failure 7. relief valve 6. Valve closed 8. High pressure switch - 81P467/ 7. Valve leaking through 568 9. DCS interlock-Valve will only open in poly mode, must have enable from A operator, has timer to alert lead operator that charge valve has been open a long time, and has pressure switch enable to allow charge. S 4 B 5 1. Operating procedures 1. Operator error 2. Operator training 2. Valve failure 3. Personal Protective Equipment 3. Valve leaking through 4. Pressure Gauge 4. High pressure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. general monitor S/E 4 C 5 3. Operating procedures S/E 4 c 5 4. Operator training S/E 4 c 5 5. relief valve 1. External heat 2. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 c 5 2. general monitor S/E 4 c 5 3. Operating procedures S 4 c 5 4. Operator training S/E 4 c 5 1. Cold weather 2. Operator error 86 ABD00037058 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 69. BME pot discharge line to Rx. Type: Line Design Conditions/Parameters: Pipe spec B16-1 Old Module Hazop Drawing: OM-090107-PID-D Georgia Gulf Corp Dev Consequences 69.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 69 2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 69.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 69.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Ram valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Line plugged 4 Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Check valve 5 2. DCS interlock-Valve will only 5 open in poly mode, must have 5 enable from A operator, has timer to alert lead operator that charge valve has been open a long time, and has pressure switch enable to allow charge. 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication 1. High Pressure in Reactor 2. Line leak/rupture 3. Low HPSW pressure 4. Operator error 5. Power failure 6. Valve failure 7. Valve leaking through 87 ABD00037059 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 70. Rx recovery header to N. K.O. Tank, DM-027. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 70.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 70.2 High Temperature 1. Fire and explosion 2 Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak 70.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 8. Pressure indication, 81P756 1 External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Relief Valve failure 7. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. External heat 2 Steam stripping valve on reactor failed open S/E 3 D S 4C S/E 4 C 5 1. DCS interlock-Rx main recovery 1. Line leak/rupture 5 valve can't be open at the same 2. Operator error 5 time as the evacuation valve 3. Valve leaking through 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 88 ABD00037060 VIII D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 71. Recirculation from recovery compressor to Rx recovery header Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 71.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 71.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Relief Valve failure 7. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 c 5 3. general monitor S/E 4 c 5 4. Operating procedures S/E 4 c 5 5. Operator training S/E 4 c 5 6. Personal Protective Equipment S/E 4 c 5 1. External heat 89 ABD00037061 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 72. RVCM feedback line from RVCM receivers to Rx recovery header Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 72.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 72.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak 72.3 Reverse/Misdirected Flow 1. Overpressure VCM Receivers 2. Fire and explosion 3. Lift relief valve 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 D 5 2. Fixed point monitor S/E 4 D 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Operator error 2. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Steam stripping valve on reactor failed open S/E 4 C S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 90 ABD00037062 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 73. Recovery line from Dump TK to Rx recovery header. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe specA2*22. Georgia Gulf Corp Dev Consequences 73.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 73.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak 73.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Overpressure dump tank 5. Lift relief valve CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P756, 81P628 8. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Valve closed 7. High pressure in dump tank 8. Instrument failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment S/E 4 C 5 7. Dump tank kill system 1. External heat 2. Reaction occurring in dump tank S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 91 ABD00037063 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 74. Recovery line from Dump TK to RVCM condensers Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 74.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 74.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 74.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P628 8. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Relief Valve failure 7. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Dump tank kill system 1. External heat 2. Reaction occurring in dump tank S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 92 ABD00037064 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 75. Jumper from RVCM feedback line to Feed Tank and Stripper feedback line. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 75.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 75.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. VCM release 75.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Dump tank kill system 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Reaction occurring in dump tank S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P756, 81P628, 81P606 8. Valve indication 1. External heat 2. High pressure in dump tank 3. High Pressure in Reactor 4. Instrument failure 5. Line plugged 6. Operator error 7. Power failure 8. Valve closed 93 ABD00037065 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 76. VCM feedback line to stripper and feed tank. Type. Line Design Conditions/Parameters: Pipe specA2-22. Old Module Hazop Drawing. OM-Q90108-PID-D Georgia Gulf Corp Dev Consequences 76.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5 VCM Leak 76.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 76.3 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Dump tank kill system 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Reaction occurring in dump tank S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 94 ABD00037066 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 77. Dump strainer recovery line to Rx recovery header. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 77.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 77.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 77.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 95 ABD00037067 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 78. Polishing strainer recovery line to Rx recovery header Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 78.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 78.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 78.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 t. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 c S/E 4 c S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 96 ABD00037068 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 79. RVCM feedback line to compressor suction header Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 79.1 Reverse/Misdirected Flow 1. No consequence 79.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 79.3 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Indication- 81P806 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 97 ABD00037069 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 80. RVCM feedback line from compressor discharge to stripper and feed tank. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 80.1 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 80.2 Reverse/Misdirected Flow 1. No consequence 80.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. Pressure indication - 81P628, 81P606 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 98 ABD00037070 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 81. Feed tank recovery line Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-09Q108-PID-D Georgia Gulf Corp Dev Consequences 81.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. VCM Leak 81.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 81.3 Reverse/Misdirected Flow 1. Overpressure feed tank 2. Fire and explosion 3. Lift relief valve 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure indication- 81P606 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure S/E 3 D S/E 4 C S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat S/E S/E ENV S S/E 4 3 4 4 4 c D c c c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Operator error 2. Valve leaking through 3. Valve failure 99 ABD00037071 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 82. HPSW supply to KO tank sight glass. Type: Line Design Conditions/Parameters: Pipe spec A2-3 Old Module Hazop Drawing: OM-090108-PID-D Georgia Gulf Corp Dev Consequences CAT S L RR Safeguards Causes 82.1 Low Pressure 1. Personal exposure 2. Reverse flow 3. VCM Leak S/E 4 C S/E 4 C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 1. Filter Plugged 2. Line plugged 3. Operator error 4. Power failure 5. Valve closed 6. Valve leaking through 7. Pump failure 82.2 High Flow 1. High Level in knockout tank, See Node 84 100 ABD00037072 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 83. Batch water stripper recovery line to Rx recovery header Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 83.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Overpressure batchwater stripper 83.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 83.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 4. High pressure in batch water stripper S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 101 ABD00037073 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 84. North KO tank, DM-027. Type: Vessel Drawing: OM-090108-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 150 F. MOC: A285 CS Georgia Gulf Corp Dev Consequences 84.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 84.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 84.3 High Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 84.4 Low Level 1. Overpressure batchwater stripper 84.5 Maintenance Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. relief valve 8. Pressure indicator, 81P756 9. Pressure Gauge 10. Kill system on reactor 1. Control Valve failure 2. Instrument failure 3. Operator error 4. Power failure 5. Relief Valve failure 6. Valve leaking through 7. External heat S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 c 5 3. Operating procedures S/E 4 c 5 4. Operator training 5. Personal Protective Equipment 1. External heat S/E 3 D S/E 4 C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. relief valve 8. sight glass 9. Level switch-81L777A 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 4 c 5 1. Operating procedures 2. Level indication - 81L777B 1. Instrument failure 2. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 c 5 3. general monitor S/E 4 c 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. sight glass 1. Operator error 102 ABD00037074 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 85. RVCM feedback line from feed tank recovery line to stripper. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 85.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 85.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 85.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 S4 ENV 4 D C C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 4. general monitor 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 103 ABD00037075 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 86. Recovery line from N KO tank to vacuum pumps and compressors Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 86.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 86.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak 86.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P756 8. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5 Power failure 6. Relief Valve failure 7. Valve closed 8. High level in Knockout tank, DM- 027 S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Steam stripping valve on reactor failed open S/E 3 D S 4C S/E 4 C 5 1. DCS interlock-Rx main recovery 1. Line leak/rupture 5 valve can't be open at the same 2 Operator error 5 time as the evacuation valve 3. Valve leaking through 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 104 ABD00037076 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 87. N. KO tank bypass line. From Rx recovery header to vacuum pumps and compressors. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 87.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 87.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P756 8. Valve indication 1. External heat 2. High level in Knockout tank, DM- 027 3. High Pressure in Reactor 4. Line plugged 5. Operator error 6. Power failure 7. Relief Valve failure 8. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. External heat 2. Steam stripping valve on reactor failed open 105 ABD00037077 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 88. RVCM feedback line from seal water separators to N KO tank. Vacuum Pump inlet pressure control. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 88.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 88.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 88.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Check valve 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 6 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 4. High Pressure in Reactor 106 ABD00037078 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 89. KO Tank recovery line. To ERS. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090108-PID-D Georgia Gulf Corp Dev Consequences 89.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 89.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 89.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 89.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line plugged 3. Operator error 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 107 ABD00037079 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 90. Feed Tank recovery line. From S KO tank to compressor. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 90.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak 90.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure feed tank 4. Personal exposure 5. VCM Leak 90.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes s/e 3 D 5 1. Fire Protection System s/e 4 C 5 2. Fixed point monitor s/e 4 C 5 3. general monitor s/e 4 C 5 4. Operating procedures s/e 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Operator error S/E 3 D S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure indication- 81P606 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure 108 ABD00037080 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 91. S KO tank, DM-028. Type: Vessel Drawing: OM-090108-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 150F MOC: A285 CS Georgia Gulf Corp Dev Consequences 91.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 91.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 91.3 High Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 91.4 Low Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 91.5 Maintenance Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Kill system on reactor 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 9. Pressure indicator, 81P606 10. relief valve 1. External heat 2. Instrument failure 3. Operator error 4. Power failure 5. Relief Valve failure 6. Valve leaking through 7. Control Valve failure 8. High Level S/E 3 D S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5. Personal Protective Equipment 1. External heat S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Level switch - 81L786A 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 3 D S/E 4 C S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Level switch - 81L786B 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8 relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 3 D S 4C S/E 3 D S/E 4 C 5 1 Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. sight glass 1. Operator error 109 ABD00037081 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 92. Drain/Recovery line from DM-027/028 To batch water strippers. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 92.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 92.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 92.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 92.4 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E S ENV 3 4 3 D C D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line plugged 3. Operator error 4. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 110 ABD00037082 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 93. S KO tank, DM-028, Water recirculation line and pump. Type: Centrifugal Pump + Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Pump 3x2-10-9.5,155 psi @ 200 GPM. Georgia Gulf Corp Dev Consequences 93.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. Valve packing leaking 7. VCM Leak 93.2 Reverse/Misdirected Flow 1. Overpressure batchwater stripper 2. Overfill/Overpressure DM-027 3. Fire and explosion 4. Lift relief valve 5. Personal exposure 6. VCM Leak 93.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. Valve packing leaking 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 6. Pressure Gauge S/E 4 C 5 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. High pressure in the Knockout tank S/E 4 C S/E 4 C S/E 3 D S/E 3 D S 4C S/E 4 C 5 1. Check valve 2. DCS interlock- batch water 5 stripper can't have high 5 pressure, high level, and the 5 receivers can't be draining 5 3. Fire Protection System 5 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Personal Protective Equipment 1. Instrument failure 2. Operator error 3. Valve leaking through 4. Check valve failure S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 5 1. External heat 2. Pump blocked in and running 111 ABD00037083 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 94. N KO Tank water recirculation line from tank to pump to cooler Type: Centrifugal Pump + Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-22. Pump 3x4-8-7.62 95 psi @ 400 GPM Georgia Gulf Corp Dev Consequences 94.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. Seal failure 6. Valve packing leaking 7 VCM Leak 94.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overfill/Overpressure DM-027 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 94.3 High Temperature 1 Fire and explosion 2 Lift relief valve 3. Overfill/Overpressure DM-028 4. Overpressure batchwater stripper 5 Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6 Pressure Gauge 5 1. External heat 2. High pressure in the Knockout tank 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. DCS interlock- batch water 5 stripper can't have high 5 pressure, high level, and the receivers can't be draining 5 3. Fire Protection System 5 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Personal Protective Equipment 1. Check valve failure 2. Instrument failure 3. Operator error 4. Valve leaking through S/E 3 D 5 1. Check valve S/E 4 C 5 2. DCS interlock- batch water S/E 4 C 5 stripper can't have high S/E 4 C 5 pressure, high level, and the receivers can't be draining S 4 C 5 3. Fire Protection System S/E 4 C 5 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Personal Protective Equipment 1. Check valve failure 2. Instrument failure 3. Operator error 4. Valve leaking through 112 ABD00037084 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 95. EX-340 N KO Tank cooler Type: Heat Exchanger Drawing: OM-090108-PID-D Design Conditions/Parameters: MAWP: 150 psi @ 400 F Georgia Gulf Corp Dev Consequences 95.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. Vessel rupture 95.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5 VCM Leak 6. VCM release 95.3 Low Temperature 1. Tube rupture 2. Frozen tubes 3. Fire and explosion 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Relief Valve failure S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. No cooling water S/E 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 113 ABD00037085 VIII.0. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 96. N KO tank water recirculation line from cooler to KO tank. Type: Line Drawing: OM-0901Q8-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 96.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. Valve packing leaking 7. VCM Leak 96.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overfill/Overpressure DM-027 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 96.3 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 6. Pressure Gauge S/E 4 C 5 1. External heat 2. High pressure in the Knockout tank 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 3 D S/E 4 C S/E 4 D S 4C S/E 4 C 5 1. Check valve 5 2. DCS interlock- batch water 5 stripper can't have high 5 pressure, high level, and the receivers can't be draining 5 3. Fire Protection System 5 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Personal Protective Equipment 1. Check valve failure 2. Instrument failure 3. Operator error 4. Valve leaking through S/E 3 D S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5 5. Operating procedures 5 6. Personal Protective Equipment 1. Check valve failure 2. Instrument failure 3. Operator error 4. Valve leaking through 114 ABD00037086 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 97. North and South KO tank blowdown line to batch water stripper. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe specA2-22. Georgia Gulf Corp Dev Consequences 97.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 97.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM Leak 97.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 D 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 2. High pressure in batch water stripper 3. Instrument failure 5. Personal Protective Equipment 4. Line plugged S 4 C 5 6. DCS interlock- batch water 5. Operator error S/E 4 C 5 stripper can't have high 6. Valve closed pressure, high level, and the receivers can't be draining 7. Pressure Indication- 84P848/845 S/E 3 D S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5 5. Operating procedures 5 6. Personal Protective Equipment 1. Instrument failure 2. Operator error 3. Valve leaking through 4. External heat S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 3. Heat tracing failure .1 115 ABD00037087 VIII D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 98. HPSW supply to mechanical seal on KO tank recirculation pumps PP-489/490. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-3/J16-1 Georgia Gulf Corp Dev Consequences 98.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 98.2 High Temperature 1. Seal failure 2. Personal exposure 3. VCM Leak 98.3 Low Pressure 1. Seal failure 2. VCM Leak 98.4 Low Temperature 1. Frozen Line 2. No flow 3. Seal failure 4. VCM Leak 5. Personal exposure CAT s L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Equipment Preventive Maintenance Program 3. Fixed point monitor 4. Operating procedures 5. Operator training 6. Pressure Gauge 7. Flow meter 1. Filter plugged 2. Line plugged 3. Operator error 4. Power Failure 5. Valve closed 6. Valve failure S/E 4 C S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fixed point monitor 5 2. Heat tracing 5 3. Personal Protective Equipment 5 4. Operating procedures 5 1. Cold weather 2. Operator error 116 ABD00037088 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 99. Cooling water supply and return line from N KO tank cooler EX-340. Type: Line Drawing: OM-090108-PID-D Design Conditions/Parameters: Pipe spec A2-3. Georgia Gulf Corp Dev Consequences 99.1 Tube Leak 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Equipment Preventive Maintenance Program 1. High pressure 2. Relief valve failure 3. Corrosion 117 ABD00037089 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 100. HPSW supply to mechanical seals on compressors & vacuum pumps. Type: Line Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: Pipe specA2-3, J16-1 Dev Consequences 100.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 100.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 100.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 100.4 Low Temperature 1. Frozen Line 2. No flow 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4C S/E 4 C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 4. Flow meter 5. Pressure Gauge 1. Operator error 2. Instrument failure 3. Line plugged S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 D 5 1. Fixed point monitor 5 2. Heat tracing 5 3. Operating procedures 5 4. Personal Protective Equipment 5 1. Cold weather 2. Operator error 118 ABD00037090 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 101. HPSW supply from mechanical seals on compressors & vacuum pumps. Type: Line Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: Pipe spec A2-3, J16-1 Dev Consequences 101.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 101.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 101.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 101.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4C S/E 4 C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 4. Flow meter 5. Pressure Gauge 1. Operator error 2. Instrument failure 3. Line plugged S 4C S/E 4 C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 4. Flow meter 5. Pressure Gauge 6. Heat tracing 1. Operator error 2. Instrument failure 3. Line plugged 119 ABD00037091 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 102. Recovery line from Dump TK to RVCM condensers Type: Line Drawing: OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 102.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 102.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. VCM Leak 102.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication. 81P628 8. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Relief Valve failure 7. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Dump tank kill system 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Reaction occurring in dump tank S/E 3 D 5 1. Fire Protection System S/E 3 D 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 3 D 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 120 ABD00037092 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 103. Stripper recovery line to "B" vacuum pump (VP-502) Type: Line Drawing: OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 103.1 High Pressure 1. High Pressure Control valve failure 2. Fire and explosion 3. Gasket failure 4. Lift relief valve 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 8. Overpressure batchwater stripper 103.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Lift relief valve 5 Line rupture 6. Personal exposure 7. Valve packing leaking 8. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock- For 81XV724 to 1. External heat open then 81XV726 must be 2. Line plugged 5 open, and 81PC756 is less then 3. Operator error 5 20 psi. 4. Vacuum Pump failure 5 2. Fire Protection System 5. Relief Valve failure 5 3. Fixed point monitor 6. Valve closed 5 4. general monitor 5 5. Operating procedures 5 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 9. relief valve S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S 4 C 5 6. relief valve S/E 4 C 5 S/E 4 C 5 1. External heat 121 ABD00037093 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 104. RVCM feedback line from compressor discharge to stripper and feed tank. Type: Line Drawing: OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 104.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 104.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 104.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 122 ABD00037094 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 105. Vacuum Pump, VP-501 & 502. Type: Centrifugal Compressor Drawing: OM-090109-PID-D Design Conditions/Parameters: 3x4-15, 780 acfm @ 24 inches Hg. Georgia Gulf Corp Dev Consequences 105.1 High Suction Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Seal failure 6. VCM Leak 105.2 High Discharge Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Instrument failure S/E 4 C 5 2. Fixed point monitor 2. Operator error S/E 4 C 5 3. general monitor 3. Pump failure S 4 C 5 4. Operating procedures 4. Relief Valve failure S/E 4 C 5 5. Personal Protective Equipment 5. Valve leaking through S/E 4 C 5 6. Pressure Gauge 7. relief valve 8. DCS interlock- VP-502, 81XM742 will not run unless 81XV725 is open and 81PC648 is less than 20 psi and 81HM730 is started. VP-501,81XM741 wills not run unless 81XV722 is open and 81HM729 is running, and 81PC756 is less than 20 psi. S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Amp indicator 8. Motor overloads 9. Pressure Gauge 1. Compressor not pulling 2. Line plugged 3. Operator error 4. Valve closed 5. External heat 123 ABD00037095 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 105A. Compressor Cp-503,504,506,111.4x3-12.5, 400acfm @ 80 psi Type: Centrifugal Compressor Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: 3x4-15, 780 acfm @ 24 inches Hg. Dev Consequences 105A.1 High Suction Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Seal failure 5. VCM Leak 105A.2 High Discharge Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 105A.3 Low Suction Pressure 1. Seal failure 2. Fire and explosion 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock-Compressor must 1. Instrument failure 5 be running to open inlet valve 2. Operator error 5 and ring seal water supply valve. 3. Pump failure 5 2. Fire Protection System 4. Valve leaking through 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock RVCM return 5 valve on receiver must be open 5 and ring seal water pump 5 running to start compressor. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Relief Valve failure S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. Line plugged 2. Operator error 3. Valve closed 124 ABD00037096 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 106. Rx recovery line to "A" vacuum pump (VP-501) Type: Line Design Conditions/Parameters: Pipe spec A2-22. Drawing: OM-090109-PID-D Georgia Gulf Corp Dev Consequences 106.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. High Pressure Control valve failure 4. Lift relief valve 5. Overpressure batchwater stripper 6. Personal exposure 7. Valve packing leaking 8. VCM Leak 106.2 High Temperature 1. Fire and explosion 2 Gasket failure 3. High pressure 4. Lift relief valve 5. Line rupture 6. Personal exposure 7. Valve packing leaking 8. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. DCS interlock- For81XV721 to 1. External heat 5 open then 81XV722 must be 2. Line plugged 5 open, and 81PC756 is less then 3. Operator error 20 psi. 5 2. Fire Protection System 4. Relief Valve failure 5. Vacuum Pump failure 5 3. Fixed point monitor 6. Valve closed 4. general monitor 5 5. Operating procedures 5 6. Operator training 5 7. Personal Protective Equipment 8. Pressure Gauge 9. relief valve S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S 4 C 5 6. relief valve S/E 4 C 5 S/E 4 C 5 1. External heat 125 ABD00037097 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 107. Vacuum Pump discharge line to compressor suction header. Type: Line Drawing. OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 107.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. High temperature 4. Line rupture 6. Personal exposure 6. Valve packing leaking 7. VCM Leak 107.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Lift relief valve 5. Line rupture 6 Personal exposure 7. Valve packing leaking 8. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Line plugged S/E 4 C 5 2. Fixed point monitor 2. Operator error S/E 4 C 5 3. general monitor 3. Valve closed S/E 4 C 5 4. Operating procedures S 4 C 5 5. Personal Protective Equipment S/E 4 C 5 6. DCS interlock- 81XV722/725 will S/E 4 C 5 not open unless 81PC756/648 is less than 20 psi S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 D 5 5. Personal Protective Equipment S 4 C 5 6. relief valve S/E 4 C 5 S/E 4 C 5 1. External heat 126 ABD00037098 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 108. Compressor suction header Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Georgia Gulf Corp Drawings: OM-090109-PID-D, OM-090109A-PID-D Dev Consequences 108.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 108.2 High Temperature 1. See High Pressure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Line plugged 3. Power failure 4. Valve closed 127 ABD00037099 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 109. RVCM feedback line to compressor suction header Type: Line Drawing: OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 109.1 Reverse/Misdirected Flow 1. See Node 79 109.2 High Pressure 1. See Node 79 109.3 High Temperature 1. See Node 79 CAT S L RR Safeguards Georgia Gulf Corp Causes 128 ABD00037100 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 110. Compressor suction line. CP-503,504,506,111. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Drawings: OM-090109-PID-D, OM-090109A-PID-D Dev Consequences 110.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 110.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 110.3 Low/No Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. Damage compressor CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Line plugged 3. Power failure 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Line plugged 3. Power failure 4. Valve dosed S/E 3 D S 4c S/E 4 C S/E 4 B 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed 129 ABD00037101 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 111. Compressor discharge line and header to seal water separator. Same on all compressors. Type: Line Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 111.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 111.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. relief valve 9. Pressure Indication - 81P759 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4 Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 1. External heat 2. Line plugged 3. Valve closed 130 ABD00037102 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 112. Compressor/Vacuum Pump individual recovery line to batch water stripper. Type: Line Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 112.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 112.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 112.3 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line plugged 3. Operator error 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 131 ABD00037103 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 113. Compressor discharge relief valve and rv discharge header. Cp-503,504,506,111. Type: Line Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 113.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 113.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 113.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 5 6. relief valve 5 1. External heat 2. High pressure in batch water stripper 3. Line plugged 4. Operator error 5. Relief Valve failure 6. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 B 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S 4 C 5 5. Personal Protective Equipment S/E 4 C 5 6. Rupture disc 1. Cold weather 2. Valve leaking through 132 ABD00037104 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 114. Ring seal water supply line to vacuum pumps and compressors. Identical to each . Type: Line Drawings: OM-090109-PID-D, OM-090109A-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 114.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 114.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Line insulation 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 133 ABD00037105 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 115. Pressure equalization line from compressor discharge to Rx recovery header. Type: Line Drawing: OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 115.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 115.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - 81P759 / 81P756 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Valve closed 134 ABD60037106 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 116. Recirculation from recovery compressor to Rx recovery header Type: Line Drawing: OM-090109-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 116.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 116.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve failure 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Relief Valve failure 7. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. External heat 135 ABD00037107 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 117. Feed Tank recovery line. From S KO tank to compressor. Type: Line Drawing: OM-090109A-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 117.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 117.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Overpressure feed tank 3. Personal exposure 4. VCM Leak 117.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure indication- 81P606 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed 5. Valve failure 136 ABB00037108 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 118. Compressor discharge header to seal water separator. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Drawing: OM-090110-PID-D Georgia Gulf Corp Dev Consequences 118.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 118.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Indication - 81P759 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Valve closed 137 ABD00037109 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 119. Seal Water separators, DM-017, DM-018. Type: Vessel Drawing: OM-090110-PID-D Design Conditions/Parameters: MAWP: 150 psig-FV @ 300F. MOC: SA516 Georgia Gulf Corp Dev Consequences 119.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 6. Lift relief valve 119.2 High Level 1. Fire and explosion 2. Personal exposure 3. Valve packing leaking 4. VCM Leak 5. Lift relief valve 119.3 Maintenance Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - 81P759 9. relief valve 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Instrument failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. High Level switch - 81L797 / S/E 4 C 5 81L796 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. sight glass 1. Operator error 138 ABD00037110 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 120. Ring seal water line from separators, thru pumps, to ring seal water filters. Type: Centrifugal Pump + Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Pumps, 20 hp, 2x3-10-5.875, 160 gpm @ 70 psi Georgia Gulf Corp Dev Consequences 120.1 High Pressure 1. Fire and explosion 2. High Level on seat water separator 3. Personal exposure 4. Seal failure 5. VCM Leak 120.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 120.3 Low/No Flow 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Lift relief valve 5. Personal exposure 6. Seal failure 7. Valve packing leaking CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment 7. Pressure Gauge 8. Seal water flow meters 1. Line plugged 2. Operator error 3. Valve closed 4. Seal leaking internally and pump blocked in S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Pump blocked in and running S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Ring Seal Water Flow meter 5 4. general monitor 5 5. Motor overloads 5 6. Operating procedures 5 7. Operator training 8. Pressure Gauge 9. relief valve 1. Check valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Power failure 6. Pump failure 7. Valve closed 139 ABD00037111 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 121. Ring seal water filters, FL-120e/w Type: Vessel Drawing: OM-090110-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 500 F; MOC: CS Georgia Gulf Corp Dev Consequences 121.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4 Vessel rupture 121.2 Maintenance Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 121.3 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 121.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 4. VCM Leak 5. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 1. Filter Plugged 5 2. Fixed point monitor 2. Line blocked in with external 5 3. general monitor heat (thermal expansion) 5 4. Locking devices on relief valves 3. Line plugged 5. Operating procedures 4. Operator error 6. Operator training 5. Relief Valve failure 7. Pressure Gauge 6. Valve closed 8. relief valve S/E 3 D S/E 4 C S/E 3 D 5 1. Maintenance & operating 5 procedures 5 2. Operating procedures 3. Operator training 4. Personal Protective Equipment 1. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 1. External heat 5 2. Fixed point monitor 5 3. general monitor 5 4. Locking devices on relief valves 5. Operating procedures 6. Operator training 7. Pressure Gauge 8. relief valve S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Heat tracing 1. Cold weather 5 2. Line insulation 2. Valve leaking through 5 3. Fire Protection System 5 4. Fixed point monitor 5 5. general monitor 6. Locking devices on relief valves 7. Operating procedures 8. Operator training 9. relief valve 140 r ABD00037112 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 122. Ring seal water filter relief valve and discharge line to DM-017 Type: Line + Relief Valve Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 122.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. Vessel rupture 122.2 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D 5 1. DCS interlock S/E 4 C 5 2. Fire Protection System S/E 4 C 5 3. Equipment Preventive S/E 4 C 5 Maintenance Program S/E 4 C 5 4. Fixed point monitor 5. general monitor 6. Heat tracing 7. Line insulation 8. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 1. Line plugged 5 2. Fixed point monitor 2. Operator error 5 3. general monitor 3. Relief Valve failure 5 4. Locking devices on relief valves 4. Valve closed 5. Operating procedures 6. Operator training 7. relief valve 141 ABD00037113 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 123. Ring seal water line from filters to coolers Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090110-PID-D Georgia Gulf Corp Dev Consequences 123.1 High Pressure 1 Fire and explosion 2. High Level on seal water separator 3. Personal exposure 4. Gasket failure 5. Line rupture 123.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. VCM Leak 123.3 Low/No Flow 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Lift relief valve 5. Personal exposure 6. Valve packing leaking CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Pressure Gauge 8. Seal water flow meters 1. Line plugged 2. Operator error 3. Valve closed 4. External heat S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S 4 C 5 5. Operator training S/E 4 C 5 6. Pressure Gauge 7. Ring Seal Water Flow meter 1. Line plugged 2. Operator error 3. Valve closed 142 ABD00037114 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 124. Seal watercoolers, EX-005/006 Type: Heat Exchanger Drawing: OM-090110-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 200F Georgia Gulf Corp Dev Consequences 124.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 5. Vessel rupture 124.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 5. VCM release 124.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. Tube rupture 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Tubeside blocked in with steam on shell S/E 3 D S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. No cooling water S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 143 ABD00037115 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 125. Ring Seal Water pump suction crossover line. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 125.1 High Pressure 1. Fire and explosion 2. High Level on seal water separator 3. Personal exposure 4. VCM Leak 125.2 High Temperature Fire and explosion Personal exposure Seal failure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. Line plugged 2. Operator error 3. Seal leaking internally and pump blocked in 4. Valve closed S/E 1. Fire Protection System 1. External heat S/E 2. Fixed point monitor S/E 3. general monitor S/E 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 144 ABDTJ0037116 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 126. Ring Seal water line from coolers to compressors/vacuum pumps Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 126.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 126.2 Low Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Line insulation 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 145 ABD00037117 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 127. VCM vapor line from separators to condensers Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 127.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 127 2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Indication - 81P759 8 Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 146 ABD0(D037118 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 128. Seal water separator recovery line to batch water stripper. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 128.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 128.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 128.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 128.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line plugged 3. Operator error 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 147 ABD00037119 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 129 RVCM feedback line from seal water separators to N KO tank. Vacuum Pump inlet pressure control. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 129.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 129.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. Valve packing leaking 6 VCM Leak 129.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D 5 1. Check valve S/E 4 C 5 2. Fire Protection System S/E 4 C 5 3. Fixed point monitor S 4 C 5 4. general monitor S/E 4 C 5 5. Operating procedures S/E 4 C 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through 148 ABD00037120 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 130. Recovery line from VCM receivers to ERS Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090110-PID-D Georgia Gulf Corp Dev Consequences 130.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 130.2 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through o 149 ABD00037121 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 131. Recovery line from RVCM condensers to ERS Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 131.1 High Temperature 1. Fire and explosion 2 Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 131.2 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E Fire Protection System 1. High Pressure in Reactor S/E Fixed point monitor 2. Operator error S/E general monitor 3. Valve failure S/E Operating procedures 4. Valve leaking through Personal Protective Equipment 4 150 ABDBBo37122 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 132. KO Tank recovery line. To ERS Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090110-PID-D Georgia Gulf Corp Dev Consequences 132.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 132.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 132.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 132.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 151 ABD0TF037123 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 133. Pressure equalization line from compressor discharge to Rx recovery header. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 133.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 133.2 High Temperature 1 Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - 81P759 / 81P756 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Valve closed 152 ABD00037124 VIII.D. Hazards Identified * P&ID/Operating Procedures Review Node: 134. Ring seal water filter recovery line to ERS. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090110-PID-D Georgia Gulf Corp Dev Consequences 134.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 134.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 134.3 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 134.4 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 4. High pressure in batch water stripper S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Heat tracing 8. Line insulation 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Operator error S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 153 ABD00037125 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 135. Recovery line off ring seal water coolers to batch water strippers. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 135.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 135.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 135.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 135.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High pressure in batch water stripper 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Operator error 154 r ABI5D0037126 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 136. North and South KO tank blowdown line to batch water stripper. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 136.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 136.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM Leak 136.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. DCS interlock- batch water 1. External heat 5 stripper can't have high 2. High pressure in batch water 5 pressure, high level, and the stripper 5 receivers can't be draining 3. Instrument failure 2. Fire Protection System 5 3. Fixed point monitor 4. Line plugged 5. Operator error 5 4. general monitor 6. Valve closed 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Indication- 84P848/845 S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Instrument failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Operating procedures 6. Personal Protective Equipment 7. Line insulation 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 155 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 137. Seal water separator blowdown line & separator sight glass recovery line to batch water strippers. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 137.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 137.2 High Temperature 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM Leak 137.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. DCS interlock- batch water 1. External heat S/E 4 C 5 stripper can't have high 2. High pressure in batch water S/E 4 C 5 pressure, high level, and the stripper S/E 4 C 5 receivers can't be draining 3. Instrument failure 2. Fire Protection System 4. Line plugged S 4C S/E 4 c 5 3. Fixed point monitor 5 4. general monitor 5. Operator error 6. Valve closed 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Indication- 84P848/845 S/E 3 D S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Instrument failure 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 6. Operating procedures 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 156 r ABD00037128 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 138. Ring seal water pump recovery line to batch water stripper. Type: Line Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 138.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 138.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 138.3 High Temperature 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor 2. High pressure in batch water S/E 4 C 5 3. general monitor stripper S/E 4 C 5 4. Operating procedures 3. Instrument failure S/E 4 C 5 5. Personal Protective Equipment 4. Line plugged 6. Pressure Indication- 84P848/845 5. Operator error 6. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 6. Operating procedures 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Instrument failure 3. Operator error 157 ABD00037129 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node. 139. Hydroquinone pump and supply line to ring seal water pump suction. Type: Line + Positive Displacement Pump Drawing: OM-090110-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 139.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 139.2 Low/No Flow 1. VCM process line pluggage 2 Poly peroxide formation in stagnant lines 3. Fire and explosion CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Check valve 7. Pressure Gauge 8. sight glass 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 4 c S/E 4 c S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1 Operator error 2. Line plugged 3. Pump failure 4. Valve closed 5. Supply tank empty 158 ABD00037130 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 140. HPSW make-up to seal water separators. Type: Line Design Conditions/Parameters: Pipe spec A2-3 Old Module Hazop Drawing: OM-090110-PID-D Georgia Gulf Corp Dev Consequences 140.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 140.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Power failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 159 ABD00037131 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 141. RVCM line from compressors to RVCM condenser Type. Line Drawing: OM-090111 -PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 141.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 141.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication 81P759 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 160 ABD00037132 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 142. Recovery line from Dump TK to RVCM condensers Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 142.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 142.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 142.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Overpressure dump tank 3. Personal exposure 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P628 6. Valve indication 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Operator error 5. Power failure 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Dump tank kill system 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Reaction occurring in dump tank S/E 3 D S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 6 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 161 ABD00037133 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 143. RVCM condensate line from RVCM condensers to RVCM subcooler. Includes transfer pumps PP-110/111. Type: Centrifugal Pump + Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Pumps, 3x2-7-7, 90 psi @ 150 GPM Dev Consequences 143.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 143.2 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. DCS interlock-81X738/737 5 pump won't run unless receiver 5 valve is open 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 8. Recirculation line 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Recirculation line 7. DCS interlock-81X738/737 pump won't run unless receiver valve is open 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed 5. Pump blocked in and running 162 ABD00037134 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 144. RVCM Subcooler, EX-102, and subcooler bypass. Type: Heat Exchanger + Line Drawing: OM-090111-PID-D Design Conditions/Parameters: MAWP: shell 150 psig @ 250 F, tube 300 psig @ 250 F Georgia Gulf Corp Dev Consequences 144.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. Vessel rupture 144.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. VCM release 144.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. Tube rupture 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Relief Valve failure S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. No cooling water S/E 3 D S/E 4 C S 4C S/E 4 C 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 163 ABD00037135 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 145. RVCM transfer pump recirculation line Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090111-PID-D Georgia Gulf Corp Dev Consequences 145.1 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak 145.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump blocked in and running 5. Valve closed S/E 3 D S/E 4 C S/E 4 c S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 164 ABDT50037 1 36 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 146. RVCM condensate line from RVCM subcooler to RVCM receivers. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 146.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 146.2 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. Recirculation line 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump blocked in and running 5. Valve closed 165 ABD00037137 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 147. HPSW supply to RVCM condensers, EX-008/009 Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-3. Georgia Gulf Corp Dev Consequences 147.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 147.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Power failure 166 ABD00037138 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 147A. RVCM Condensers, Ex-008/009. Type: Heat Exchanger Drawing: OM-090111-PID-D Design Conditions/Parameters: MAWP: shell/tube, 150 psig @ 400F. Georgia Gulf Corp Dev Consequences CAT s L RR Safeguards Causes 147A.1 High Pressure 1. Fire and explosion 2 Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. Vessel rupture S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Relief Valve failure 147A.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. VCM release S/E 3 D S/E 4 C S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. No cooling water 147A.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. Tube rupture 5. VCM Leak S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 147A.4 Maintenance Hazards 1. Fire and explosion S/E 3 D 2. Personal exposure S 4C 3. VCM Leak S/E 4 C 4. VCM release S/E 4 C 5. Personal injury due to falling, S 4C bumping head, or straining back. 5 1. Maintenance & operating 5 procedures 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Personal Protective Equipment 1. Poor access 2. Not blanked out 3. Operator error 167 ABDOOD37139 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 148. Cooling water supply & return lines for EX-008/009. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-3. Georgia Gulf Corp Dev Consequences 148.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. VCM Leak 148.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure VCM Receivers 5. Personal exposure 6. VCM Leak 148.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Exchanger blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Valve closed S/E 3 D 5 1. Fixed point monitor S/E 4 C 5 2. general monitor S/E 4 C 5 3. Operating procedures S/E 4 C 5 4. Operator training S/E 4 C 5 5. Personal Protective Equipment 6. Fire Protection System 1. Cold weather 2. Valve leaking through 168 ABDU0O3714O VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 149. EX-00B/009 relief valve. Type: Line + Relief Valve Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090111-PID-D Georgia Gulf Corp Dev Consequences 149.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure VCM Receivers 5. Personal exposure 6. VCM Leak 149.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. VCM Leak 149.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment 7. Pressure Gauge 8. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Valve closed 5. Relief Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Operator training 6. Pressure Gauge 1. Exchanger blocked in with external heat (thermal expansion) 2. External heat 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 6. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 169 ABD00037141 VIH.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 150. Recovery lines from RVCM condensers to ERS Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 150.1 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 150.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 150.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 150.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 c 5 4. Operating procedures S/E 4 c 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 170 ABD00037142 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 151. Inert vent from RVCM condenser recovery line to RVCM receivers. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 151.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 151.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 151.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 4. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 171 ABD00037143 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Ha20p Node: 152. Inert vent from RVCM condenser relief valve inlet line to RVCM receivers. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 152.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 152 2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 152.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Line blocked in with external heat {thermal expansion) 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3 general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 172 ABD00037144 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 153. HPSW supply to mechanical seal on RVCM transfer pumps PP-110/111. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-3/J16-1 Georgia Gulf Corp Dev Consequences 153.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 153.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 153.3 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 153.4 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 4. Heat tracing 5. Line insulation 1. Operator error 2. Cold weather S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 4. Pressure Gauge 5. Flow meter 1. Operator error 2. Line plugged 3. Instrument failure 173 ABD00037145 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 154. Recovery line from RCVM transfer pumps to ERS. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 154.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 154.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3 Line rupture 4. Personal exposure 5. VCM Leak 154.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 154.4 High Temperature 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. High pressure in DM-701 3. Instrument failure 4. Line plugged 5. Operator error 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Instrument failure 3. Operator error 174 ABD00037146 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 155. RVCM condensate line from ERS condensers to RVCM transfer pump discharge line. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 155.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5 VCM Leak 155.2 Reverse/Misdirected Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. VCM Leak 155.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. VCM Leak 155.4 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4 VCM Leak 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Check valve 1. Instrument failure 2. Line plugged 3 Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 c 5 4. Operating procedures S/E 3 D 5 5. Personal Protective Equipment 1. External heat 175 ABD00037147 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 156. RVCM condensate line from RVCM condensers to RVCM subcooler. Type: Line Drawing: OM-090111-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 156.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 156.2 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. DCS interlock- 81X738/737 1. External heat S/E 4 C 5 pump won't run unless receiver 2. Line plugged S/E 4 C 5 valve is open 3. Operator error S 4 C 5 2. Fire Protection System 4. Valve closed S/E 4 C 5 3. Fixed point monitor S/E 4 C 5 4 general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 8. Recirculation line S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. DCS interlock- 81X738/737 5 pump won't run unless receiver 5 valve is open 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Recirculation line 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump blocked in and running 5. Valve closed 176 ABD00037148 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 157. RVCM receivers, DM-011, DM-012. Type: Vessel Drawing: OM-090112-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 100 F Georgia Gulf Corp Dev Consequences 157.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 6 Overpressure batchwater stripper 157.2 High Temperature 1. Fire and explosion 2. Gasket failure 3 Lift relief valve 4. Overpressure batchwater stripper 5 Personal exposure 6. Vessel rupture 157.3 High Level 1. Fire and explosion 2. High pressure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 157.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 1. External heat 2. Instrument failure 3. Line blocked in with external S 4 C 5 4. Operating procedures heat (thermal expansion) S/E 3 D 5 5 Operator training 4. Line plugged S/E 4 C 5 6. Personal Protective Equipment 5. Operator error 7. Pressure Gauge 6. Relief Valve failure 8. Pressure indication, 81P750/753 7. Valve closed 9. relief valve 8. vent plugged 9. No cooling water on knockback condenser S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Operator training S 4 C 5 6. Personal Protective Equipment S/E 3 D 5 7. Pressure Gauge 8. relief valve 1. External heat 2. No cooling water on knockback condenser 3. Temperature indication on chiller S/E 3 D S/E 4 C S/E 4 C S 4c S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. relief valve 9. Level indication, 81L755/761, 81LSH752 10. sight glass 1. Instrument failure 2. Operator error 3. Valve leaking through S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4 Maintenance & operating procedures 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Operator error 2. Valve leaking through 177 ABD00037149 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 158. RVCM charge pump relief valve and discharge header. Type: Line + Relief Valve Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 158.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Overpressure batchwater stripper 5 Personal exposure 6. Seal failure 7. VCM Leak 158.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 158.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 5. Overpressure batchwater stripper CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 1. High pressure in batch water 5 2. Equalization line stripper 5 3. Fixed point monitor 2. Line blocked in with external 5 4. Locking devices on relief valves heat (thermal expansion) 5. Operator training 3. Line plugged 5 6. relief valve 4. Operator error 5 7. Equipment Preventive 5 Maintenance Program S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6 Operator training 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 4 C S/E 3 D S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Equipment Preventive Maintenance Program 1. Operator error 2. Valve leaking through 178 ABD00037150 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 159. RVCM condensate line from RVCM subcooler to RVCM receivers. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 159.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 159.2 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. Recirculation line 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. DCS interlock- 81X738/737 1. Instrument failure S/E 4 C 5 pump won't run unless receiver 2. Line plugged S/E 4 C 5 valve is open 3. Operator error S/E 4 C 5 2. Fire Protection System 4. Pump blocked in and running S/E 4 C 5 3. Fixed point monitor 5. Valve closed 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Recirculation line 179 ABD00037151 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 160. Inert vent line from RVCM knockback condenser to incinerator. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 160.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 160.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure 180 ABD00037152 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 161. RVCM charge line from RVCM receivers to RVCM charge filters. Includes RVCM charge pumps. PP-477/058. Type: Centrifugal Pump + Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Pumps, 2x3-13, 200 GPM @ 35 psi Dev Consequences 161.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 161.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Line rupture 5 Personal exposure 6. VCM Leak 161.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4 No flow 5 Personal exposure 6. VCM Leak 161.4 Reverse/Misdirected Flow 1. Fire and explosion 2. High Level on Knockout Tank 3. Lift relief valve 4. Line rupture 5. Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 B 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. Recirculation line 8. relief valve 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Relief Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1 Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line plugged 3. Operator error 4. Relief Valve failure 5. Pump blocked in and running S/E 3 D S/E 4 C S/E 4 B S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 5 6. Operating procedures 7. Personal Protective Equipment 1. Cold weather 2. Operator error 3. Valve leaking through 4. Heat tracing failure S/E 3 D S/E 4 C S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 5 6. Operator training 7. Personal Protective Equipment 8. relief valve 1. Check valve failure 2. High Pressure in Reactor 3. Pump failure 181 ABDO0O37153 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 162. RVCM charge line from RVCM filters to Rx's. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 162.1 High Pressure 1. Lift relief valve 2. Valve packing leak 3. Line rupture 4. Fire and explosion 5. Gasket failure 162.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 4. VCM Leak 162.3 High Temperature 1. Fire and explosion 2. High pressure 3. Lift relief valve 4. Personal exposure CAT S L RR Safeguards Causes S/E 4 C 5 1. DCS interlocks, valve 81hv703, 1. external heat S/E 4 C 5 pump won't run if valve closed 2. Plugged filter pack S/E 4 C 5 2. Operating procedures 3. Plugged relief valve S/E 3 D 5 3. Flow indication, 81F744 4. Valve blocked in/closed S/E 4 C 5 4. Pressure Gauge S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Personal Protective Equipment 5. relief valve 1. External heat 182 ABD0fi&37154 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 163. Inert line from New Module receivers Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090112-PID-D Georgia Gulf Corp Dev Consequences 163.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 163.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 163.3 Low Temperature 1. Frozen Line 2. Gasket failure 3. Line rupture 4. Fire and explosion CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. Knockback condensers on RVCM receivers 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 7. Chiller unit cooling knockback condensers 1. External heat 2. Heat tracing failure 3. Chiller unit not working S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Valve leaking through 3. Heat tracing failure 183 ABDO'0037155 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 164. Receiver equalization line from fresh receiver. Type: Line Drawing. OM-Q90112-PIO-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 164.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4 VCM release 164.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 164.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 3 D 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure indication, 81P750 1. Line blocked in with external heat (thermal expansion) 2. Operator error 3. Valve failure 4. Valve leaking through 5. High pressure in VCM receivers S/E 3 D 5 1. Fire Protection System S/E 4 D 5 2. Fixed point monitor S/E 4 D 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 6. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 184 ABDO0O37156 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 165. RVCM charge filter, FL-691. Type; Vessel Design Conditions/Parameters: MAWP: 300 psig @ 650 F Drawing: OM-090112-PID-D Georgia Gulf Corp Dev Consequences 165.1 High Pressure 1. Blown O-Ring 2. Fire and explosion 3. Lift relief valve 4. Personal exposure 165.2 High Temperature 1. Fire and explosion 2. High pressure 3. Lift relief valve 4. Personnel exposure 165.3 Low Temperature 1. Frozen Line 2. High pressure 3. No flow 4. Fire and explosion 165.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 4 C S/E 3 D S/E 4 C S 4C 5 1. Equalization line 5 2. Operating procedures 5 3. Pressure Gauge 5 4. relief valve 1. Closed Outlet Valve 2. Equalization Line Plugged 3. External Heat 4. Plugged Filter S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Operating procedures S/E 4 C 5 3. relief valve S 4 C 5 4. Fixed point monitor 5. general monitor 6. Personal Protective Equipment 1. External heat S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Operating procedures 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Maintenance & operating procedures 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Operator error 2. Valve leaking through 185 ABDOOt)37157 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 166. RVCM receiver recovery line to batch water stripper. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 166.1 High Pressure 1 Fire and explosion 2. Personal exposure 3 VCM Leak 4. VCM release 166 2 High Temperature 1. Fire and explosion 2 Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6 VCM Leak 166.3 Low Temperature 1. Fire and explosion 2 Frozen Line 3 Line rupture 4. No flow 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3 Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 186 r ABD00037158 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 167. RVCM Feedback feedback line from RVCM receivers to Rx recovery header. See node 72. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 167.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 167.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 167.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure VCM Receivers 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Operator error 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Steam stripping valve on reactor failed open S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 187 ABD00037159 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 168. Inert vent from RVCM condenser recovery line to RVCM receivers. See node 151 Type: Line Drawings: OM-090111-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 168.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 168.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 168.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes s/e 3 D s 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Line blocked in with external heat (thermal expansion) 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 188 ABD0G037160 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 169. Inert vent line from Ex-102 (RVCM Subcooler) to RVCM receivers. Type: Line Drawings: OM-090111-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 169.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 169.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 169.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 169.4 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 189 ABOTf037161 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 170. RVCM Receiver recovery line to ERS. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090112-PID-D Georgia Gulf Corp Dev Consequences 170.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 170.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 170.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 190 ABD00037162 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 171. RVCM recycle line from RVCM charge pumps to RVCM receivers. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 171.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 171.2 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump blocked in and running 5. Valve closed 191 ABD00037163 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 172. Jumper from NM inert line and receiver recovery line to ERS. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 172.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 172.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 192 ABDO0O37164 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 173. VCM charge line from NM VCM charge pumps to OM RVCM charge pumps. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 173.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 173.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 193 ABD00037165 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 174. DM-013, FVCM Receiver Drain Line to batch water stripper. Type: Line Drawings: OM-090100-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe Spec A2-22 Dev Consequences 174.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 174.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 174.3 Low Temperature 1. Frozen Line 174.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Line blocked in with external heat (thermal expansion) S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. External heat S/E 4 C 5 1. Heat tracing 2. Operating procedures 3. Operator training 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 194 ABD00037166 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 175. Inert vent from RVCM condenser relief valve inlet line to RVCM receivers. Type: Line Drawings: OM-090111-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 175.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 175.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4 Personal exposure 5. VCM Leak 175.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Line blocked in with external heat {thermal expansion) 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 195 ABD00037167 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 176. DM-011/012, RVCM Receiver Drain Line to batch water stripper. Type: Line Drawings: OM-090100-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe Spec A2-22 Dev Consequences 176.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 176.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 176.3 Low Temperature 1. Frozen Line 176.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat S/E 4 C 5 1. Heat tracing 2. Operating procedures 3. Operator training 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 196 ABDTJ0037168 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 177. Secondary inert vent line from NM RVCM receivers to incinerator. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 177.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 177.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 177.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Knockback condensers on 5 RVCM receivers 5 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Chiller unit cooling knockback 5 condensers 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 1. Chiller unit not working 2. External heat 3. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 197 ABD00037169 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 178. Jumper line from secondary inert vent line to batch water stripper line. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 178.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 178.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 178.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Knockback condensers on 5 RVCM receivers 5 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Chiller unit cooling knockback 5 condensers 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 1. Chiller unit not working 2. External heat 3. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 198 ABD00037170 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 179. Jumper line, primary inert vent from new module to batch water stripper Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 179.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 179 2 High Temperature 1. Fire and explosion 2. Line rupture 3 Personal exposure 4 VCM Leak 179.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Knockback condensers on 5 RVCM receivers 5 5. Operating procedures 6. Personal Protective Equipment 7 Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Chiller unit cooling knockback 5 condensers 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 1. Chiller unit not working 2. External heat 3. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 199 ABD00037171 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 180. Recovery header from RVCM charge filter & RVCM condensers to batch water strippers. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 180.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 180.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 180.3 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure 200 ABD00037172 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 181. Recovery line from trans-unit vcm charge line to batch water stripper. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 181.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 181.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 181.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 181.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. DCS interlock-Fill valves on 1. Instrument failure 5 batch water stripper will close on 2. Line plugged 5 high pressure/level. 3. Operator error 5 2. Fire Protection System 4. Power failure 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 201 ABDOT37173 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 182. Recovery line from fresh vcm charge filters FL-008/009. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 182.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 182.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 182.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 182.4 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. DCS interlock-Fill valves on 1. Instrument failure 5 batch water stripper will close on 2. Line plugged 5 high pressure/level. 3. Operator error 5 2. Fire Protection System 4. Power failure 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure 202 ABD00037174 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 183. RVCM charge pump, PP-477/058, recovery line. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 183.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 183.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 183.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 183 4 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Line insulation 5. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D 5 1. DCS interlock-Fill valves on 1. Instrument failure S/E 4 C 5 batch water stripper will close on 2. Line plugged S/E 4 C 5 high pressure/level. 3 Operator error S/E 4 C 5 2. Fire Protection System 4. Power failure 3. Fixed point monitor S 4 C 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4 Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3 Line plugged 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure 203 ABD00037175 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 184. RVCM filter, FL-691, recovery line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090112-PID-D Georgia Gulf Corp Dev Consequences 184.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 184.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 184.3 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 184.4 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. DCS interlock-Fill valves on 1. Instrument failure 5 batch water stripper will close on 2. Line plugged 5 high pressure/level. 3. Operator error 5 2. Fire Protection System 4. Power failure 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure 204 ABD00037176 VIIID Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 185. Inert vent from RVCM condenser relief valve inlet line to RVCM receivers Type: Line Drawings: OM-090111-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 185.1 High Pressure 1. Fire and explosion 2. Personal exposure 3 VCM Leak 4 VCM release 185.2 High Temperature 1. Fire and explosion 2. High pressure 3. Line rupture 4. Personal exposure 5. VCM Leak 185.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2 Fixed point monitor 5 3 general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. Line blocked in with external heat (thermal expansion) 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 205 ABD00037177 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 186. Relief valve discharge header from RVCM charge filter, FL-691, to batch water stripper. Type: Line Drawings: OM-090100-PID-D, OM-090112-PID-D Design Conditions/Parameters: Pipe Spec A2-22 Dev Consequences 186.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM release 186.2 Low Temperature 1. Fire and explosion 2. High pressure 3. No flow 4. Personal exposure 5. VCM Leak 186.3 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. DCS interlock, valve 81xv709 1. High pressure in batch water S/E 4 C 5 2. Fire Protection System stripper S/E 4 C 5 3. Fixed point monitor 2. Line plugged S 4 c 5 4. general monitor 3. Valve closed S/E 3 D 5 5. Locking devices on relief valves 6. Personal Protective Equipment 7. relief valve S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Personal Protective Equipment S/E 4 C 5 1. Cold weather S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Personal Protective Equipment S 4 C 5 5. relief valve S/E 4 C 5 1. External heat 206 ABD00037178 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 187. ERS inlet KO tank.DM-701. drain line to batch water stripper. Type: Line Drawings: OM-090112-PID-D, OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 187.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. Seal failure 7. Vessel rupture 187.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure filter pack 5. Personal exposure 6. Seal failure 187.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 187.4 Low/No Flow 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. Overpressure filter pack 6. Seal failure 7. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 6. Pressure Gauge 5 5 1. External heat 2. Filter Plugged 3. High pressure in batch water stripper 4. Instrument failure 5. Line blocked in with external heat (thermal expansion) 6. Line plugged 7. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operator training S 4C 5 S/E 4 C 5 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 5 6. Operator training 5 7. Personal Protective Equipment 8. Pressure Gauge 1. Cold weather 2. Filter Plugged 3. Heat tracing failure 4. High pressure in batch water stripper 5. Line plugged 6. Operator error 7. Pump failure 8. Valve closed 207 ABD00037179 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 188. North and South KO tank blowdown line to batch water stripper. Type: Line Drawings: OM-090108-PID-D, OM-090112-PID-D, OM-090110-PIDD Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 188.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 188.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM Leak 188.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 5 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line plugged 5. Operator error 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. Instrument failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 208 ABD00037180 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 189. HPSW supply to mechanical seal on RVCM charge pump, PP-477. Type: Line Drawing: OM-090112-PID-D Design Conditions/Parameters: Pipe spec A13-1. Georgia Gulf Corp Dev Consequences 189.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 189.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 189.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 189.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Heat tracing 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error 209 ABD00037181 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 190. RVCM Receiver recovery line to ERS. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Georgia Gulf Corp Drawings: OM-090112-PID-D, OM-090113-PID-D Dev Consequences 190.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 190.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 190.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure control valve, 84P857 1. Operator error 2. Valve failure 3. Valve leaking through 4. High pressure in batch water stripper 5. Line blocked in with external heat (thermal expansion) S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4 Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 210 ABDOO0T7182 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 191. Batch water stripper recovery line to ERS inlet condenser EX-351. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 191.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 191.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 191.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5 Line plugged 6. Operator error 7. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Heat tracing 7. Line insulation 1. Cold weather 2. Valve leaking through 3. Heat tracing failure 211 ABD00037183 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 192. ERS inlet VCM condenser, EX-351. Type: Heat Exchanger Drawing: OM-090113-PID-D Design Conditions/Parameters: MAWP: for shell & tubes, 150 psig @ 450 F. Georgia Gulf Corp Dev Consequences CAT S L RR Safeguards Causes 192.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. Tube leak/rupture S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. Exchanger blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Relief Valve failure 192.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. VCM release S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 6. relief valve 1. External heat 2. No cooling water 192.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. Tube rupture 5. VCM Leak S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 192.4 Start-up/Shutdown Hazards 1. Fire and explosion S/E 3 D 2. Personal exposure S 4C 3. Personal injury due to falling, S/E 4 C bumping head, or straining back. 4. VCM Leak S/E 4 C 5. VCM release S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating 5 procedures 5 5. Personal Protective Equipment 1. Not blanked out 2. Operator error 3. Poor access 212 ABD00037184 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 193. ERS vcm condenser, EX-351, outlet to DM-701. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 193.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 193.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 193.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line blocked in with external heat (thermal expansion) 3. Operator error 4. Valve failure 5. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 1. Cold weather 2. Valve leaking through 213 ABD00037185 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 194. VCM tank farm recovery line to ERS inlet KO tank. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 194.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 194.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 194.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 214 ABD00037186 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node. 195. Recovery line from NM Blowdown tank to ERS. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 195.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 195.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 195.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error 7. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 215 ABD00037187 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 196. DM-701 outlet to ERS vacuum pumps & compressors Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 196.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 196.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Pressure control valve 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Personal Protective Equipment 6. Pressure Gauge 1. High pressure in batch water stripper 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Valve closed 216 ABD00037188 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 197. ERS Inlet KO TK, DM-701. Type: Vessel Drawing: OM-090113-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 350 F Georgia Gulf Corp Dev Consequences 197.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 197.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 197.3 High Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 197.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Control Valve failure S/E 4 C 5 2. Fixed point monitor 2. External heat S/E 4 C 5 3. general monitor 3. High Level S 4 C 5 4. Operating procedures 4. Instrument failure S/E 3 D 5 5. Operator training 5. Operator error 6. Personal Protective Equipment 6. Power failure 7. Pressure Gauge 7. Relief Valve failure 8. Pressure indicator, 84P855 / 8. Valve leaking through 84P857 & pressure control valve 9. relief valve S/E 3 D S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5. Personal Protective Equipment 1. External heat S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Level switch - 1701C S/E 3 D 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 3 D S 4C S/E 3 D S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. sight glass 1. Operator error 217 ABD00037189 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 198. ERS ring seal water filters recovery line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090113-PID-D Georgia Gulf Corp Dev Consequences 198.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 198.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 198.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error 7. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error 218 ABD00037190 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 199. Recovery line from RCVM transfer pumps to ERS. Type: Line Drawings: OM-090111-PID-D, OM-090113-PID-D Design Conditions/Parameters: Pipe specA2-22. Dev Consequences 199.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 199.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 199.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error 7. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 c S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error 219 ABD00037191 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 200. Recovery line from DM-701 water outlet strainers. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 200.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 200.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 200.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line blocked In with external heat (thermal expansion) 5. Line plugged 6. Operator error 7. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through 220 ABD00037192 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 201. ERS vacuum pumps, VP-703/704. Type: Centrifugal Compressor Design Conditions/Parameters: 5x5-14, 280 acfm @ 25" hg. Drawing: OM-090113-PID-D Georgia Gulf Corp Dev Consequences 201.1 High Suction Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Seal failure 6. VCM Leak 201.2 High Discharge Pressure Fire and explosion Gasket failure Line rupture Personal exposure Seal failure VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. relief valve 1. Instrument failure 2. Operator error 3. Pump failure 4. Relief Valve failure 5. Valve leaking through S/E 1. Amp indicator 1. Compressor not pulling S/E 2. Fire Protection System 2. External heat S/E 3. Fixed point monitor 3. Line plugged S 4. general monitor 4. Operator error S/E 5. Motor overloads 5. Valve closed S/E 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Pressure Gauge 221 ABD00037193 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 202. ERS vacuum pump, VP-704/704, discharge line and discharge header to DM-702. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 202.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. High temperature 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 202.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High temperature 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 c S/E 4 c S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 5 1. Line plugged 2. Operator error 3. Valve closed S/E 3 D S/E 4 c S/E 4 c S/E 4 c S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 5 1. Line plugged 2. Operator error 3. Valve closed 222 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 203. ERS vacuum pump bypass line to ERS compressors. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 203.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 203.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Power failure 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 B 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Power failure 4. Valve closed 223 ABD00037195 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 204. Ring seal water supply line to ERS vacuum pump Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 204.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 204.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4c S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5 5. Operating procedures 5 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 c S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2 Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 224 ABD00037196 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 205. HPSW supply line to ERS vacuum pump mechanical seals. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-3 and J16-1. Georgia Gulf Corp Dev Consequences 205.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 205.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 205.3 Low Pressure 1. Personal exposure 2. Seal failure 3 VCM Leak 205.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Cold weather 225 ABD00037197 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 206. HPSW supply line to DM-701 and DM-701 sight glass. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 206.1 Low Pressure 1. Personal exposure 2. Reverse flow 3. VCM Leak 206.2 High Flow 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4 Personal exposure 5. Vessel rupture CAT S L RR Safeguards Causes S 4C S/E 4 C S/E 4 c 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 1. Filter Plugged 2. Line plugged 3. Operator error 4. Power failure 5. Pump failure 6. Valve closed 7. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Level switch - 1701C 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure 226 ABD00037198 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 207. ERS vacuum pump, VP-703/704, relief valve and RV discharge line. Type: Line + Relief Valve Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 207.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 207.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6 VCM Leak 207.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 5 6. relief valve 5 1 External heat 2. High pressure in batch water stripper 3. Line plugged 4. Operator error 5. Relief Valve failure 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Rupture disc 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Operator error 227 ABD0OO37199 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 208. ERS inlet KO tank,DM-701, drain line to batch water stripper. Type: Centrifugal Pump + Line Drawings: OM-090112-PID-D, OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 208.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. Seal failure 7. Vessel rupture 208.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure filter pack 5. Personal exposure 6. Seal failure 208.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 208.4 Low/No Flow 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. Overpressure frlter pack 6. Seal failure 7. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 6. Pressure Gauge 5 5 1. External heat 2. Filter Plugged 3. High pressure in batch water stripper 4. Instrument failure 5. Line blocked in with external heat (thermal expansion) 6. Line plugged 7. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operator training S 4C 5 S/E 4 B 5 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 5 6. Operator training 5 7. Personal Protective Equipment 8. Pressure Gauge 1. Cold weather 2. Filter Plugged 3. Heat tracing failure 4. High pressure in batch water stripper 5. Line plugged 6. Operator error 7. Pump failure 8. Valve closed 228 ABD00037200 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 209. DM-701 and DM-701 sight glass recovery line. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 209.1 Low/No Flow 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. Personal Exposure 209.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal Exposure 209.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c S 4c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operator training 7. Personal Protective Equipment 8 Pressure Gauge 1. Cold weather 2. Filter Plugged 3. Heat tracing failure 4. High pressure in batch water stripper 5. Line plugged 6. Operator error 7. Pump failure 8. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 1. Filter Plugged 2. High pressure in batch water stripper 3. Line plugged 4. Operator error 5. Pump failure 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 1. External heat 2. Heat tracing failure 3. Operator error 229 ABD00037201 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 210. Recirculation line from PP-112 discharge to DM-701. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 210.1 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5. VCM Leak 210.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump blocked in and running 5. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 230 ABD00037202 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 211. DM-702 blowdown line to DM-701. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090113-PID-D Georgia Gulf Corp Dev Consequences 211.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 211.2 High Temperature 1. Fire and explosion 2 Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Heat tracing failure 231 ABD00037203 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 212. Jumper from DM-702 blowdown line to DM-701 drain line. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 212.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 212.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 212.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operator training 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Line plugged 4. Operator error 232 ABD00037204 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 213. DM-703 drain line to DM-701 drain line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090113-PID-D Georgia Gulf Corp Dev Consequences 213.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 213.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 213.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Line plugged 4. Operator error S 3D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. Filter Plugged 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 233 ABD00037205 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 214. HPSW supply line to ERS ring seal water pump mechanical seals. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A13-1. Georgia Gulf Corp Dev Consequences 214.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 214.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 214.3 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 214.4 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 1. External heat S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Heat tracing 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 234 ABD00037206 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 215. DM-702 drain/recovery line to DM-701 drain line. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 215.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 215.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. VCM Leak 215.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. Filter Plugged 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Line plugged 4. Operator error 235 ABD00037207 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 216. ERS compressor relief valve discharge line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090113-PID-D Georgia Gulf Corp Dev Consequences 216.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 216.2 Low Temperature 1. Fire and explosion 2 Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 216.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor 2. High pressure in batch water S/E 4 C 5 3. general monitor stripper S/E 4 c 5 4. Operating procedures 3. Line plugged 5. Personal Protective Equipment 4. Operator error S 4 c 5 6. relief valve 5. Relief Valve failure S/E 4 c 5 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Rupture disc 7. Equipment Preventive Maintenance Program 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Operator error 236 ABD00037208 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 217. HPSW line to ERS compressor mechanical seal. Type: Line Drawing: OM-090113-PID-D Design Conditions/Parameters: Pipe spec A13-1 Georgia Gulf Corp Dev Consequences 217.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 217.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 217.3 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 217.4 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Personal Protective Equipment 1. External heat S 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. Heat tracing 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3 Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 237 ABD00037209 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 218. ERS vacuum pump, VP-704/704, discharge line and discharge header to DM-702. Type: Line Drawings: OM-090113-PID-D, OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 218.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. High temperature 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 218.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High temperature 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S 4 C 5 5. Personal Protective Equipment S/E 4 C 5 S/E 4 C 5 1. Line plugged 2. Operator error 3. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 5 1. Line plugged 2. Operator error 3. Valve closed 238 ABD00037210 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 219. ERS vacuum pump seal water separator, DM-702. Type: Vessel Drawing: OM-090114-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 140 F Georgia Gulf Corp Dev Consequences 219.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 219.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 219.3 High Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 219.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure indicator controller (PIC) 1301 & PIC 1302 9. relief valve 1. Control Valve failure 2. External heat 3. High Level 4. Instrument failure 5. Operator error 6. Power failure 7. Relief Valve failure 8. Valve leaking through S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. Operating procedures S/E 3 D 5 4. Operator training 5. Personal Protective Equipment 6. Temperature switch/alarm 1702 S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. relief valve 8. sight glass 9. Level Switch 1702 B/C 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 3 D S 4C S/E 3 D S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. sight glass 1. Operator error 239 ABD00037211 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 220. Ring seal water supply header from DM-702, thru pumps, PP-707/708, filters, FL-050/051, to ring seal water coolers, EX-002/ 004/311. Type: Centrifugal Pump + Line + Vessel Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Pumps: 2x3-10-8.5,132 psig @ 90 GPM. Filters: MAWP 150 psig @ 500 F. Dev Consequences 220.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Line rupture 5. Overpressure filter pack 6. Personal exposure 7. Seal failure 220.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 220.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 220.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Filter Plugged S/E 4 C 5 2. Fixed point monitor 2. Line blocked in with external S/E 4 C 5 3. general monitor heat (thermal expansion) S/E 4 C 5 4. Locking devices on relief valves 3. Line plugged S/E 4 C 5 5. Operating procedures 4. Operator error S 4 C 5 6. Operator training 5. Relief Valve failure S/E 4 c 5 7. Personal Protective Equipment 6. External heat 8. Pressure Gauge 9. relief valve S/E 3 D S/E 4 C S 4C s 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. relief valve 1. External heat S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. relief valve 8. DCS interlock Batch water stripper fill valves close on high pressure/level. 1. instrument failure 2. Operator error 240 ABD00037212 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 221. Ring seal water filter, FL-050/051, relief valve and RV discharge line to ring seal water pump suction line. Type: Line + Relief Valve Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe specA2-22. Georgia Gulf Corp Dev Consequences 221.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 221.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 221.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Equipment Preventive 5 Maintenance Program 5 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Rupture disc 8. Line insulation 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Line plugged 3. Relief Valve failure 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Operator error 3. Pump blocked in and running 241 ABD00037213 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 222. Ring Seal Water Coolers, EX-311, EX-004, EX-002. Type: Heat Exchanger Drawing: OM-090114-PID-D Design Conditions/Parameters: MAWP: 75 psig @ 400 F Georgia Gulf Corp Dev Consequences 222.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 5. Vessel rupture 222.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 5. VCM release 222.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. Tube rupture 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 3 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 4 5. Personal Protective Equipment 1. External heat 2. Exchanger blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Tubeside blocked in with steam on shell 6. Over pressure by ring seal water pump S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. No cooling water S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 242 ABD00037214 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 223. ERS ring seal water header from coolers to compressors and vacuum pumps. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 223.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 223.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5 5. Operating procedures 5 6. Personal Protective Equipment 7. Heat tracing 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3 Operator error 4. Valve closed 243 ABD00037215 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 224. VCM vapor from LRS separators Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090114-PID-D Georgia Gulf Corp Dev Consequences 224.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 224.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 244 ABD00037216 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 225. DM-702 vapor outlet to ERS compressors. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090114-PID-D Georgia Gulf Corp Dev Consequences 225.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 225.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - PIC 1302 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Check valve failure S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 245 ABD00037217 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 226. Jumper from ring seal water header to DM-702. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 226.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 226.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - 81P759 1. External heat 2. Line plugged S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. External heat 246 ABD00037218 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 227. DM-702 blowdown line to DM-701. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Georgia Gulf Corp Drawings: OM-090113-PID-D, OM-090114-PID-D Dev Consequences 227.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 227.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 247 ABD00037219 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 228. HPSW supply line to DM-702 and DM-703 and sight glasses on each. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 228.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 228.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 248 ABD00037220 VIII.D Hazards Identified - P&ID/Operating Procedures Review Node: 229. DM-702 make-up water line. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090114-PID-D Georgia Gulf Corp Dev Consequences 229.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 229.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5 5. Operating procedures 6. Personal Protective Equipment 7. Heat tracing 1. Cold weather 2. Heat tracing failure 249 ABD00037221 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 230. DM-703 & DM-702 drain lines to DM-701 drain line. Type: Line Drawings: OM-090113-PID-D, OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 230.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Personal exposure 230.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 230.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. Filter Plugged 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error S/E 3 D S/E 4 C S/E 4 C 4C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 250 ABD00037222 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 231. ERS ring seal water filters recovery line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Georgia Gulf Corp Drawings: OM-090113-PID-D, OM-090114-PID-D Dev Consequences 231.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 231.2 Low Temperature 1. Fire and explosion 2 Frozen Line 3. Line rupture 231.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 B S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 5 1. External heat 2. High pressure in batch water stripper 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) 5. Line plugged 6. Operator error 7. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Operator error 251 ABD00037223 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 232. HPSW supply line to ERS ring seal water pump mechanical seals. Type: Line Drawings: OM-090113-PID-D, OM-090114-PID-D Design Conditions/Parameters: Pipe spec A13-t. Dev Consequences 232.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 232.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 232.3 Low Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 232.4 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Personal Protective Equipment 1. External heat S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Heat tracing 5 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 252 ABD00037224 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 233. Hydroquinone addition line to ERS ring seal water supply header. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-3. Georgia Gulf Corp Dev Consequences 233.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 233.2 Low/No Flow 1. Fire and explosion 2. Poly peroxide formation in stagnant lines 3. VCM process line pluggage CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 8. sight glass 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Pump failure 4. Supply tank empty 5 Valve closed 253 ABD00037225 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 234. ERS compressor seal water separator, DM-703. Type: Vessel Drawing: OM-090114-PID-D Design Conditions/Parameters: MAWP: 140 psig @ 100 F Georgia Gulf Corp Dev Consequences 234.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 234.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM release 234.3 High Level 1. Fire and explosion 2. Gasket failure 3. Lift relief vah/e 4. Personal exposure 5. Vessel rupture 234.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure switch, PS 1703 9. relief valve 1. Control Valve failure 2. External heat 3. High Level 4. Instrument failure 5. Operator error 6. Power failure 7. Relief Valve failure 8. Valve leaking through S/E 3 D S/E 3 D S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5. Personal Protective Equipment 6. Temperature switch/alarm 1702 1. External heat S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Level Switch 1702B/C S/E 4 C 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S/E 3 D S 4C S/E 3 D S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. sight glass 1. Operator error 254 ABD00037226 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 235. ERS compressor discharge header to DM-703 Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 235.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 235.2 High Temperature 1. Fire and explosion 2. Line rupture 3 Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - PS 1703 9. relief valve 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 1. External heat 2. Line plugged 3. Valve closed 255 ABD00037227 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 236. ERS compressor seal water drain line to DM-703. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 236.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 236.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Line blocked in with external heat (thermal expansion) 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error 256 ABD00037228 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 237. DM-703 vapor outlet to ERS recovery condenser, EX-376. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 237.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 237.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - PS 1703 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 257 ABD00037229 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 238. DM-702 pressure feedback line from DM-703. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe specA2-22. Georgia Gulf Corp Dev Consequences 238.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 238.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication 81P759 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - 81P759 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 258 ABD0OO3723O VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 239. ERS ring seal water balance line from DM-703 to DM-702. Type: Line Drawing: OM-090114-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 239.1 Low/No Flow 1. Fire and explosion 2. High Level on Knockout Tank 3. Lift relief valve 239.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4 VCM Leak 239.3 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Level indicator controller, LIC 1301 1. Control Valve failure 2. Instrument failure 3. Operator error S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure switch, PS 1703 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. general monitor S/E 4 C 5 2. Operating procedures S 4 C 5 3. Operator training S/E 4 C 5 4. Personal Protective Equipment 5. Fixed point monitor 1. External heat 259 ABD00037231 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 240. ERS vacuum pump bypass line to ERS compressors (compressor suction lines and header). Type: Line Drawings: OM-090113-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe specA2-22. Dev Consequences 240.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 240.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - PIC 1302 1. Check valve failure 2. External heat 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 260 ABD00037232 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 241. ERS compressor discharge header to DM-703 Type: Line Drawings: OM-090114-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 241.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak 241.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - PS 1703 9. relief valve 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 1. External heat 261 ABD00037233 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 242. ERS compressors, CP-107/108. Type: Centrifugal Compressor Drawing: OM-090115-PID-D Design Conditions/Parameters: 3x3-18.5; 175 scfm @ 110 psig. Georgia Gulf Corp Dev Consequences 242.1 High Suction Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Seal failure 5. VCM Leak 242.2 High Discharge Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4 VCM Leak 242.3 Low Suction Pressure 1. Fire and explosion 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. DCS interlock-Compressor must 1. Instrument failure 5 be running to open inlet valve 2. Operator error 5 and ring seal water supply valve. 3. Pump failure 5 2. Fire Protection System 4. Valve leaking through 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. DCS interlock - RVCM return 5 valve on receiver must be open 5 and ring seal water pump 5 running to start compressor. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Relief Valve failure 5. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. Line plugged 2. Operator error 3. Valve closed 262 ABD00037234 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 243. ERS compressor relief valve discharge line and RV. Type: Line + Relief Valve Drawings: OM-090113-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe specA2-22. Dev Consequences 243.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 243.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 243.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 5 6. relief valve 5 1. External heat 2. High pressure in batch water stripper 3. Line plugged 4. Operator error 5. Relief Valve failure 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Equipment Preventive 5 Maintenance Program 5 3. Fixed point monitor 5 4. general monitor 5 5. Operating procedures 6. Personal Protective Equipment 7. Rupture disc 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Operator error 263 ABD0dd37235 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 244. ERS ring seal water header from coolers to compressors. Type: Line Drawings: OM-090114-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 244.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 244.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 c S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 6 4. Heat tracing 5 5. Line insulation 5 6. Operating procedures 7. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure gauge 7. Flow indication, 84FC830 / 833 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 264 ABD00037236 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 245. ERS compressor seal water drain line to DM-703. Type: Line Drawings: OM-090114-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 245.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 245.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 1. Line blocked in with external 5 2. Fixed point monitor heat (thermal expansion) 5 3. general monitor 2. Line plugged 5 4. Operating procedures 3. Operator error 5 5. Personal Protective Equipment 4. Valve closed 6. Interlock - drain line opens when 5. Valve failure compressor inlet opens S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error 265 ABD00037237 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 246. DM-703 vapor outlet to ERS recovery condenser, EX-376. Type: Line Drawings: OM-090114-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 246.1 High Pressure 1. Fire and explosion 2. Line rupture 3 Personal exposure 4. Valve packing leaking 5. VCM Leak 246.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Valve packing leaking 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6 Personal Protective Equipment 7. Pressure Gauge 8. Pressure Indication - PS 1703 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. External heat 266 ABD00037238 VIIID. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 247. RVCM condensate line from ERS condensers to RVCM transfer pump discharge line. Type: Line Drawings: OM-090111-PID-D, OM-090115-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 247.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Seal failure 6. VCM Leak 247.2 Low/No Flow 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. Recirculation line 1. External heat 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump blocked in and running 5. Valve closed 267 ABD00037239 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 248. ERS VCM condenser, EX-376 Type: Heat Exchanger Drawing: OM-090115-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 400 F Georgia Gulf Corp Dev Consequences CAT S L RR Safeguards Causes 248.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. Vessel rupture S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Relief Valve failure 248.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. VCM Leak 6. VCM release S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 6. relief valve 1. External heat 2. No cooling water 248.3 Low Temperature 1. Fire and explosion 2. Frozen tubes 3. Personal exposure 4. Tube rupture 5. VCM Leak S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment 6. Temperature gauge 1. Cold weather 2. Valve leaking through 248.4 Maintenance Hazards 1. Fire and explosion S/E 3 D 5 1. Fire Protection System 2. Personal exposure S 4 C 5 2. Fixed point monitor 3. Personal injury due to falling, S/E 4 C 5 3. general monitor bumping head, or straining back. 4. Maintenance & operating 4. VCM Leak S/E 4 C 5 procedures 5. VCM release S/E 4 C 5 5. Personal Protective Equipment 1. Not blanked out 2. Operator error 3. Poor access 268 ABD00037240 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 249. HPSW supply to ERS compressor mechanical seals. Type: Line Drawing: OM-090115-PID-D Design Conditions/Parameters: Pipe spec A13-1 Georgia Gulf Corp Dev Consequences 249.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 249.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 249.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 249.4 Low Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 c 5 4. Personal Protective Equipment 1. External heat S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Heat tracing 5 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error 3. Heat tracing failure 269 ABD00037241 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 250. Rx atmospheric dump line to slurry screener, GR-001. Type: Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Pipe spec At 3-5 Georgia Gulf Corp Dev Consequences 250.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 250.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. DCS interlock Dump valve can 1. External heat 5 only be open in atmospheric 2. High Pressure in Reactor 5 dump mode. 3. Instrument failure 5 2. Fire Protection System 4. Line plugged 5 3. Fixed point monitor 5. Operator error 4. general monitor 6. Valve closed 5. Operating procedures 7. Valve failure 6. Personal Protective Equipment 8. Valve leaking through 7. Pressure Gauge S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 t. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error 270 ABD00037242 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 251. Slurry screener, GR-001 Type: Tank Design Conditions/Parameters: Old Module Hazop Drawing: OM-090116-PID-D Dev Consequences 251.1 High Level 1. No consequences 251.2 Low Level 1. No consequences 251.3 Contaminants 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 271 ABD00037243 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 252. Slurry screener drain line to slurry dump tank, TK-007. Type: Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Dev Consequences 252.1 Low/No Flow 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 272 ABD00037244 VIII.D Hazards Identified - P&ID/Operating Procedures Review Node: 253. Atmospheric slurry dump tank, TK-007. Type: Tank Design Conditions/Parameters: 450 Gal. Old Module Hazop Drawing: OM-090116-PID-D Dev Consequences 253.1 High Level 1. No consequences 253.2 Low Level 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 273 ABD00037245 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 254. Atmospheric dump tank drain line and slurry transfer pumps, PP-496/497. Type. Centrifugal Pump + Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Pipe spec A13-5. Pumps 4x6-10-9.625, 600 GPM @ 40 psi Georgia Gulf Corp Dev Consequences 254.1 High Pressure 1. Personal exposure CAT S L RR Safeguards Causes S 4 C 5 1. Operating procedures 1. Gasket failure 2. Operator training 2. Line plugged 3. Personal Protective Equipment 3. Operator error 274 ABD00037246 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 255. MSPW supply to slurry transfer pump mechanical seals. Type: Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 255.1 High Pressure 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 275 ABD00037247 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 256. Atmospheric dump slurry screener and slurry dump tank exhaust piping and fan, FN-025. Type: Centrifugal Compressor + Line Drawing: OM-090116-PID-D Design Conditions/Parameters: FN-025: 2000scfm @ 0.5" H20. Dev Consequences 256.1 High Discharge Pressure 1. No consequences 256.2 Low Suction Pressure 1. No consequences 256.3 Contaminants Enter Compressor 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 276 ABD00037248 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 257. Rinse water line to atmospheric slurry screener and slurry dump tank. Type: Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Pipe spec A2-3. Dev Consequences 257.1 Low/No Flow 1. No consequences 257.2 Contamination 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 277 ABD00037249 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 258. HPSW supply to slurry dump tank, TK-007, level well. Type: Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Pipe spec A2-3. Dev Consequences 258.1 High Flow 1. No consequences 258.2 Low/No Flow 1. No consequences 258.3 Contamination 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 278 ABD00037250 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 259. Sample line from dump hdr to slurry dump tank. Type: Line Drawing: OM-090116-PID-D Design Conditions/Parameters: Pipe spec A13-1. Dev Consequences 259.1 Low/No Flow 1. No consequences 259.2 Contamination 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 279 ABD00037251 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 260. Wet calcium stearate tank, TK-313. Type: Tank Drawing: OM-090117-PID-D Design Conditions/Parameters: MAWP: 30 psig @ 200 F Dev Consequences 260.1 High Pressure 1. NOTIN SERVICE CAT S L RR Safeguards Georgia Gulf Corp Causes 280 ABD00037252 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 261. Calcium stearate drum Type: Tank Design Conditions/Parameters: 55 gal drum Old Module Hazop Drawing: OM-090117-PID-D Dev Consequences 261.1 High Temperature 1. NOT IN SERVICE CAT S L RR Safeguards Georgia Gulf Corp Causes 281 r ABD00037253 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 262. Wet calcium stearate pump, PP-651 Type: Positive Displacement Pump Design Conditions/Parameters: 250 GPH @ 165 psi. Old Module Hazop Drawing: OM-090117-PID-D Dev Consequences 262.1 High Pressure 1. NOT IN SERVICE CAT S L RR Safeguards Georgia Gulf Corp Causes 282 ABD00037254 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 263. Low mole atm. dump line to screener, GR-601 from Rx-700. Type: Line Drawing: OM-090118-PID-D Design Conditions/Parameters: Pipe spec A13-5. Georgia Gulf Corp Dev Consequences 263.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 263.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 1. External heat 6 2. Fixed point monitor 2. High Pressure in Reactor 5 3. general monitor 3. Instrument failure 5 4. Operating procedures 4. Line plugged 5 5. Personal Protective Equipment 5. Operator error 6. Pressure Gauge 6. Valve closed 7. DCS interlock Dump valve can 7. Valve failure only be open in atmospheric 8. Valve leaking through dump mode. S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error 283 ABD00037255 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 264. Low Mole atm. dump line and dump pumps, PP-801 A/801 B, to screener GR-601. Type: Centrifugal Pump + Line Drawing: OM-090118-PID-D Design Conditions/Parameters: Pipe spec A13-5. Pumps, 6x6-18-13. 1000 GPM@ 13 psi. Georgia Gulf Corp Dev Consequences 264.1 High Pressure 1. Fire and explosion 2. Gasket failure 3 Line rupture 4. Personal exposure 264.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. DCS interlock Dump valve can 1. External heat 5 only be open in atmospheric 2. High Pressure in Reactor 5 dump mode. 3 Instrument failure 5 2. Fire Protection System 4. Line plugged 3. Fixed point monitor 5. Operator error 4. general monitor 6. Valve closed 5. Operating procedures 7. Valve failure 6. Personal Protective Equipment 8. Valve leaking through 7. Pressure Gauge S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. High Pressure in Reactor 3. Instrument failure 4. Line plugged 5. Operator error 6. Valve closed 7. Valve failure 8. Valve leaking through 284 ABD00037256 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 265. Low Mole slurry screener Type: Line Design Conditions/Parameters: Pipe spec A13-5. Old Module Hazop Drawing: OM-090118-PID-D Dev Consequences 265.1 High Pressure 1. No consequences 265.2 Low/No Flow 1. No consequences 265.3 Contamination 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 285 ABD00037257 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 266. Low mole atmospheric dump slurry screener and slurry dump tank exhaust piping and fan, FN-026. Type: Centrifugal Compressor + Line Drawing: OM-090118-PID-D Design Conditions/Parameters: FN-026: 4000scfm @ 2" H20. Georgia Gulf Corp Dev Consequences 266.1 High Discharge Pressure 1. No consequences 266.2 Low Suction Pressure 1. No consequences 266.3 Contaminants Enter Compressor 1. No consequences CAT S L RR Safeguards Causes 286 ABD00037258 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 267. Low mole atmospheric dump tank drain line and slurry transfer pumps, PP-601/602. Type: Centrifugal Pump + Line Drawing: OM-090118-PID-D Design Conditions/Parameters: Pipe spec A13-5. Pumps, 4x6-13-10.625, 1000 GPM @ 38 psi Georgia Gulf Corp Dev Consequences 267.1 High Pressure 1. Personal exposure CAT S L RR Safeguards Causes S 4 C 5 1. Operating procedures 1. Gasket failure 2. Operator training 2. Line plugged 3. Personal Protective Equipment 3. Operator error 287 ABD00037259 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 268. Low mole atmospheric slurry dump tank, TK-601. Type: Tank Drawing: OM-090118-PID-D Design Conditions/Parameters: 1000 Gal. Dev Consequences 268.1 High Level 1. No consequences 268.2 Low Level 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 288 ABD00037260 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 269. MSPW supply to slurry transfer pump mechanical seals. Type: Line Drawing: OM-090118-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 269.1 High Pressure 1. No consequences 269.2 Low Pressure 1. No consequences 269.3 Low/No Flow 1. No consequences 269.4 Contamination 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 289 ABD00037261 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 270. Batch water strippers, DM-801/802 Type: Vessel Drawing: OM-090119-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 350 F. MOC: SA516 Gr 70. Georgia Gulf Corp Dev Consequences 270.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM Leak 5. Vessel rupture 270.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM Leak 5. Vessel rupture 270.3 Low Temperature 1. Personal exposure 2. Dump water still contains VCM 270.4 High Level 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. VCM Leak 5. Vessel rupture 270.5 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Pressure indication, 84P845/ 5 84P848 / 84P853 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 9. Valve indication 1. External heat 2. High Level 3. Instrument failure 4. Line plugged 5. Operator error 6. Power failure 7. Valve failure S/E 3 D 5 1. Temperature indicator, 84T846 / 1. External heat S/E 4 C 5 84T849 2. Instrument failure S 4 C 5 2. Fire Protection System 3. Steam Control Valve failure S/E 4 C 5 3. Fixed point monitor S/E 3 D 5 4. general monitor 5. Operator training 6. relief valve 7. Temperature gauge S 4 C 5 1. Temperature indicator, 84T846 / 1. Instrument failure S/E 4 C 5 84T849 2. Operating procedures S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. sight glass 8. Level indication, 84L854 / 84L856; Low Level Switch, 84L847 / 84L852; High Level Switch, 84L844 / 84L850 1. Instrument failure 2. Drain line plugged 3. Valve leaking through 4. Operator error S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve leaking through 3. Instrument failure 290 ABD00037262 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 271. Batch water stripper recovery line to large recovery system. Type: Line Drawing: OM-090119-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 271.1 High Pressure 1. Fire and explosion 2. Overpressure batchwater stripper 3 Personal exposure 4 VCM release 271.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. Valve packing leaking 6 VCM Leak 271.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2 High pressure in batch water stripper 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D 5 1 Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Personal Protective Equipment S/E 4 C 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor 3. general monitor S 4 C 5 4. Operating procedures S/E 3 D 5 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 291 ABD00037263 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 272. Batch water stripper recovery line, contains pressure control valve. Type: Line Drawing: OM-090119-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 272.1 High Pressure 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM release 272.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4 Personal exposure 5. Valve packing leaking 6. VCM Leak 272.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Overpressure batchwater stripper 3. Personal exposure 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. High pressure in batch water stripper 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through 292 ABD00037264 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 273. Batch water stripper fill line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 273.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 273.2 Low Temperature 1. Frozen Line 273.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 273.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Double valves at Batch Water Stripper 1. Line blocked in with external heat (thermal expansion) 2. High pressure in batch water stripper 3. Valve failure S/E 4 C 5 1. Heat tracing 2. Operating procedures 3. Operator training 4. Line insulation 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 293 ABD00037265 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 274. Batch water stripper (BWS) effluent transfer pumps. Type: Centrifugal Pump Drawing: OM-090119-PID-D Design Conditions/Parameters: 1.5x3-8-7.375. 150 GPM @ 98 psi. Georgia Gulf Corp Dev Consequences 274.1 High Pressure 1. Fire and explosion 2. Line rupture 3 Personal exposure 274.2 Low Temperature 1. Fire and explosion 2 Frozen Line 3. Overpressure batchwater stripper 4. Personal exposure 274.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3 general monitor 4. Operating procedures 5 Operator training 6. Personal Protective Equipment 7. Valve indication 1. External heat 2. Line plugged 3. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. DCS interlock 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5 5. Heat tracing 6. Line insulation 7. Operator training 8. Personal Protective Equipment 9. relief valve 1. Cold weather 2. Heat tracing failure 3. Operator error S/E 3 D S 4C S/E 3 D 5 1. DCS interlock Drain valve won't 1. Instrument failure 5 open unless stripper in dump 2. Operator error 5 mode or in manual and stripper 3. Valve leaking through pressure below dump pressure. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 294 ABD00037266 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 275. HPSW supply to BWS level well. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 275.1 Rupture 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Heat tracing 5. HNU unit 6. Line insulation 7. Operator training 8. Personal Protective Equipment 1. External heat 2. Operator error 3. Cold weather 295 ABD00037267 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 276. Steam supply line to BWS sparger. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 276.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 276.2 Low Pressure 1 Fire and explosion 2. Line rupture 3. Personal exposure 4. Stripper contents back into steam line 276.3 Low Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Frozen Line CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Line insulation 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 9. Steam flow indication, 84F843 1. Line blocked in with external heat (thermal expansion) 2. Valve leaking through 3. Check valve failure 4. Low steam pressure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Steam flow indication, 84F843 1. Line plugged 2. Steam Control Valve failure 3. Valve closed 4. Power failure S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 6 4. Heat tracing 5. Line insulation 6. Operator training 7. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 296 ABDOU037268 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 277. BWS fill line through 3-way valve. Type: Line Design Conditions/Parameters. Pipe spec A2-22. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 277.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 277.2 Low Temperature 1. Frozen Line 277.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 277.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 3 D 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line blocked in with external heat {thermal expansion) 3. Valve failure S/E 4 C 5 1. Operating procedures 2. Operator training 1. Cold weather S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat S/E 3 D S/E 4 C S/E 4 C S 4c S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 297 ABD00037269 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 278. BWS fill line from ERS equipment. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090119-PiD-D Georgia Gulf Corp Dev Consequences 278.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Valve packing leaking 4. VCM release 278.2 Low Temperature 1. Frozen Line 278.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM release 278.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure batchwater stripper 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line blocked in with external heat (thermal expansion) 3. Valve failure S/E 4 C 5 1. Operating procedures 2. Operator training 1. Cold weather S/E 3 D S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat S/E 3 D S/E 4 C S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. Operator error 2. Valve failure 298 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 279. BWS fill line from large recovery system equipment. Type: Line Drawing: OM-090119-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 279.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure 6. VCM Leak 279.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. Personal exposure 6. VCM Leak 279.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. Valve packing leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 5 5 1. External heat 2. High pressure in batch water stripper 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Rupture disc 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. relief valve 1. External heat 2. Operator error 299 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 280. BWS fill line from RVCM equipment. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 280.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 280.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 280.3 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 280.4 Reverse/Misdirected Flow 1. Fire and explosion 2 Gasket failure 3. Line rupture 4. Overpressure batchwater stripper 5. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 c 5 4. Heat tracing 5. Line insulation 6. Operator training 1. Cold weather 2. Heat tracing failure 3. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 5 6. Personal Protective Equipment 7. relief valve 1. Instrument failure 2. Line plugged 3. Operator error 4. Power failure ABD00037272 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 281. BWS fill line from VCM tank farm fill line. Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 281.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 281.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. High Pressure in Reactor 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Operator error 301 ABD00D37273 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 282. Recovery line from large recovery system to ERS Type: Line Drawing: OM-090119-PID-D Design Conditions/Parameters: Pipe spec A2-22. Georgia Gulf Corp Dev Consequences 282.1 High Temperature 1. Fire and explosion 2 Line rupture 3 Personal exposure 4. VCM Leak 282.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 282.3 Reverse/Misdirected Flow 1. Fire and explosion 2 Personal exposure 3. VCM release 282.4 High Pressure 1. Fire and explosion 2. Gasket failure 3 Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3 general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3 Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 1. High pressure in batch water stripper 2. Line plugged 3. Operator error 4. Valve leaking through 302 AB51jo037274 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 283. HPSW pumps, PP-010/011. Type: Centrifugal Pump + Line Drawing: OM-090120-PID-D Design Conditions/Parameters: 1.5x3-10*9,100 psig @ 200 GPM: 130 psig @20 GPM. Georgia Gulf Corp Dev Consequences 283.1 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 283.2 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 283.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 283.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 6. Line insulation 1. Cold weather 303 ABDOO037275 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 284. Line to utility station @ RVCM receiver. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences 284.1 High Temperature 1. Personal exposure CAT S L RR Safeguards Causes S/E 4 C 5 1. Personal Protective Equipment 1. External heat 2. Heat tracing failure 304 ABD00037276 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 285. HPSW to EX-008/009. See node 147. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090119-PID-D Georgia Gulf Corp Dev Consequences 285.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 285.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Power failure 305 ABD00037277 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 286. HPSW supply line to DM-701 and DM-701 sight glass, see node 206. Type: Line Drawings: OM-090113-PID-D, OM-090120-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 286.1 High Flow 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 5. Vessel rupture 286.2 Low Pressure 1. Personal exposure 2. Reverse flow 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Level switch - 1701C 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. relief valve 9. sight glass 1. Instrument failure 2. Line plugged 3. Operator error 4. Pump failure 5. Valve failure S 4C S/E 4 C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 1. Filter Plugged 2. Line plugged 3. Operator error 4. Power failure 5. Pump failure 6. Valve closed 7. Valve leaking through 306 ABD00037278 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 287. HPSW line to LRS KO tanks and recirculation pumps. Type: Line Drawing: OM-090120-PID-D Design Conditions/Parameters: Pipe spec A2-3. Georgia Gulf Corp Dev Consequences 287.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 287.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 287.3 Low Pressure 1. Seal failure 2. VCM Leak 287.4 Low Temperature 1. Frozen Line 2. No flow 3. Personal exposure 4 Seal failure 5 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Equipment Preventive Maintenance Program 3. Fixed point monitor 4. Flow meter 5. Operating procedures 6. Operator training 7. Pressure Gauge 1. Filter plugged 2. Line plugged 3. Operator error 4. Power Failure 5. Valve closed 6. Valve failure S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fixed point monitor 5 2. Heat tracing 5 3. Operating procedures 5 4. Personal Protective Equipment 5 1. Cold weather 2. Operator error 307 ABD0'(T037279 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 288. HPSW supply - header section Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences 288.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 288.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 288.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 288.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Valve closed 4. Valve failure S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 1. External heat S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 6. Pressure switch low - 81P055 1. Instrument failure 2. Line plugged 3. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Line insulation 4. Personal Protective Equipment 1. Cold weather 2. Operator error 308 ABD00037280 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 289. HPSW to DM-027/028 Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences CAT S L RR Safeguards 289.1 Low Pressure 1. Personal exposure 2. Reverse flow 3. VCM Leak S 4C S/E 4 C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 289.2 High Flow 1. High Level in knockout tank, See Node 84 Causes 1. Filter Plugged 2. Line plugged 3. Operator error 4. Power failure 5. Pump failure 6. Valve closed 7. Valve leaking through 309 ABD00037281 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 290. HPSW supply line to DM-702 and DM-703 and sight glasses on each. Type: Line Design Conditions/Parameters: Pipe specA2-22. Drawings: OM-090114-PID-D, OM-090120-PID-D Dev Consequences 290.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 290.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 310 ABD00037282 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 291. HPSW supply from mechanical seals on compressors & vacuum pumps. Type: Line Design Conditions/Parameters: Pipe spec A2-3, J16-1 Drawings: OM-090109-PID-D, OM-090109A-PID-D, OM-090120PID-D Dev Consequences 291.1 High Pressure 1. Fire and explosion 2 Personal exposure 3. Seal failure 4. VCM Leak 291.2 High Temperature 1 Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 291.3 Low Pressure 1. Personal exposure 2 Seal failure 3. VCM Leak 291 4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2 Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4 C 5 1. Fire Protection System S/E 4 C 5 2 Fixed point monitor S/E 4 C 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3 Operator error S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Heat tracing 5. Personal Protective Equipment 6. Pressure Gauge 1. Cold weather 2. Heat tracing failure 311 ABD00037283 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 292. HPSW supply to ring seal water pumps PP-491/492 Type: Line Drawings: OM-090110-PID-D, OM-090120-PID-D Design Conditions/Parameters: Pipe spec A2-3. Dev Consequences 292.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4 VCM Leak 292.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 292.3 Low Pressure 1. Seal failure 2. VCM Leak 3. Personal exposure 4. Fire and explosion 292.4 Low Temperature 1. Frozen Line 2. No flow 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4 Valve closed 5. Valve failure S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1 External heat 2. Operator error S/E 4 c 5 1. Fire Protection System S/E 4 c 5 2. Equipment Preventive S 4c 5 Maintenance Program S/E 3 D 5 3. Fixed point monitor 4. Flow meter 5. Operating procedures 6. Operator training 7. Pressure Gauge 1. Filter plugged 2. Line plugged 3. Operator error 4. Power Failure 5. Valve closed 6. Valve failure S/E 4 C S/E 4 C S 4C S/E 4 c S/E 4 c 5 1. Fixed point monitor 5 2. Heat tracing 5 3. Operating procedures 5 4. Personal Protective Equipment 5 1. Cold weather 2. Operator error 312 ABTO0037284 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 293. HPSW make-up to seal water separators. Type: Line Design Conditions/Parameters: Pipe spec A2-3 Old Module Hazop Georgia Gulf Corp Drawings: OM-090110-PID-D, OM-090120-PID-D Dev Consequences 293.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 293.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Operating procedures 6. Personal Protective Equipment 1. Cold weather 2. Heat tracing failure 3. Power failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 1. External heat 2. Line plugged 3. Operator error 313 ABD00037285 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 294. HPSW supply to mechanical seal on RVCM charge pump PP-477. Type: Line Drawings: OM-090112-PID-D, OM-090120-PID-D Design Conditions/Parameters: Pipe spec A13-1. Dev Consequences 294.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 294.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 294.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 294.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Heat tracing 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error 314 ABD00037286 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 295. HPSW supply to mechanical seal on RVCM transfer pumps PP-110/111. Type: Line Drawings: OM-090111-PID-D, OM-090120-PID-D Design Conditions/Parameters: Pipe spec A2-3/J16-1 Dev Consequences 295.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 295.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 295.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 295.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Heat tracing 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 2. Operator error 315 ABD00037287 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 296. MSPW Line To FVCM Charge Pumps Type: Line Design Conditions/Parameters: Pipe Spec A2-3 Old Module Hazop Georgia Gulf Corp Drawings: OM-090100-PID-D, OM-090120-PID-D Dev Consequences 296.1 High Temperature 1. Seal failure 296.2 Low Pressure 1. Seal failure 2. VCM Leak 296.3 Low Temperature 1. Frozen Line 2. Seal failure 3. VCM Leak 296.4 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. Fire Protection System 1. External heat S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Equipment Preventive Maintenance Program 3. Fixed point monitor 4. Operating procedures 5. Operator training 6. Pressure Gauge 1. Filter plugged 2. Line plugged 3. Operator error 4. Power Failure 5. Valve closed 6. Valve failure S/E 4 C 5 1. Fixed point monitor S/E 4 C 5 2. Heat tracing S/E 4 C 5 1. Cold weather S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure 316 ABD00037288 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 297. HPSW supply to BWS level well. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Georgia Gulf Corp Drawings: OM-090119-PID-D, OM-090120-PID-D Dev Consequences 297.1 Rupture 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Heat tracing 5. HNU unit 6. Line insulation 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Operator error 317 ABD00037289 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 298. HPSW pumps,PP-874/134 Type: Centrifugal Pump Design Conditions/Parameters: 1x2-10-9 Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences 298.1 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 298.2 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 298.3 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 298.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 1. External heat 2. Operator error S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. Flow meter 4. Line insulation 5. Personal Protective Equipment 6. Pressure Gauge 1. Cold weather 318 ABDO0D3729O VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 299. MSPW supply to slurry transfer pump mechanical seals. Type: Line Drawings: OM-090116-PID-D, OM-090120-PID-D Design Conditions/Parameters: Pipe spec A2-3 Dev Consequences 299.1 High Pressure 1. No consequences CAT S L RR Safeguards Causes 319 ABD0DO37291 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 300. HPSW to Rx hose stations. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences 300.1 High Temperature 1. Personal exposure CAT S L RR Safeguards Causes S 4 C 5 1. Personal Protective Equipment 1. External heat 2. Heat tracing failure 320 ABDOO037292 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 301. HPSW supply to Rx catalyst pot. Type: Line Design Conditions/Parameters: Pipe spec A13-1. Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences 301.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 301.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 301.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 301.4 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 1. High Pressure in Reactor 2. Line leak/rupture 3. Low HPSW pressure 4. Operator error 5. Power failure 6. Valve failure 7. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Ram valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 c 5 4. Heat tracing S/E 4 c 5 5. Line insulation 6. Operating procedures 7. Operator training 1. Cold weather 2. Valve leaking through 321 ABD00U37293 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 302. HPSW supply line to RX-600,700 BME charge pot Type: Line Drawings: OM-090107-PID-D, OM-090120-PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 302.1 Low Pressure 1. No flow 2. Personal exposure 3. Reverse flow 302.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. Personal exposure 6. Reverse flow 7. VCM Leak 302.3 High Pressure 1. Gasket failure 2. Line rupture 3. Valve leaking 302.4 High Temperature 1. Gasket failure 2. Line rupture 3. Personal exposure 4. Valve failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S 4C S/E 4 c 5 1. Check valve 5 2. DCS interlock-Rx BME charge 5 valve won't open unless adequate pressure 3. Flow indication. 81F565 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure switch, 81P469/569 1. Instrument failure 2. Line leak/rupture 3. Line plugged 4. Operator error 5. Valve failure 6. Valve leaking through S/E 3 D 5 1. Heat tracing S/E 4 c 5 2. Line insulation S/E 4 C S/E 4 c S 4c S/E 4 c S/E 4 c 5 5 5 5 5 1. Cold weather S/E 4 c 5 1. Pressure Gauge S/E 4 c 5 2. Fire Protection System S/E 4 c 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Valve closed S/E 4 c S/E 4 c S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Operating procedures 5 3. Operator training 5 4. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 3. Line blocked in with external heat (thermal expansion) 322 ABD0TO7294 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 303. HPSW pumps, PP-953/954 Type: Centrifugal Compressor + Line Drawing: OM-090120-PID-D Design Conditions/Parameters: 1.5x2-11-8, 209psi @60 GPM Georgia Gulf Corp Dev Consequences 303.1 High Temperature 1. High pressure 303.2 Low/No Flow 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak 303.3 High Pressure 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures 2. Operator training 1. External heat 2. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fixed point monitor 5 2. Flow meter 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Low Pressure switch- 81P057 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure S/E 3 D 5 1. Fixed point monitor S/E 4 C 5 2. general monitor S/E 4 C 5 3. Operating procedures S/E 4 c 5 4. Operator training S/E 4 c 5 5. Personal Protective Equipment 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure 323 ABD00037295 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 304. HPSW to Rx rinse nozzle flush Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Drawing: OM-090120-PID-D Georgia Gulf Corp Dev Consequences 304.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 304.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Hydro fill the reactor 3. Personal exposure 4. VCM Leak 5. VCM release 304.3 Low/No Flow 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High Pressure in Reactor 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. Check valve 1. Line leak/rupture 5 2. DCS interlock-AII RX slow vent 2. Operator error 5 valves must be closed & 3. Pump failure 5 recovery system discharge 4. Valve leaking through 5 pressure is < 110 psig (81p759) before slow vent flush valve will open. 3. Fire Protection System 4. Fixed point monitor 5. Flow meter 6. general monitor 7. Operating procedures 8. Operator training 9. Personal Protective Equipment S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 1. Cold weather 2. Valve leaking through 324 ABD0(TO7296 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 305. MSPW flush line to Rx seal. Rx-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D, OM-090120PID-D Design Conditions/Parameters: Pipe spec A13-1, J16-1 Dev Consequences 305.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak 305.2 High Temperature 1. High pressure 305.3 Low/No Flow 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fixed point monitor 5 2. general monitor 5 3. Operating procedures 5 4. Operator training 5 5. Personal Protective Equipment 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure S/E 4 c 5 1. Operating procedures 2. Operator training 1. External heat 2. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 4 c S/E 4 c 5 1. Fixed point monitor 5 2. Flow meter 5 3. general monitor 5 4. Low Pressure switch* 81P057 5 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure 325 ABD00037297 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 306. AMS drum to AMS transfer pump, PP-020, to AMS kill pot. Type: Line + Positive Displacement Pump + Tank Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1. PP-020, air driven diaphragm pump, 32 GPM @ 120 120 psig Georgia Gulf Corp Dev Consequences 306.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 306.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 306.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Check valve 5 2. Fire Protection System 5 3. Operator training 5 4. Personal Protective Equipment 5. Pressure Gauge 6. relief valve 1. Check valve failure 2. External heat 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Relief Valve failure 6. Nitrogen bottle regulator failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Check valve 5 2. Fire Protection System 5 3. Operator training 5 4. Personal Protective Equipment 5. Pressure Gauge 6. relief valve 7. Safety Shower 1. External heat S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Check valve 5 2. Fire Protection System 5 3. Operator training 5 4. Personal Protective Equipment 5. Pressure Gauge 6. relief valve 7. Safety Shower 1. Check valve failure 2. Nitrogen bottle regulator failure 326 ABD00037298 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 307. AMS kill pots (RX-300/400/500/600/700/Dump Tank) Type: Vessel Drawing: OM-090121-PID-D Design Conditions/Parameters: MAWP: 400 psig @ 650 F Georgia Gulf Corp Dev Consequences 307.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 307.2 Maintenance Hazards 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release 307.3 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 307.4 Low Level 1. Can't emergency kill reactor CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Operator training 5 3. Personal Protective Equipment 5 4. Pressure Gauge 5. relief valve 6. Low pressure switch - 81P558 1. External heat 2. Nitrogen bottle regulator failure 3. Relief Valve failure S/E 3 D S 4C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Maintenance & operating procedures 5. Personal Protective Equipment 1. Instrument failure 2. Operator error 3. Valve leaking through S/E 3 D 5 1. Check valve S/E 4 C 5 2. Fire Protection System S/E 4 C 5 3. Operator training S/E 4 C 5 4. Personal Protective Equipment 5. Pressure Gauge 6. relief valve 7. Safety Shower 1. External heat S/E 3 D 5 1. Operating procedures 2. Operator training 3. sight glass 4. Low level switch - 81L557 (similar on other reactors) 1. Instrument failure 2. Operator error 327 ABD00037299 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 308. Nitrogen supply bottle and supply line to AMS kill pot. Type: Line + Vessel Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1 Georgia Gulf Corp Dev Consequences 308.1 High Pressure 1. Fire and explosion 2. Lift relief valve on reactor 3. Line rupture 4. Personal exposure 308.2 Low Pressure 1. Fire and explosion 2. Lift relief valve on reactor 3. Line rupture 4. Personal exposure 5. Can't emergency kill reactor CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. relief valve 8. Low pressure switch 81P558 1. External heat 2. Instrument failure 3. Line plugged 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Low pressure switch - 81P558 1. Bottle empty 2. regulator failure 3. Instrument failure 4. Operator error 328 ABD00037300 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 309. Automatic emergency kill line from AMS pot to RX. Type: Line Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1 Georgia Gulf Corp Dev Consequences 309.1 Low Temperature 1. Fire and explosion 2 Frozen Line 3. Lift relief valve 4 Overpressure reactor 5. Personal exposure 6 VCM release 309.2 High Pressure 1. AMS release 2. Fire and explosion 3. Line rupture 4. Valve failure 5. VCM Leak 309.3 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. No flow 5. Overpressure reactor 6. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 S/E 4 C 5 S 4C 5 S/E 3 D 5 1. Cold weather 2. Valve leaking through S/E 4 C 5 1. Fire Protection System S/E 3 D 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. HNU unit S/E 4 C 5 5. Operating procedures 6. Operator training 7. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line leak/rupture 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Pressure Gauge 8. Low pressure switch - 81P558 1. Line leak/rupture 2. Operator error 3. Valve failure 4. Valve leaking through 329 ABD0tiff37301 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 310. Manual emergency kill line header from AMS pot to RXs. Type: Line Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1 Georgia Gulf Corp Dev Consequences 310.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Lift relief valve 4. Overpressure reactor 5. Personal exposure 6. VCM release 310.2 High Pressure 1. AMS release 2. Fire and explosion 3. Line rupture 4. Valve failure 5. VCM Leak 310.3 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Overpressure reactor 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 S/E 4 C 5 S 4C 5 S/E 4 C 5 1. Cold weather 2. Valve leaking through S/E 4 C 5 1. Fire Protection System S/E 3 D 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. HNU unit S/E 4 c 5 5. Operating procedures 6. Operator training 7. Pressure Gauge 8. Low pressure switch - 81P558, similar other reactors 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line leak/rupture 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Low pressure switch - 81P558, similar other reactors 1. Line leak/rupture 2. Operator error 3. Valve failure 4. Valve leaking through 330 ABD00037302 VIII D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 311. Manual emergency kill line from AMS pot to RX. Type: Line Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1 Georgia Gulf Corp Dev Consequences 311.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Lift relief valve 4. Overpressure reactor 5. Personal exposure 311.2 High Pressure 1. AMS release 2. Fire and explosion 3. Line rupture 4. Valve failure 5. VCM Leak 311.3 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Overpressure reactor 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 S/E 4 C 5 S 4C 5 1. Cold weather 2. Valve leaking through S/E 4 C 5 1. Fire Protection System S/E 3 D 5 2. Fixed point monitor S/E 4 c 5 3. general monitor S/E 4 c 5 4. HNU unit S/E 4 c 5 5. Operating procedures 6. Operator training 7. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line leak/rupture 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Low pressure switch - 81P558, 5 similar other reactors 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Line leak/rupture 2. Operator error 3. Valve failure 4. Valve leaking through 331 ABD00G37303 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 312. Nitrogen supply lines to Rx's emergency kill valves. Type: Line Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1 Georgia Gulf Corp Dev Consequences 312.1 High Pressure 1. Actuator failure 2. Line rupture 3. O-Ring failure 312.2 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Overpressure reactor 4. Personal exposure 312.3 Low Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure reactor 4. Personal exposure 5. Solenoid failure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C 5 1. Operating procedures 5 2. Operator training 5 1. External heat 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Instrument failure 2. Line leak/rupture 3. Line plugged 4. Nitrogen bottle empty 5. Operator error 6. Valve failure S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Cold weather 2. Valve leaking through 332 ABD00037304 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 313. Nitrogen supply lines to dump tank emergency kill valves. Type: Line Drawing: OM-090121-PID-D Design Conditions/Parameters: Pipe spec B2-1 Georgia Gulf Corp Dev Consequences 313.1 High Pressure 1. Actuator failure 2. Line rupture 3. O-Ring failure 313.2 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Overpressure reactor 4. Personal exposure 313.3 Low Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure reactor 4. Personal exposure 5. Solenoid failure CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 c 5 3. Pressure Gauge 1. External heat 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 8. Pressure Gauge 1. Instrument failure 2. Line leak/rupture 3. Line plugged 4. Nitrogen bottle empty 5. Operator error 6. Valve failure S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Cold weather 2. Valve leaking through 333 ABD00037305 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 314. Stripping steam supply to rx's. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090122-PID-D Georgia Gulf Corp Dev Consequences 314.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Overpressure reactor 4. Personal exposure 5. VCM Leak 314.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Overpressure reactor 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 8. Flow indicator controller - 81F083 9. Pressure Gauge 1. Line leak/rupture 2. Line plugged 3. Low steam pressure 4. Valve closed 5. Valve leaking through S/E 3 D 5 1. DCS interlock-steam supply 1. Line leak/rupture S/E 4 C 5 valve will not open unless steam 2. Line plugged S/E 4 C S/E 4 c S/E 4 c 5 5 5 pressure > 120 psig and recovery valves, 81H130 & 81 HI 31 are open 3. Low steam pressure 4. Valve closed 5. Valve leaking through 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Personal Protective Equipment 334 ABD00037306 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 315. Brine tank, TK-313 Type: Tank Design Conditions/Parameters: 1000 Gal Old Module Hazop Drawing: OM-090123-PID-D Dev Consequences 315.1 High Level 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 335 ABD00037307 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 316. Brine transfer pump, PP-481. Type: Centrifugal Pump Drawing: OM-090123-PID-D Design Conditions/Parameters: 1x1.5-8, 80 GPM @ 50 psi. Dev Consequences 316.1 Low/No Flow 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 336 ABD00037308 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 317. Brine tank, TK-004. Type: Tank Design Conditions/Parameters: 850 Gal Old Module Hazop Drawing: OM-090123-PID-D Dev Consequences 317.1 High Level 1. No consequences 317.2 Low Level 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 337 ABD00037309 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 318. Brine transfer pump, PP483. Type: Centrifugal Pump Drawing. OM-090123-PID-D Design Conditions/Parameters: 2x2.5-11.88, 100 GPM @ 300 psi Dev Consequences 318.1 High Pressure 1. No consequences 318.2 Low/No Flow 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 338 ABD00037310 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 319. Seal oil reservoir for Rx seal oil system. Type: Tank Design Conditions/Parameters: 140 gal Old Module Hazop Drawing: OM-090124-PID-D Georgia Gulf Corp Dev Consequences 319.1 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 319.2 Low Temperature 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure 319 3 Low Level 1. Fire and explosion 2. Personal exposure 3. Seal failure CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Temperature indication/alarm - 81T077 1. External heat 2. Heater coil failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Temperature indication/alarm - 81T077 7. Heater coil 1. Cold weather 2. Heat tracing failure 3. Operator error 4. Heater coil failure S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 1. Operator error 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Low level switch/alarm - 81L069 339 ABD00037311 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 320. Seal oil supply lines and seal oil puppy pump to Rx seals. Type: Line + Positive Displacement Pump Drawing: OM-090124-PID-D Design Conditions/Parameters: Pipe spec A13-2. Pump: Gear 8 GPM @ 220 psi. (PP-472/473) Georgia Gulf Corp Dev Consequences 320.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 320.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 320.3 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Reverse flow 4. Seal failure 5. VCM Leak 320.4 Low Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure transmitter, 81P171, 81P066 9. relief valve 1. External heat 2. Filter Plugged 3. Heat tracing failure 4. Instrument failure 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) S/E 3 D S 4C S/E 4 c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure transmitter, 81P171, 81P066 8. Bladder 9. Pump On UPS system 1. Instrument failure 2. Line leak/rupture 3. Operator error 4. Power failure 5. Pump failure 6. Seal failure 7. Valve closed 8. Valve leaking through S/E 3 D S/E 4 c S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Pressure transmitter, 81 PI 71 1. Cold weather 2. Heat tracing failure 3. Instrument failure 340 ABD00037312 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 321. Seal oil system bladder. Type: Vessel Drawing: OM-090124-PID-D Design Conditions/Parameters: 15 gal capacity @ 220 psig Georgia Gulf Corp Dev Consequences 321.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. Vessel rupture 321.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Vessel rupture 321.3 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Reverse flow 4. Seal failure CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Nitrogen supply regulator 1. External heat 2. Nitrogen supply regulator failure S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 1. External heat S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. Line leak/rupture 2. Line plugged 3. Operator error 4. Nitrogen supply regulator 5. Nitrogen bottle empty 6. Valve leaking through 341 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 322. Seal oil system return header including seal oil filters. Type: Line + Vessel Drawing: OM-090124-PID-D Design Conditions/Parameters: Pipe spec A13-2. Filter FL-113/115 MAWP 300 psi @ 200 F Georgia Gulf Corp Dev Consequences 322.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 322.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 322.3 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Reverse flow 4. Seal failure 322.4 Low Temperature 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. relief valve 9. Pressure regulator 1. External heat 2. Filter Plugged 3. Heat tracing failure 4. Instrument failure 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure 9. Pressure regulator failure S/E 3 D S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure regulator 1. Instrument failure 2. Line leak/rupture 3. Operator error 4. Power failure 5. Pump failure 6. Seal failure 7. Valve closed 8. Valve leaking through 9. Pressure regulator failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2 Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operating procedures 7. Operator training 1. Cold weather 2. Heat tracing failure 3. Instrument failure 342 ABD00037314 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 323. Seal oil return header from filters to reservoir. Type: Line Drawing: OM-090124-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 323.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 323.2 Low Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 323.3 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 323.4 Low Temperature 1. Fire and explosion 2. High pressure 3. Personal exposure 4. Seal failure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure regulator 9. relief valve 1. External heat 2. Filter Plugged 3. Heat tracing failure 4. Instrument failure 5. Line plugged 6. Operator error 7. Pressure regulator failure 8. Valve closed 9. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Operating procedures 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure regulator 1. Instrument failure 2. Line leak/rupture 3. Operator error 4. Power failure 5. Pressure regulator failure 6. Pump failure 7. Seal failure 8. Valve closed 9. Valve leaking through S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Instrument failure 4. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operating procedures 7. Operator training 1. Cold weather 2. Heat tracing failure 3. Instrument failure 343 ABD00037315 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 324. Chiller unit for RVCM Knock Back condensers. Type: Chiller Drawing: OM-090125-PID-D Design Conditions/Parameters: 30 ton, R22 refrigerant. Georgia Gulf Corp Dev Consequences 324.1 High Temperature 1. High pressure on VCM Receivers CAT S L RR Safeguards S/E 4 C 5 1. Temperature gauge Causes 1. Chiller failure 344 ABD00037316 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 325. Chiller recirculation water hold tank. TK-471 Type: Tank Design Conditions/Parameters: 1750 Gal Old Module Hazop Drawing: OM-090125-PID-D Georgia Gulf Corp Dev Consequences 325.1 High Temperature 1. No consequences 325.2 High Level 1. Ethylene glycol release CAT S L RR Safeguards S/E 4 C 5 1. sight glass 325.3 Low Level 1. no flow S/E 4 C 5 1. sight glass 2. High pressure on VCM receivers S/E 4 C 5 2. Low level switch - 81L800 Causes 1. Instrument failure 2. Operator error 1. Line leak/rupture 2. Operator error 345 ABD00037317 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 326. HPSW supply header. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090127-PID-D Georgia Gulf Corp Dev Consequences 326.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3 Gasket failure 4. Line rupture 5. VCM Leak 326.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 326.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Hydro fill the reactor 3. Personal exposure 4. VCM Leak 5. VCM release CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High Pressure in Reactor 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Check valve 1. Line leak/rupture 5 2. DCS interlock-AII RX slow vent 2. Operator error 5 valves must be closed & 3. Pump failure 5 recovery system discharge 4. Valve leaking through 5 pressure is < 110 psig (81 p759) before slow vent flush valve will open. 3. Fire Protection System 4. Fixed point monitor 5 Flow meter 6. general monitor 7. Operating procedures 8. Operator training 9. Personal Protective Equipment 346 ABD00037318 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 327. MSPW supply header. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090127-PID-D Georgia Gulf Corp Dev Consequences 327.1 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Gasket failure 4. Line rupture 5. VCM Leak 327.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 327.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Hydro fill the reactor 3. Personal exposure 4. VCM Leak 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 1. Cold weather 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High Pressure in Reactor 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D 5 1. Check valve 1. Line leak/rupture S/E 4 C 5 2. DCS interlock-AII RX slow vent 2. Operator error S 4C 5 valves must be closed & 3. Pump failure S/E 4 C 5 recovery system discharge 4. Valve leaking through S/E 4 C 5 pressure is < 110 psig (81p759) before slow vent flush valve will open. 3. Fire Protection System 4. Fixed point monitor 5. Flow meter 6. general monitor 7. Operating procedures 8. Operator training 9. Personal Protective Equipment 347 ABD00037319 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 328. Normal kill line from kill tank thru transfer pump to kill solution filter. Type: Line + Positive Displacement Pump Drawing: OM-090128-PID-D Design Conditions/Parameters: Pipe spec A2-1. Pump, PP-276, gear, 10 gpm @ 150 psi. Georgia Gulf Corp Dev Consequences 328.1 High Pressure 1. Lift relief valve 2. Personal exposure 328.2 Low Temperature 1. Lift relief valve 2. Personal exposure 3 Frozen Line 328.3 High Temperature 1. Lift relief valve 2. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S 4C 5 1. Operator training 5 2. Personal Protective Equipment 3. Pressure Gauge 4. relief valve 5. Recirculation line 1. External heat 2. Line plugged 3. Relief Valve failure 4. Valve closed 5. Filter Plugged S/E 4 C S 4C S/E 4 C 5 1. Operator training 5 2. Personal Protective Equipment 5 3. Pressure Gauge 4. Recirculation line 5. relief valve 6. Heat tracing 7. Operating procedures 1. Cold weather 2. Heat tracing failure 3. Operator error S/E 4 C S 4C 5 1. Operator training 5 2. Personal Protective Equipment 3. Pressure Gauge 4. Recirculation line 5. relief valve 1. External heat 2. Pump blocked in and running 348 ABD00037320 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 329. Normal kill solution filter, FL-395. Type: Vessel Drawing: OM-090128-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 500 F Georgia Gulf Corp Dev Consequences 329.1 High Pressure 1. Lift relief valve 2. Personal exposure 3. Vessel rupture 4. O-Ring failure 329.2 Start-up/Shutdown Hazards 1. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Operator training 5 2. Personal Protective Equipment 5 3. Pressure Gauge 5 4. Recirculation line 5. relief valve 1. External heat 2. Filter Plugged 3. Line plugged 4. Operator error 5. Relief Valve failure 6. Valve closed S 4 C 5 1. Maintenance & operating procedures 1. Operator error 2. Valve leaking through 349 ABD00037321 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 330. Normal kill line from filter to catalyst charge pot. Type: Line Drawing: OM-090128-PID-D Design Conditions/Parameters: Pipe spec A2-1. Georgia Gulf Corp Dev Consequences 330.1 High Pressure 1. Lift relief valve 2. Personal exposure 330.2 High Temperature 1. Lift relief valve 2. Personal exposure 330.3 Low Temperature 1. Frozen Line 2. Lift relief valve 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C 5 1. Operator training 5 2. Personal Protective Equipment 3. Pressure Gauge 4. Recirculation line 5. relief valve 1. External heat 2. Filter Plugged 3. Line plugged 4. Relief Valve failure 5. Valve closed S/E 4 c S/E 4 c 5 1. Operator training 5 2. Personal Protective Equipment 3. Pressure Gauge 4. Recirculation line 5. relief valve 1. External heat 2. Pump blocked in and running S/E 4 c S/E 4 c S 4c 5 1. Heat tracing 5 2. Operating procedures 5 3. Operator training 4. Personal Protective Equipment 5. Pressure Gauge 6. Recirculation line 7. relief valve 1. Cold weather 2. Heat tracing failure 3. Operator error 350 ABD00D37322 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 331. Rx catalyst charge pot. Type: Vessel Drawing: OM-090128-PID-D Design Conditions/Parameters: MAWP: 450 psig @ 300 F Georgia Gulf Corp Dev Consequences 331.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Vessel rupture 4. Personal exposure 5. VCM Leak 331.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Vessel rupture 4. Personal exposure 5. VCM Leak 331.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Vessel rupture 4. Personal exposure 5. VCM Leak 331.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Ram valve 1. External heat 2. Vessel blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 1. Cold weather 2. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 1. Operator error 2. Valve leaking through 351 ABD00ffS7323 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 332. Normal kill line to Rx-300,400,500,600,700. Type: Line Design Conditions/Parameters: Pipe spec B13-3 Old Module Hazop Georgia Gulf Corp Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D, OM-090128PID-D Dev Consequences 332.1 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 332.2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 5. VCM Leak 332.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 332.4 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Line plugged 4. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 c 5 4. Heat tracing S/E 4 c 5 5. Line insulation 6. Operating procedures 7. Operator training 1. Cold weather 2. Valve leaking through S/E 3 D 5 1. Check valve 1. High Pressure in Reactor S/E 4 C 5 2. DCS interlock-Valve will only 2. Line leak/rupture S 4C 5 open in poly mode, must have 3. Low HPSW pressure S/E 4 C 5 enable from lead operator, and 4. Operator error has timer to alert lead operator 5. Power failure that charge valve has been open 6. Valve failure a long time. 7. Valve leaking through 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Ram valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 352 ABD00037324 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 333. HPSW supply to Rx catalyst charge pot. Type: Line Design Conditions/Parameters: Pipe spec A2-3. Old Module Hazop Drawing: OM-090128-P1D-D Georgia Gulf Corp Dev Consequences 333.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Check valve 1. High Pressure in Reactor 5 2. DCS interlock-Valve will only 2. Line leak/rupture 5 open in poly mode, must have 3. Low HPSW pressure 5 enable from lead operator, and 4. Operator error has timer to alert lead operator 5. Power failure that charge valve has been open 6. Valve failure a long time. 7. Valve leaking through 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication 353 ABD00037325 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 334. Cleanwall supply line to Rx's. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Drawing: OM-090129-PID-D Georgia Gulf Corp Dev Consequences 334.1 High Pressure 1. Gasket failure 2. Line rupture 334.2 High Temperature 1. Gasket failure 2. High pressure 3. Line rupture 334.3 Low Temperature 1. Frozen Line 334.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Line rupture 5. No flow 6. Personal exposure 7. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. Maintenance & operating S/E 4 C 5 procedures 2. Pressure Gauge at pump 3. relief valve at pump 1. High Pressure in Reactor 2. Line plugged 3. RX nozzle plug 4. Valve closed 5. Valve leaking through S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Pressure Gauge 5 1. External heat 2. Line leak/rupture 3. Line plugged 4. Operator error 5. RX nozzle plug 6. Valve closed 7. Valve leaking through S/E 4 C 5 1. Line insulation 1. Cold weather S/E 3 D 5 1. Fire Protection System 1. Line leak/rupture S/E 4 C 5 2. Fixed point monitor 2. Line plugged S/E 4 C 5 3. general monitor 3. Operator error S/E 4 C 5 4. Operating procedures 4. Power failure S/E 4 C 5 5. Operator training 5. Pump failure S/E 4 C 5 6. Personal Protective Equipment 6. RX nozzle plug S/E 4 C 5 7. DCS Interlock - Cleanwall valve 7. Valve leaking through will not open if steam purge valve is open, reactor is not in cleanwall mode, and if any other cleanwall valve on another reactor is open. 354 ABD00037326 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 335. Steam supply to clean wall nozzle. Type: Line Design Conditions/Parameters: Pipe spec A2-3/A13-1. Old Module Hazop Drawing: OM-090129-PID-D Georgia Gulf Corp Dev Consequences 335.1 High Pressure 1. Gasket failure 2. Line rupture 335.2 High Temperature 1. Gasket failure 2. High pressure 3. Line rupture 335.3 Low Temperature 1. Frozen Line 335.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S/E 4 C 5 1. Maintenance & operating 5 procedures 2. Pressure Gauge at pump 3. relief valve at pump 1. High Pressure in Reactor 2. Line plugged 3. RX nozzle plug 4. Valve closed 5. Valve leaking through S/E 4 c 5 1. Fire Protection System S/E 4 c 5 2. Pressure Gauge S/E 4 c 5 1. External heat 2. Line feak/rupture 3. Line plugged 4. Operator error 5. RX nozzle plug 6. Valve closed 7. Valve leaking through S/E 4 c 5 1. Line insulation 1. Cold weather S/E 4 c 5 1. DCS Interlock - Steam valve will 1. Line leak/rupture S/E 4 c 5 not open if reactor is not in 2. Line plugged S/E 4 c 5 cleanwall mode. 3. Operator error S 4 c 5 2. Fire Protection System 4. Power failure S/E 4 c 5 3. Fixed point monitor 5. Pump failure 4. general monitor 6. RX nozzle plug 5. Operating procedures 7. Valve leaking through 6. Operator training 7. Personal Protective Equipment 355 ABD00037327 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 336. Steam supply to clean wall nozzle inlet (for nozzle clean out) Type: Line Drawing: OM-090129-PID-D Design Conditions/Parameters: Pipe spec A13-1 Georgia Gulf Corp Dev Consequences 336.1 High Pressure 1. Gasket failure 2. Line rupture 336.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Line rupture 5. No flow 6. Personal exposure 7. VCM Leak CAT S L RR Safeguards Causes S/E 4 C 5 1. DCS interlock steam purge and 1. High Pressure in Reactor S/E 4 c 5 cleanwall supply cannot be open 2. Line plugged at the same time. 3. RX nozzle plug 4. Valve closed 5. Valve leaking through S/E 3 D 5 1. DCS Interlock Steam purge will 1. Line leak/rupture S/E 4 C 5 not open unless reactor is in 2. Line plugged S/E 4 C 5 cleanwall mode, and cleanwall 3. Operator error S/E 4 C 5 supply valve is closed. 4. Power failure S/E 4 C 5 2. Fire Protection System 5. Pump failure S/E 4 C 5 3. Fixed point monitor 6. RX nozzle plug S/E 4 C 5 4. general monitor 7. Valve leaking through 5 Operating procedures 6. Operator training 7. Personal Protective Equipment 356 ABD00037328 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 337. F-50 charge line to RX-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PID-D, OM-090106-PID-D, OM-090130PID-D Design Conditions/Parameters: Pipe spec A13-1 Dev Consequences 337.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 337.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Line rupture 5. Personal exposure 6. Valve packing leaking 7. VCM Leak 337.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak 337.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 5 1. External heat 2. Heat tracing failure 3. Operator error S/E 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing S/E 4 C 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather S/E 3 D 5 1. Check valve 1. High Pressure in Reactor S 4 C 5 2. DCS interlock - abort F-50 2. Operator error S/E 4 C 5 charge on low flow 3. Power failure S/E 4 C 5 3. DCS interlock - valve 81hv110. 4. Pump failure Won't open unless RX in charge 5. Valve failure and all other RX F-50 valves 6. Valve leaking through closed 4. Fire Protection System 5. Fixed point monitor 6. general monitor 7. Operator training 8. Personal Protective Equipment 357 ABD0(5037329 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 338. F-50 filter, FL-130, for RX-700. Type: Vessel Design Conditions/Parameters: MAWP: 300 psig Old Module Hazop Drawing: OM-090130-PID-D Georgia Gulf Corp Dev Consequences 338.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 4. VCM Leak 5. Lift relief valve 338.2 High Temperature 1. Fire and explosion 2 Gasket failure 3. Personal exposure 4. VCM Leak 338.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. VCM Leak 338.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. relief valve 10. Differential pressure switch 81P996 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Heat tracing 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 1. Operator error 2. Valve leaking through 358 ABD0TO7330 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 339. Outlet line to F-50 filter, FL-130, to Rx-700. Type: Line Design Conditions/Parameters: Pipe spec A13-1 Old Module Hazop Drawing: OM-090130-PID-D Georgia Gulf Corp Dev Consequences 339.1 High Pressure 1. Fire and explosion 2 Gasket failure 3. Line rupture 4. Personal exposure 5. Lift relief valve 339.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 339.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. relief valve 1. Cold weather 2. External heat 3. High Pressure in Reactor 4. Line plugged 5. Operator error 6. Valve closed 7. Valve failure S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 359 ABD0D037331 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 340. Inlet line to F-50 filter, FL-130, for Rx-700. Type: Line Design Conditions/Parameters: Pipe spec A13-1. Old Module Hazop Drawing: OM-090130-PID-D Georgia Gulf Corp Dev Consequences 340.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 340.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 340.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. No flow 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 2. External heat 3. Filter Plugged 4. High Pressure in Reactor 5. Line plugged 6. Operator error 7. Valve closed 8. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Heat tracing failure 3. Operator error S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Heat tracing 5 5. Line insulation 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 1. Cold weather 360 ABD00037332 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 341. Slurry feed line from slurry feed pump, PP-511, to interchanger, EX-011. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-5. Georgia Gulf Corp Dev Consequences 341.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 341.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Flow indicator controller - 91F622 1. External heat 2. Line plugged 3. Operator error 4. Valve closed 5. High pressure in Feed Tank S/E 3 D S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 361 ABD00037333 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 342. EX-011, slurry feed side. Type: Heat Exchanger Drawing: OM-090132-PID-D Design Conditions/Parameters: MAWP: 190 psig @ 400 F Georgia Gulf Corp Dev Consequences 342.1 High Pressure 1. Gasket failure 2. Channel Failure 3. Fire and explosion 4. Personal exposure 342.2 Low Temperature 1. Channel Failure 2. Gasket failure 3. High pressure 4. VCM Leak 342.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor S 4 C 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. High pressure in Feed Tank 3. Line plugged 4. Operator error 5. Valve closed 6. Slurry feed side blocked in. S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Temperature gauge 1. Cold weather S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Personal Protective Equipment 5. Temperature gauge 1. External heat 362 ABD00037334 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 343. Slurry feed line from interchanger, EX-011, to stripper, TW-002. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-5 Georgia Gulf Corp Dev Consequences 343.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 343.2 High Temperature 1. Fire and explosion 2. Line rupture 3 Personal exposure 343.3 Reverse/Misdirected Flow 1 Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 1. External heat 2. High pressure in Feed Tank 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 1. External heat 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Temperature gauge 7. Temperature indication - 91T627 S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 1. Instrument failure 2. Operator error 3. Valve leaking through 363 ABD00037335 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 344. OM Stripping column, TW-002. Type: Column Drawing: OM-090132-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 400 F Georgia Gulf Corp Dev Consequences 344.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 344.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 344.3 Low Temperature 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Inadequately stripped slurry leaves stripper 344.4 Start-up/Shutdown hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Pressure indication - 91P866, 5 91P867, 91P868, 91P639, 5 91P869 5 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Pressure Gauge 9. relief valve 1. Feed Control Valve failure 2. Steam Control Valve failure 3. Recovery valve closed 4. Valve indication failure 5. Instrument failure 6. Rinse valve left open S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Temperature indication - 91T638, 91T637 1. Cooling Water Control Valve failure 2. External heat 3. Steam Control Valve failure S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure indication - 91P866, 91P867, 91P868, 91P639, 91P869 8. Temperature indication 91T638, 91T637 1. Instrument failure 2. Operator error 3. Steam Control Valve failure S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 1. Operator error 364 ABD0tf037336 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 345. Outlet line from stripper, TW-002, through bottoms pump, PP-515, to interchanger, EX-011. Type: Centrifugal Pump + Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-5. PP-515: 390 GPM @ 196 ft. Georgia Gulf Corp Dev Consequences 345.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 5. Lift relief valve 345.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 5. Seal failure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 6. relief valve 7. Pressure indication - 91P625 8. Pressure Gauge 1. Line blocked in with external heat (thermal expansion) 2. External heat S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 1. External heat 2. Pump blocked in and running 365 ABD00037337 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 346. EX-011, stripped slurry side. Type: Heat Exchanger Drawing: OM-090132-PID-D Design Conditions/Parameters: MAWP: 190 psig @ 400 F Georgia Gulf Corp Dev Consequences 346.1 High Pressure 1. Channel Failure 2. Fire and explosion 3. Gasket failure 4. Personal exposure 5. Lift relief valve 346 2 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure 346.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 91P625 1. External heat 2. Line plugged 3. Operator error 4. Stripped slurry side blocked in. 5. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 1. Cold weather S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor 4. Personal Protective Equipment 5. Temperature gauge 6. relief valve 1. External heat 366 ABD00037338 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 347. Stripped slurry line from EX-011 to blend tanks. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-5 Georgia Gulf Corp Dev Consequences 347.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 347.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 347.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 91P625 8. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Valve closed S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 c 5 4. Operator training 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 8. Temperature indication - 91T629 S/E 3 D 5 1. Fire Protection System 1. Cold weather S/E 4 C 5 2. Fixed point monitor S/E 4 c 5 3. general monitor S 4 c 5 4. Line insulation 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 8. Temperature indication - 91T629 367 ABD00037339 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 348. Stripped slurry recycle line to feed tank, DM-079. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-5. Georgia Gulf Corp Dev Consequences 348.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 348.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 348.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4 Personal exposure CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 91P625 8. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 c 5 4. Operator training 1. External heat 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 8. Temperature indication - 91T629 S/E 3 D 5 1. Fire Protection System S/E 4 c 5 2. Fixed point monitor S/E 4 c 5 3. general monitor S 4 c 5 4. Line insulation 1. Cold weather 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 8. Temperature indication - 91T629 368 ABD00d37340 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 349. HPSW line to bottoms pump, PP-515, mechanical seal. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 349.1 High Pressure 1. Fire and explosion 2 Personal exposure 3. Seal failure 4. VCM Leak 349.2 High Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak 4. Fire and explosion 349.3 Low Pressure 1. Personal exposure 2. Seal failure 3. VCM Leak 4. Fire and explosion 349.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. Flow meter 8. Pressure regulator 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S 4C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 5 1. External heat 2. Operator error S 4C S/E 4 C S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 5 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed S 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. Flow meter 4. Line insulation 5. Personal Protective Equipment 6. Pressure Gauge 1. Cold weather 369 ABD00037341 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 350. Process water flush line to bottoms pump, PP-515, suction line. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 350.1 High Pressure 1. Line rupture 2. Personal exposure 350.2 High Temperature 1. Line rupture 2. Personal exposure 350.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S 4C 5 1. Personal Protective Equipment 5 1. Line blocked in with external heat (thermal expansion) S/E 4 C 5 1. Fire Protection System S 4C 5 1. External heat S/E 4 C S/E 4 C S/E 4 C 5 1. Heat tracing 5 2. Line insulation 5 1. Cold weather 2. Heat tracing failure 370 ABD00037342 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 351. Process water flush line to bottoms pump, PP-515, discharge line. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 351.1 High Pressure 1. Line rupture 351.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C 5 1. Personal Protective Equipment 1. Line blocked in with external heat (thermal expansion) S/E 4 C 5 1. Heat tracing S/E 4 c 5 2. Line insulation S 4c 5 1. Cold weather 2. Heat tracing failure 371 ABD00037343 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 352. Process water flush line to EX-011 outlet line to stripper. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 352.1 High Pressure 1. Line rupture 2. Personal exposure 352.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S 4C 5 1. Personal Protective Equipment 5 1. Line blocked in with external heat (thermal expansion) S/E 4 c 5 1. Heat tracing S/E 4 c 5 2. Line insulation S 4c 5 1. Cold weather 2. Heat tracing failure 372 ABD00037344 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 353. Process water flush line to EX-011 outlet line to blend tanks. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 353.1 High Pressure 1. Line rupture 353.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C 5 1. Personal Protective Equipment 1. Line blocked in with external heat (thermal expansion) S/E 4 C 5 1. Heat tracing S/E 4 c 5 2. Line insulation S 4c 5 1. Cold weather 2. Heat tracing failure 373 ABD00037345 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 354. Process water flush line to top of stripper, TW-002. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 354.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 354.2 High Pressure 1. Line rupture 2. Personal exposure 354.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Valve indication 1. Operator error 2. Pump failure 3. Valve closed S/E 4 C 5 1. Persona] Protective Equipment S 4C 5 1. Line blocked in with external heat (thermal expansion) S/E 4 C 5 1. Heat tracing S/E 4 C 5 2. Line insulation S 4C 5 1. Cold weather 2. Heat tracing failure 374 ABD00037346 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 355. Process water flush line to top of stripper condenser, TW-002. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 355.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 355.2 High Pressure 1. Line rupture 2. Personal exposure 355.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Valve indication 1. Operator error 2. Pump failure 3. Valve closed S/E 4 C 5 1. Personal Protective Equipment S 4C 5 1. Line blocked in with external heat (thermal expansion) S/E 4 C 5 1. Heat tracing S/E 4 C 5 2. Line insulation S 4C 5 1. Cold weather 2. Heat tracing failure 375 ABD00037347 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 356. Antifoam addition line to stripper, TW-002. Type: Line Design Conditions/Parameters: Pipe spec A13-2 Old Module Hazop Drawing: OM-090132-PID-D Georgia Gulf Corp Dev Consequences 356.1 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure 356.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S 4C 5 1. Personal Protective Equipment 5 5 1. Line blocked in with external heat (thermal expansion) S/E 4 C S/E 4 C S 4C 5 1. Heat tracing 5 2. Line insulation 5 1. Cold weather 2. Heat tracing failure 376 ABD00037348 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 357. Process water flush line to stripper, TW-002, Antifoam addition line. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2. Georgia Gulf Corp Dev Consequences 357.1 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards S/E 4 C S/E 4 C S 4c 5 1. Heat tracing 5 2. Line insulation 5 Causes 1. Cold weather 2. Heat tracing failure 377 ABD00037349 VIII.0. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 358. Cooling water supply line to stripper condenser, TW-002. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 358.1 High Temperature 1. Gasket failure 2. Line rupture 358.2 High Pressure 1. Damage condenser 2. Gasket failure 3. Line rupture CAT S L RR Safeguards S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. general monitor S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 Causes 1. Cooling Water Control Valve failure 2. External heat 3. Line plugged 4. Operator error 5. Power failure 6. Pump failure 7. Valve closed 1. Line plugged 2. Valve closed 378 ABD00037350 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 359. Stripper condenser, TW-002. Type: Heat Exchanger Drawing: OM-090132-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 400 F Georgia Gulf Corp Dev Consequences 359.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Tube leak/rupture CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. Condenser blocked in on water side 2. External heat 379 ABD00037351 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 360. Cooling water return line from stripper condenser, TW-002. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 360.1 High Pressure 1. Damage condenser 2. Gasket failure 3. Line rupture 4. Lift relief valve 360.2 High Temperature 1. Gasket failure 2. Line rupture 3. Lift relief valve CAT S L RR Safeguards S/E 4 C S/E 4 C S/E 4 C 5 1. Operating procedures 5 2. Operator training 5 3. relief valve Causes 1. Line plugged 2. Valve closed S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 1. Cooling Water Control Valve 5 2. general monitor failure 5 3. Temperature indication - 91T649 2. External heat 4. relief valve 3. Line plugged 4. Operator error 5. Power failure 6. Pump failure 7. Valve closed 380 ABD00037352 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 361. VCM Recovery line from stripper condenser, TW-002. Type. Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-5/A2-22. Georgia Gulf Corp Dev Consequences 361.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Personal exposure 361.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Line rupture 5. Personal exposure 6. Valve packing leaking CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure indication - 91P869 1. External heat 2. Line plugged 3. Operator error 4. Relief Valve failure 5. Valve closed S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 1. External heat 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. relief valve 7. Temperature indication - 91T655 381 ABD00037353 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 362. HPSW line to stripping steam desuperheater for stripper, TW-002.. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 362.1 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards S/E 4 C 5 1. Heat tracing S/E 4 C 5 2. Line insulation S 4c 5 Causes 1. Cold weather 2. Heat tracing failure 382 ABD00037354 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 363. Stripping steam supply to stripper, TW-002. Type: Line Design Conditions/Parameters: Pipe spec A2-3/A13-5 Old Module Hazop Drawing: OM-090132-PID-D Georgia Gulf Corp Dev Consequences 363.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Overpressure stripper 4. Personal exposure 5. VCM Leak 363.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Overpressure reactor 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Personal Protective Equipment 5 5. Pressure indication - 91P643 1. External heat 2. Line plugged 3. Operator error 4. Valve failure 5. Valve leaking through 1. Fire Protection System 2. Fixed point monitor 3. general monitor 4. Personal Protective Equipment 5. Flow indication - 91F634 1. Line leak/rupture 2. Line plugged 3. Low steam pressure 4. Valve closed 5. Valve leaking through 383 ABD00037355 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 364. Steam line to polishing strainers, FL-030/031. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 364.1 Reverse/Misdirected Flow 1. Line rupture 2. Personal exposure 364.2 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure 4. Fire and explosion CAT S L RR Safeguards Causes S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Operator error 2. Valve failure 3. Valve leaking through S/E 4 c S/E 4 c S 4c S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Operator error 384 ABD00037356 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 365. Steam line to dump tank, DM-075, outlet line. Type: Line Drawing: OM-090132-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 365.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 365.2 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Check valve failure 2. Operator error 3. Power failure S/E 4 C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Valve at polishing strainer leaking through into steam line 385 ABD00037357 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 366. Dump line from Rx's 300/400 to dump pump. Type: Line Drawing: OM-090134-PID-D Design Conditions/Parameters: Pipe spec B13-22 Georgia Gulf Corp Dev Consequences 366.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 366.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. High pressure 4. Personal exposure 5. VCM Leak 366.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 81P867 8. Flow switch - 81F866 1. External heat 2. High Pressure in Reactor 3 Instrument failure 4. Line plugged 5 Operator error 6. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 1. External heat 2. Operator error S/E 3 D S 4C S/E 4 C 5 1. DCS interlock - Dump valve can 1. High pressure in dump tank 5 only be open in closed dump 2. Instrument failure 5 mode. 3. Operator error 2. Dump line bullseye 4. Pump failure 3. Dump pump amp indication 5. Valve failure 4. Fire Protection System 5. Fixed point monitor 6. general monitor 7. Maintenance & operating procedures 8. Personal Protective Equipment 386 ABD00037358 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 367. Reactor dump pump. Type: Centrifugal Pump Design Conditions/Parameters: 1500 GPM @ 175 ft Old Module Hazop Drawing: OM-090134-PID-D Georgia Gulf Corp Dev Consequences 367.1 High Pressure 1. Pump casing failure 2. Fire and explosion 3. Seal failure 4. VCM Leak 367.2 Low/No Flow 1. Fire and explosion 2. High temperature 3. Personal exposure 4. Seal failure 367.3 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure CAT S L RR Safeguards Causes S/E 4 C S/E 3 D S/E 4 C S/E 4 C 5 1. Amp indicator 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. External heat 2. Line plugged 3. Valve closed S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Amp indicator 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 1. Line plugged 2. Operator error 3. Valve closed S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Pump blocked in and running 387 ABD00037359 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 368. HPSW supply line to dump pump mechanical seal. Type: Line Drawing: OM-090134-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 368.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 368.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 368.3 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 368.4 Low Temperature 1. Personal exposure 2. Seal failure 3. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure regulator 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 5 4. Personal Protective Equipment 5. Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed S 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. Flow meter 4. Line insulation 5. Personal Protective Equipment 6. Pressure Gauge 1. Cold weather 388 ABD00037360 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 369. Dump line from dump pump to dump strainer. Type: Line Drawing: OM-090134-PID-D Design Conditions/Parameters: Pipe spec B13-22 Georgia Gulf Corp Dev Consequences 369.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 369.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 81P870 1. External heat 2. Operator error S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. Operator error 2. Valve leaking through 3. Low steam pressure 389 ABD00037361 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Ha20p Node: 370. Dump strainer Type: Vessel Drawing: OM-090134-PID-D Design Condrtions/Parameters: MAWP: 300 psig @ 365 F Georgia Gulf Corp Dev Consequences 370.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Vessel rupture 370.2 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 370.3 High Temperature 1. Fire and explosion 2. Personal exposure 3. Vessel rupture 370.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge/transmitter (local) 8. Temperature gauge 1. Unrecovered strainer blocked in with recovery steam applied 2. Line plugged 3. Valve closed 4. Steam valve leaking through to blocked in strainer S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. Valve indication 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Temperature gauge 1. External heat 2. Steam valve leaking through to blocked in strainer 3. Unrecovered strainer blocked in with recovery steam applied S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge/transmitter (local) 8. Temperature gauge 1. Operator error 390 ABD00037362 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 371. Dump line from dump strainer to dump tank. Type: Line Drawing: OM-090134-PID-D Design Conditions/Parameters: Pipe spec B13-22 Georgia Gulf Corp Dev Consequences 371.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 371.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 c S 4c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 81P872 1. External heat 2. Operator error S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. Low steam pressure 2. Operator error 3. Valve leaking through 391 ABD00037363 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 372. Steam line to dump strainer for recovery. Type: Line Drawing: OM-090134-PID-D Design Conditions/Parameters: Pipe spec A2-3/A13-22/B13-22 Georgia Gulf Corp Dev Consequences 372.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 372.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. DCS interlock steam valve to 1. Operator error 5 strainer will not open if strainer is 2. Low steam pressure 5 in service. 5 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 9. Check valve S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Gauge/transmitter (local) 1. Operator error 2. External heat 3. VCM backing into the steam line 392 ABD00037364 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 373. VCM recovery line from dump strainers. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: OM-090134-PID-D Georgia Gulf Corp Dev Consequences 373.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 373.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 373.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Gauge/transmitter (local) 1. External heat 2. Operator error 3. VCM blocked in between strainer and recovery system. S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. DCS interlock Recovery valve 5 to strainer will not open if 5 strainer is in service. 5 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 1. Operator error 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Temperature gauge 1. External heat 2. Operator error 3. VCM blocked in between strainer and recovery system. 393 ABD00037365 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 374. VCM recovery line from dump pump. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: OM-090134-PID-D Georgia Gulf Corp Dev Consequences 374.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 374.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 t. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure Gauge/transmitter (local) 1. External heat 2. Operator error 3. VCM blocked in between pump and recovery system. S/E 1. Fire Protection System 1. Operator error S/E 2. Fixed point monitor 2. Valve leaking through S/E 3. general monitor S 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Valve indication 394 ABD00037366 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 375. Flush water flush line to dump strainers. Type: Line Design Conditions/Parameters: Pipe spec A13-2 Old Module Hazop Drawing: OM-090134-PID-D Georgia Gulf Corp Dev Consequences 375.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 375.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 375.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Check valve 1. Low water pressure 5 2. DCS interlock rinse valve to 2. Operator error 5 strainer will not open if strainer is 3. Valve leaking through 5 in service, the rinse valve to opposite strainer is open, the steam supply valve is open, or the recovery valve is open. 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Operator error 3. VCM backing into the rinse line S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Temperature gauge 1. External heat 395 ABD00037367 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 376. Dump line from dump strainers to dump tank. Type: Line Drawing: OM-090135-PID-D Design Conditions/Parameters: Pipe spec B13-5 Georgia Gulf Corp Dev Consequences 376.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 376.2 Reverse/Misdirected Flow Fire and explosion Gasket failure Line rupture Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication -81P872 1. External heat 2. Operator error S/E 1. Fire Protection System t. Operator error S/E 2. Fixed point monitor 2. Valve leaking through S/E 3. general monitor 3. Pump failure S 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Amp indicator and run indication on dump pump 8. sight glass 396 ABD00037368 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 377. Dump tank, DM-075. Type: Vessel Drawing: OM-090135-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 400 F ; 50,000 Gal Georgia Gulf Corp Dev Consequences 377.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 5. Seal failure 377.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 377.3 High Level 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 377.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 3 D S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. relief valve 8. Pressure indication - 91P671, 91P871 9. Kill system on dump tank 1. Instrument failure 2. Operator error 3. Outlet Line plugged 4. Reaction in dump tank 5. High Pressure in Reactor 6. Relief Valve failure S/E 3 D 5 1. Fire Protection System 1. External heat S/E 4 C 5 2. Fixed point monitor 2. Operator error - steam line open S 4 C 5 3. general monitor into dump tank 4. Kill system on dump tank 3. Reaction in dump tank 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Temperature indication - 91T668 9. relief valve S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 1. Instrument failure 5 2. Fixed point monitor 2. Operator error 5 3. general monitor 3. Rinse valve failure 4. Kill system on dump tank 4. Outlet Line plugged 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Level indication - 91L669 9. relief valve 10. Level switch 91L653, 91L670 11. DCS interlock - Can't dump to dump tank if dump tank level > 60% S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 1. Operator error 397 ABD00037369 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 378. Dump tank outlet line to feed tank. Type: Line Design Conditions/Parameters: Pipe spec A13-5 Old Module Hazop Drawing: OM-090135-PID-D Georgia Gulf Corp Dev Consequences 378.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 378.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Gasket failure 4. Line rupture CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 1. High pressure in dump tank 2. High pressure in Feed Tank 3. Line blocked in with external heat (thermal expansion) S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 1. External heat 2. Operator error steam line open into dump tank 3. Reaction in dump tank 398 ABD00037370 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 379. Recovery line from Dump TK to Rx recovery header. Type: Line Drawings: OM-090108-PID-D, OM-090135-PID-D Design Conditions/Parameters: Pipe spec A2-22. Dev Consequences 379.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 379.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 379.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication, 81P756, 81P628 8. Valve indication 1. External heat 2. High pressure in dump tank 3. High Pressure in Reactor 4. Instrument failure 5. Line plugged 6. Operator error 7. Power failure 8. Valve closed S/E 3 D 5 1. Dump tank kill system S/E 4 C 5 2. Fire Protection System S/E 4 C 5 3. Fixed point monitor S 4 c 5 4. general monitor S/E 4 c 5 5. Operating procedures S/E 4 c 5 6. Operator training 7. Personal Protective Equipment 1. External heat 2. Reaction occurring in dump tank S/E 3 D S/E 4 C S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 399 ABD00tT37371 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 380. Rinse water supply to dump tank rinse nozzle. Type: Line Drawing: OM-090135-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 380.1 High Pressure 1. Line rupture 2. No flow 3. Overpressure dump tank 4. Personal exposure 5. VCM Leak 380.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 4. Valve leaking through 5. Line plugged S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 400 ABD00037372 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 381. Process water flush line to dump tank outlet line. Type: Line Drawing: OM-090135-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 381.1 High Pressure 1. Line rupture 2. No flow 3. Overpressure dump tank 4. Personal exposure 5. VCM Leak 381.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve leaking through S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 401 ABD00037373 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node : 382. Antifoam addition line to dump tank Type: Line Design Conditions/Parameters: Pipe spec A13-2 Old Module Hazop Drawing: OM-090135-PID-D Georgia Gulf Corp Dev Consequences 382.1 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure 382.2 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S 4C 5 1. Heat tracing 5 2. Line insulation 5 1. Line blocked in with external heat (thermal expansion) 2. Cold weather 3. Heat tracing failure S/E 1. Personal Protective Equipment 1. Line blocked in with external S/E heat (thermal expansion) S 402 ABD00037374 VIII.D. Hazards Identified P&ID/Operating Procedures Review Node: 383. Emergency kill addition line. Type: Line Design Conditions/Parameters: Pipe spec B2-1 Old Module Hazop Drawing: OM-090135-PID-D Georgia Gulf Corp Dev Consequences 383.1 High Pressure 1. AMS release 2. Fire and explosion 3. Line rupture 4. Valve failure 5. VCM Leak 383.2 Low Pressure 1. Fire and explosion 2. Lift relief valve on dump tank 3. No flow 383.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Lift relief valve on dump tank 4. Overpressure dump tank 5. Personal exposure 6. VCM release CAT S L RR Safeguards Causes S/E 4 C S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. HNU unit 5 5. Operating procedures 6. Operator training 7. Pressure Gauge 1. Instrument failure 2. Line blocked in with external heat (thermal expansion) 3. Line leak/rupture 4. Operator error 5. Valve failure S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge 1. Line leak/rupture 2. Operator error 3. Valve failure 4. Valve leaking through S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 S/E 4 C 5 S 4C 5 S/E 4 C 5 1. Cold weather 2. Valve leaking through 403 ABD00037375 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 384. Nitrogen line to emergency kill valves. Type: Line Design Conditions/Parameters: Pipe spec B2-1 Old Module Hazop Drawing: OM-090135-PID-D Georgia Gulf Corp Dev Consequences 384.1 High Pressure 1. Actuator failure 2. Line rupture 3. O-Ring failure 384.2 Low Pressure 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. Valves won't open 6. VCM release 384.3 Low Temperature 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. Solenoid failure 6. VCM release CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training S/E 4 C 5 1. External heat 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve failure S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Valve indication 1. Instrument failure 2. Line leak/rupture 3. Line plugged 4. Nitrogen bottle empty 5. Operator error 6. Valve failure S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 5 6. Personal Protective Equipment 7. Valve indication 1. Cold weather 2. Valve leaking through 404 ABD00037376 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 385. MSPW to mechanical seal on dump tank agitator. Type: Line Drawing. OM-090135-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 385.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak 385.2 High Temperature 1. High pressure 385.3 Low/No Flow 1. Fire and explosion 2. Line rupture 3. Seal failure 4. Valve leaking 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fixed point monitor 5 2. general monitor 5 3. Operating procedures 5 4. Operator training 5 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure regulator 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure S/E 4 C 5 1. Operating procedures 2. Operator training 1. External heat 2. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fixed point monitor 5 2. Flow meter 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Flow switch -91F660 1. Control Valve failure 2. Instrument failure 3. Line plugged 4. Operator error 5. Valve closed 6. Valve failure 405 ABD00037377 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 386. Steam line to dump tank outlet line. Used for steam injection during recovery for entry. Type: Line Drawing: OM-090135-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 386.1 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure 4. Fire and explosion 5. VCM Leak 386.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S 4C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Valve at polishing strainer leaking through into steam line S/E 4 c 5 1. Check valve S/E 4 c 5 2. Fire Protection System S 4 c 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Check valve failure 2. Operator error 3. Power failure 406 ABD00037378 VIIID. Hazards Identified - P&ID/Operating Procedures Review Node: 387. Oil reservoir unit for dump tank agitator Type: Tank Design Conditions/Parameters: Old Module Hazop Drawing: OM-090135-PID-D Georgia Gulf Corp Dev Consequences 387.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 387.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 387.3 Low Level 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 387.4 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Pressure Gauge 6. Pressure regulator 1. Operator error 2. Pressure regulator failure S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 c 5 4. Operator training 1. External heat S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. sight glass 7. Level switch-91L620 1. Line leak/rupture 2. Seal leaking S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S/E 4 C 5 4. Operator training 5. Pressure Gauge 6. Pressure regulator 1. Operator error 2. Pressure regulator failure 3. Line leak/rupture 4. Line plugged 5. Valve closed 6. Nitrogen bottle empty 407 ABD00037379 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 388. Feed tank, DM-079, inlet line from dump tank, DM-075. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-5 Georgia Gulf Corp Dev Consequences 388.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 388.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 1. High pressure in dump tank 2. High pressure in Feed Tank 3. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 1. External heat 2. Operator error - steam line open into dump tank 3. Reaction in dump tank 408 ABD00037380 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 389. Feed tank, DM-079 Type: Vessel Drawing: OM-090136-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 230 F ; 8600 Gal Georgia Gulf Corp Dev Consequences 389.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 4. Seal failure 5. Vessel rupture 389.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 389.3 High Level 1. Fire and explosion 2. Lift relief valve 3. Personal exposure 389.4 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Pressure indication - 91P605, 91P872, 91P873, 91P874 8. relief valve 1. Instrument failure 2. Operator error 3. Outlet Line plugged 4. Relief Valve failure S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 1. External heat 5 2. Fixed point monitor 2. Operator error - steam line open 5 3. general monitor into feed tank 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. relief valve 8. Temperature indication - 91T802 S/E 3 D S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Level indication - 91L601, 91L600 5. Level switch - 91L673 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. relief valve 1. Instrument failure 2. Operator error 3. Outlet Line plugged 4. Rinse valve failure S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 1. Operator error 409 ABD00037381 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 390. Stripped slurry recycle line to feed tank, DM-079. Type: Line Drawings: OM-090132-PID-D, OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-5. Dev Consequences 390.1 High Pressure 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 390.2 High Temperature 1. Fire and explosion 2. Lift relief valve 3. Line rupture 4. Personal exposure 390.3 Low Temperature 1. Fire and explosion 2. Frozen Line 3. Line rupture 4. Personal exposure CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure indication - 91P625 8. relief valve 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 1. External heat 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. relief valve 7. Temperature gauge 8. Temperature indication - 91T629 S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 1. Cold weather 5 2. Fixed point monitor 5 3. general monitor 5 4. Line insulation 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 8. Temperature indication - 91T629 410 ABD00037382 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 391. Feed tank outlet line including stripper feed pump, PP-511 Type: Centrifugal Pump + Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-5; Pump 365 gpm @ 189 ft Georgia Gulf Corp Dev Consequences 391.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. Seal failure 391.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow indicator controller 5 91F622 4. general monitor 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High pressure in Feed Tank 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Pump blocked in and running 411 ABD00037383 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 392. Stripper feed line from feed pump to polishing strainers. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-5 Georgia Gulf Corp Dev Consequences 392.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 392.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow indicator controller - 91F622, 91P608 4. general monitor 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High pressure in Feed Tank 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 412 I ABD00037384 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 393. Polishing strainer, FL-130/131 Type: Vessel Drawing: OM-090136-PID-D Design Conditions/Parameters: MAWP: 300 psig @ 365 F Georgia Gulf Corp Dev Consequences 393.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Vessel rupture 393.2 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 393.3 High Temperature 1. Fire and explosion 2. Personal exposure 3. Vessel rupture 393.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. Vessel rupture CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge/transmitter (local) 8. Temperature gauge 1. Line plugged 2. Steam valve leaking through to blocked in strainer 3. Unrecovered strainer blocked in with recovery steam applied 4. Valve closed S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5 Personal Protective Equipment 6. Pressure Gauge 7. Valve indication 1 Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Temperature gauge 1. External heat 2. Steam valve leaking through to blocked in strainer 3. Unrecovered strainer blocked in with recovery steam applied S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Pressure Gauge/transmitter (local) 8. Temperature gauge 1. Operator error 413 ABD00037385 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 394. Stripper feed line from polishing strainers to stripper. Type: Heat Exchanger Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-5 Georgia Gulf Corp Dev Consequences 394.1 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 394.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Pressure indicator-91P875 4. general monitor 5. Operator training 6. Personal Protective Equipment 1. External heat 2. High pressure in Feed Tank 3. Line plugged 4. Operator error 5. Valve closed S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operator training 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 414 r ABD00037386 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 395. Nitrogen supply to Dump tank & feed tank oil reservoir. Type: Line + Vessel Drawings: OM-090136-PID-D, OM-090135-PID-D Design Conditions/Parameters: Pipe spec H16-1 Dev Consequences 395.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 395.2 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak CAT S L RR Safeguards S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Pressure Gauge 6. Pressure regulator S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Pressure Gauge 6. Pressure regulator Causes 1. Operator error 2. Pressure regulator failure 1. Line leak/rupture 2. Line plugged 3. Nitrogen bottle empty 4. Operator error 5. Pressure regulator failure 6. Valve closed 415 ABD00037387 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 396. Rinse water supply to feed tank rinse nozzle. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 396.1 High Pressure 1. Line rupture 2. No flow 3. Overpressure dump tank 4. Personal exposure 5. VCM Leak 396.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve leaking through S/E 4 c 5 1. Fire Protection System S/E 4 c 5 2. Fixed point monitor S 4 c 5 3. general monitor 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 416 ABD00037388 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 397. Flush water flush line to polishing strainers, FL-030/031. Type: Line __ Drawing. OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 397.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 397.2 High Pressure 1. Fire and explosion 2. Line rupture 3. Personal exposure 397.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure. CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Check valve 5 2. DCS interlock rinse valve to 5 strainer will not open if rinse 5 water is being used elsewhere. 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Operating procedures 7. Operator training 8. Personal Protective Equipment 9. Valve indication 1. Low water pressure 2. Operator error 3. Valve leaking through S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 1. External heat 2. Operator error 3. VCM backing into the rinse line S/E 3 D 5 1. Fire Protection System S/E 4 D 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 c 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. Temperature gauge 1 External heat 417 ABD00037389 VIIID. Hazards Identified - P&ID/Operating Procedures Review Node: 398. Antifoam addition line to feed tank Type: Line Design Conditions/Parameters: Pipe spec A13-2 Old Module Hazop Drawing: OM-090136-PID-D Georgia Gulf Corp Dev Consequences 398.1 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure 398.2 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S 4C 5 1. Heat tracing 5 2. Line insulation 5 1. Cold weather 2. Heat tracing failure 3. Line blocked in with external heat (thermal expansion) S/E 4 C S/E 4 C S 4C 5 1. Personal Protective Equipment 5 5 1. Line blocked in with external heat (thermal expansion) 418 ABD00037390 VIII.D. Hazards Identified * P&ID/Operating Procedures Review Old Module Hazop Node: 399. HPSW flush to antifoam addition line, feed tank. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 399.1 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards S/E 3 D 5 1. Heat tracing S/E 4 C 5 2. Line insulation S 4C 5 Causes 1 Cold weather 2. Heat tracing failure 419 ABD00037391 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 400. Process water flush line to feed tank outlet line. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 400.1 High Pressure 1. Line rupture 2. No flow 3. Overpressure dump tank 4. Personal exposure 5. VCM Leak 400.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve leaking through S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 420 ABD00037392 Vltl.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 401. Process water flush line to stripper recirculation line from stripper. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-5 Georgia Gulf Corp Dev Consequences 401.1 High Pressure 1. Line rupture 2. No flow 3. Overpressure dump tank 4. Personal exposure 5. VCM Leak 401.2 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5 5. Personal Protective Equipment 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Line plugged 4. Operator error 5. Valve leaking through S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Line insulation 5. Personal Protective Equipment 1. Cold weather 421 ABD00037393 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 402. HPSW supply line to stripper feed pump mechanical seal. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 402.1 High Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 402.2 High Temperature 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 402.3 Low Pressure 1. Fire and explosion 2. Personal exposure 3. Seal failure 4. VCM Leak 402.4 Low Temperature 1. Personal exposure 2. Seal failure 3 VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Pressure Gauge 8. Pressure regulator 1. Line plugged 2. Operator error 3. Regulator failure 4. Valve closed 5. Valve failure S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Personal Protective Equipment 5 1. External heat 2. Operator error S/E 3 D S 4C S/E 4 C S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 5 4. Personal Protective Equipment 5 Pressure Gauge 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed S 4c S/E 4 c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow meter 4. Line insulation 5. Personal Protective Equipment 6. Pressure Gauge 1. Cold weather 422 ABD00037394 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 403. Feed tank recovery line Type: Line Design Conditions/Parameters: Pipe spec A2-22. Old Module Hazop Georgia Gulf Corp Drawings: OM-090108-PID-D, OM-090136-PID-D Dev Consequences 403.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 403.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve failure 6. VCM Leak 403.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Lift relief valve 3. Overpressure dump tank 4. Personal exposure 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. External heat 2. Instrument failure 3. Line plugged 4. Operator error 5. Power failure 6. Valve closed S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Operating procedures S/E 4 C 5 5. Operator training S/E 4 C 5 6. Personal Protective Equipment 1. External heat S/E 3 D S/E 3 D S/E 4 C S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment 7. Valve indication 1. Line leak/rupture 2. Operator error 3. Valve leaking through 423 ABD00037395 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 404. VCM recovery line from stripper feed pump. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: OM-090136-PID-D Georgia Gulf Corp Dev Consequences 404.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak 404.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 404.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4 Operating procedures 5 5. Operator training 6. Personal Protective Equipment 1. External heat 424 ABD00037396 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 405. VCM recovery line from polishing strainers. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: OM-090136-PID-D Georgia Gulf Corp Dev Consequences 405.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6 VCM Leak 405.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 405.3 High Temperature 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve packing leaking 6. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error S/E 3 D S/E 4 C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve failure 3. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 1. External heat 2. Line blocked in with external heat (thermal expansion) 3. Operator error 425 ABD00037397 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 406. Steam line to polishing strainer for recovery. Type: Line Drawing: OM-090136-PID-D Design Conditions/Parameters: Pipe spec A2-3/A13-22/BI 3-22 Georgia Gulf Corp Dev Consequences 406.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 406.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Check valve 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 1. Check valve failure 2. Operator error 3. Power failure S/E 3 D S/E 4 C S/E 4 C S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Operator training 6. Personal Protective Equipment t. External heat 2. Valve at polishing strainer leaking through into steam line 426 ABD00037398 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 407. Recycled centrate tank, TK-014. Type: Tank Drawing: OM-090137-PID-D Design Conditions/Parameters: MOC: FRP 18,000 Gal Georgia Gulf Corp Dev Consequences 407.1 Reverse/Misdirected Flow 1. Personal exposure CAT S L RR Safeguards Causes S 4 C 5 1. Maintenance & operating 1. Operator error procedures 2. Personal Protective Equipment 427 ABD00037399 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 408. Rinse water pump, PP-229, and discharge line to rinse water filter, FL-103. Type: Centrifugal Pump + Line Drawing: OM-090137-PID-D Design Conditions/Parameters: Pipe spec A2-3; Pump 3x4-11.25-11 800 GPM @ 220 psig Georgia Gulf Corp Dev Consequences 408.1 High Pressure 1. Gasket failure 2. Line rupture 3. Overpressure filter pack 4. Seal failure 5. Valve packing leaking 408.2 High Temperature 1. Gasket failure 2. Line rupture 3. Seal failure 4. Valve packing leaking 408.3 Low Temperature 1. Frozen Line CAT S L RR Safeguards Causes S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Pressure Gauge S/E 4 c 5 S/E 4 c 5 S/E 4 c 5 1. External heat 2. Filter plugged 3. Line plugged 4. Valve closed 5. Valve failure S/E 4 c S/E 4 c S/E 4 c S/E 4 c 5 1. Operating procedures 5 2. Personal Protective Equipment 5 3. Pressure Gauge 5 1. External heat 2. Pump blocked in and running S/E 4 c 5 1. Line insulation 1. Cold weather 428 ABD00037400 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 409. Charge water line from rinse tank. Type: Line Design Conditions/Parameters: Pipe spec A2-3 Old Module Hazop Georgia Gulf Corp Drawings: OM-090101-PID-D, OM-090137-PID-D Dev Consequences 409.1 High Pressure 1. Gasket failure 2. Line rupture 3. Valve packing leaking 409.2 Low Temperature 1. Frozen Line CAT S L RR Safeguards S/E 4 C S/E 4 C S/E 4 C 5 1. Operating procedures 5 2. Pressure Gauge 5 S/E 4 c 5 1. Line insulation Causes 1. External heat 2. Filter plugged 3. Line plugged 4. Valve closed 5. Valve failure 1. Cold weather 429 ABD00037401 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 410. Rinse water line to RX condenser, shell, and dump header. RX-300,400,500,600,700. Type: Line Drawings: OM-090102-PID-D, OM-090103-PID-D, OM-090104-PIDD, OM-090105-PI D-D, OM-090106-PID-D Design Conditions/Parameters: Pipe spec A2-3.A13-2 Dev Consequences 410.1 High Pressure 1. Gasket failure 2. Line rupture 3. Lift relief valve 4. O-Ring failure 5. Overpressure filter pack 410.2 High Temperature 1. High pressure 2. Line rupture 410.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Valve failure 410.4 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3, High pressure 4. Personal exposure 5. VCM Leak CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Operating procedures 5 2. Operator training 5 3. Recycle line on rinse pump, pp5 229, thru valve, 81h018. 5 1. External heat 2. High Pressure in Reactor 3. Line plugged 4. Valve closed 5, Valve leaking through 6, Filter Plugged 7, Relief Valve failure S/E 4 C 5 1. Fire Protection System S/E 4 C 5 2. Operating procedures 3. Operator training 1. External heat S/E 4 C 5 1. Line insulation S/E 4 C 5 2. Operating procedures S/E 4 C 5 3. Operator training 1. Cold weather S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Check valve 1. High Pressure in Reactor 5 2. DCS interlock - valve 81 hi 45 will 2. Operator error 5 open if RX pressure < 120 psig 3. Power failure 5 and all other reactor flush 4. Pump failure 5 header valves are closed. 5. Valve failure 3. DCS interlock - valve 81 hvl 38. 6. Valve leaking through Won't open unless RX in dump and all other RX rinse valves closed 4. Fire Protection System 5. Fixed point monitor 6. general monitor 7. Operator training 8. Personal Protective Equipment 430 ABDOD037402 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 411. Old module stripper rinse header Type: Line Design Conditions/Parameters: Pipe spec A13-2 Old Module Hazop Drawing: OM-090137-PID-D Georgia Gulf Corp Dev Consequences 411.1 High Pressure 1. Line rupture 2. Personal exposure 411.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 411.3 Low Temperature 1. Frozen Line 2. Line rupture 3. Personal exposure CAT s L RR Safeguards Causes 4C S/E 4 C 5 1. Personal Protective Equipment 5 1. Line blocked in with external heat (thermal expansion) S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operator training 5. Personal Protective Equipment 6. Valve indication 1. Operator error 2. Pump failure 3. Valve closed S/E 4 C 5 1. Line insulation S/E 4 C 5 S 4C 5 1. Cold weather 431 ABD00037403 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 412. Rinse Pump, PP-547 Type: Centrifugal Pump Design Conditions/Parameters: 510 GPM @ 190 ft Old Module Hazop | Drawing: OM-090137-PID-D Georgia Gulf Corp Dev Consequences 412.1 High Pressure 1. Gasket failure 2. Seal failure 412.2 High Temperature 1. Gasket failure 2. Seal failure CAT S L RR Safeguards Causes S/E 4 C S/E 4 C 5 1. Operating procedures 5 2. Operator training 3. Pressure indication - 81P856 4. Recirculation line 1. Line plugged 2. Operator error 3. Valve closed S/E 4 C 5 1. Operating procedures S/E 4 C 5 2. Operator training 1. External heat 2. Pump blocked in and running 432 ABD00037404 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 413. Centrate collection tank, TK-138 Type: Tank Design Conditions/Parameters: 15,000 Gal Old Module Hazop Drawing: DY-090119-PID-D Georgia Gulf Corp Dev Consequences 413.1 Reverse/Misdirected Flow 1. Personal exposure CAT S L RR Safeguards S/E 4 C 5 1. Maintenance & operating procedures Causes 1. Operator error 433 ABD00037405 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 414. Caustic addition line to Centrate pumps, PP-546/545 Type: Line Drawing: DY-090119-PID-D Design Conditions/Parameters: Pipe spec A2-23 Georgia Gulf Corp Dev Consequences 414.1 High Pressure 1. Gasket failure 2. Line rupture 3. Personal exposure 414.2 Low Temperature 1. Gasket failure 2. Line rupture 3. Personal exposure 4. Frozen Line CAT S L RR Safeguards Causes S/E 4 C S/E 4 C S 4C 5 1. Operating procedures 5 2. Operator training 5 3. Personal Protective Equipment 4. Pressure Gauge 5. relief valve 6. Caustic pump and supply tote located In diked area 1. Line plugged 2. Operator error 3. Valve closed 4. Line blocked in with external heat {thermal expansion) S/E 1. Caustic pump and supply tote 1. Cold weather S/E located in diked area 2. Heat tracing failure S/E 2. Operating procedures S/E 3. Operator training 4. Personal Protective Equipment 5. Pressure Gauge 6. relief valve 7. Heat tracing 8. Line insulation 434 ABD00037407 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 416. Sodium Hypochlorite addition line to centrate pump suction. Type: Line Drawing: DY-090119-PID-D Design Conditions/Parameters: Pipe spec Q41-1 Georgia Gulf Corp Dev Consequences 416.1 High Pressure 1. Line rupture 2. Personal exposure 416.2 Low Temperature 1. Frozen Line 2. Gasket failure 3. Line rupture 4. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S 4C 5 1. Operating procedures 5 2. Operator training 3. Personal Protective Equipment 4. Pressure Gauge 1. Line blocked in with external heat (thermal expansion) 2. Operator error S/E 4 C S/E 4 C S/E 4 C S 4C 5 1. Operating procedures 5 2. Operator training 5 3. Personal Protective Equipment 5 4. Pressure Gauge 1. Cold weather 436 ABD00037406 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 415. Chlorine/Water solution addition line to centrate pump suction. Type: Line Drawing. DY-090119-PID-D Design Conditions/Parameters: Pipe spec Q41-1 Georgia Gulf Corp Dev Consequences 415.1 High Pressure 1. Line rupture 2. Personal exposure 415.2 Low Temperature 1. Frozen Line 2. Gasket failure 3. Line rupture 4. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S 4c 5 1. Operating procedures 5 2. Operator training 3. Personal Protective Equipment 4. Pressure Gauge 1. Line blocked in with external heat (thermal expansion) 2. Operator error S/E 4 c S/E 4 c S/E 4 c S 4c 5 1. Operating procedures 5 2. Operator training 5 3. Personal Protective Equipment 5 4. Pressure Gauge 1. Cold weather 435 ABD00037408 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 417. Centrate pump, PP-545/546, including suction & discharge line. Type: Centrifugal Pump + Line Drawing: DY-090119-PID-D Design Conditions/Parameters: Capacity 950 GPM @ 222 ft Georgia Gulf Corp Dev Consequences 417.1 High Pressure 1. Gasket failure 2. Seal failure 417.2 High Temperature 1. Gasket failure 2. Seal failure CAT S L RR Safeguards S/E 4 C S/E 4 C 5 1. Operating procedures 5 2. Operator training 3. Recirculation line S/E 4 c 5 1. Operating procedures S/E 4 c 5 2. Operator training Causes 1. Line plugged 2. Operator error 3. Valve closed 1. External heat 2. Pump blocked in and running 437 ABD00037409 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 418. MSPW line to centrate pump mechanical seals and TK-138 level transmitter impulse line Type: Line Drawing: DY-090119-PID-D Design Conditions/Parameters: Pipe spec A13-2 Georgia Gulf Corp Dev Consequences 418.1 Low/No Flow 1. Seal failure CAT S L RR Safeguards S/E 4 C 5 1. Operating procedures 2. Operator training 3. Flow meter 4. Heat tracing 5. Line insulation Causes 1. Line plugged 2. Operator error 3. Valve closed 438 ABD00037410 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 419. Centrate flocculating tank, DM-001 Type: Vessel Drawing: DY-090119-PID-D Design Conditions/Parameters: 1000 Gal, MAWP: 150 psig @ 200 F Georgia Gulf Corp Dev Consequences 419.1 High Pressure 1. Gasket failure 2. Lift relief valve 3. Personal exposure 4. Vessel rupture 419.2 Start-up/Shutdown Hazards 1. Personal exposure CAT s L RR Safeguards Causes S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Operating procedures 5 2. Operator training 5 3. Personal Protective Equipment 5 4. relief valve 1. Vessel blocked in with external heat (thermal expansion) 2. Line plugged 3. Relief Valve failure 4. Valve closed S 4 C 5 1. Maintenance & operating procedures 1. Operator error 439 ABD00037411 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 420. Inerts line from plant RVCM receivers Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: DY-090133-PID-D Georgia Gulf Corp Dev Consequences 420.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 420.2 High Temperature 1. Fire and explosion 2. Line rupture 3 Personal exposure 4 VCM Leak CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Control Valve failure S/E 4 C 5 2. Fixed point monitor 2. Instrument failure S/E 4 C S 4c S/E 4 c S/E 4 c 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 7. High pressure switch - 81P739, 6. Valve failure 84P103 8. Flow indication - 84F102 S/E 3 D S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat 2. Heat tracing failure 440 ABD00037412 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 421. Inerts supply line from plant. Bypasses flow control Type: Line Drawing. DY-090133-PID-D Design Conditions/Parameters: Pipe spec A2-22 Georgia Gulf Corp Dev Consequences 421.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 421.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D 5 1. Chiller unit cooling knockback S/E 4 C 5 condensers S 4 C 5 2. Fire Protection System S/E 4 C 5 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 1. Chiller unit not working 2. External heat 3. Heat tracing failure 441 ABD00037413 VIII.0. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 422. Liquid flame arrester Type: Vessel Drawing: DY-090133-PID-D Design Conditions/Parameters: MAWP: 150 psig @ 200 F Georgia Gulf Corp Dev Consequences 422.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. VCM Leak 5. VCM release 422.2 High Temperature 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 422.3 Start-up/Shutdown Hazards 1. Fire and explosion 2. Personal exposure 3. VCM release 422.4 High Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure 422.5 Low Level 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. Personal exposure CAT S L I RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 7. relief valve 8. DCS interlock valve 84H104 will close on high pressure in flame arrester 9. Pressure indicator - 84P105 1. Control Valve failure 2. External heat 3. High Level 4. Instrument failure 5. Operator error 6. Relief Valve failure 7. Flash back from incinerator S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 C 5 4. Personal Protective Equipment 5. relief valve 1. External heat 2. Flash back from incinerator S/E 3 D S 4C S/E 3 D 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Personal Protective Equipment 1. Operator error 2. Valve leaking through S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Operator training 6. Personal Protective Equipment 7. sight glass 8. Level Transmitter 28, High level switch 28 1. Instrument failure 2. Operator error 3. Valve failure 4. Valve leaking through S/E 3 D S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 1. Instrument failure 2. Operator error S/E 4 C 5 3. general monitor 3. Valve failure S/E 4 c 5 4. Level Transmitter 28, Low level 4. Valve leaking through switch 28 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. sight glass 442 ABD00037414 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node. 423. Flame arrester outlet to incinerator Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: DY-090133-PID-D Georgia Gulf Corp Dev Consequences 423.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 423.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4 VCM Leak 423.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture' 3. Personal exposure 4. VCM Leak 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat S/E 3 D S/E 4 C S 4C S/E 4 c S/E 3 D 5 1. DCS interlock valves to 1. Instrument failure 5 incinerator will open if incinerator 2. Operator error 5 is selected, incinerator has run 3. Incinerator not in operation 5 permissive, incinerator 5 temperature is > 1800 F, pressure on flame arrestor tank is < 15 psig, and fuel gas hi fire permissive is met 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Triple valves for isolating flame arrestor from incinerator 443 ABD00037415 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 424. Flame arrester vent to atmosphere Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: DY-090133-PID-D Georgia Gulf Corp Dev Consequences 424.1 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 424.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor S 4 c 5 4. Operating procedures 5. Personal Protective Equipment 1. Line blocked in with external heat (thermal expansion) S/E 1. Fire Protection System 1. Instrument failure S/E 2. Fixed point monitor 2. Line blocked in with external S/E 3. general monitor heat (thermal expansion) S/E 4. Operating procedures 3. Operator error S/E 5. Personal Protective Equipment 4. Valve failure 444 ABD00037416 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 425. Eythelene Glycol supply to flame arrester. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Drawing: DY-090133-PID-D Georgia Gulf Corp Dev Consequences 425.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. Valve leaking 6. VCM Leak 425.2 Reverse/Misdirected Flow 1. Fire and explosion 2. Gasket failure 3. Lift relief valve 4. VCM Leak 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 5 6. Pressure Gauge 7. Pressure indicator - 84P105 1. Nitrogen pressure regulator failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Operator error S/E 3 D 5 1. Fire Protection System 1. Check valve failure S/E 4 C 5 2. Fixed point monitor 2. Operator error S/E 4 C 5 3. general monitor 3. Nitrogen pressure regulator S/E 4 c 5 4. Level Transmitter 28, Low level failure S/E 3 D 5 switch 28 4. Valve failure 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. sight glass 9. Check valve 10. relief valve 445 ABD00037417 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 426. Steam supply to incinerator combustion chamber Type: Line Drawing: DY-090135-PID-D Design Conditions/Parameters: Pipe spec A2-3 Georgia Gulf Corp Dev Consequences 426.1 Low/No Flow 1. Fire and explosion 2. Personal exposure 3. VCM release 4. Melt down incinerator CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S/E 4 C 5 1. Safety Interlock - Incinerator will 1. Instrument failure 5 not run without sufficient steam 2. Line plugged 5 pressure, and incinerator has 3. Low steam pressure 5 high temperature alarm. 4. Operator error 2. Fire Protection System 5. Valve closed 3. Fixed point monitor 4. general monitor 5. Operator training 6. Personal Protective Equipment 446 ABD00037418 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 427. Inert line to incinerator from flame arrester. Type: Line Design Conditions/Parameters: Pipe spec A2-22 Old Module Hazop Georgia Gulf Corp Drawings: DY-090133-PID-D, DY-090135-PID-D Dev Consequences 427.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 5. VCM Leak 427.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 427.3 Reverse/Misdirected Flow 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 5. VCM release CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5 5. Personal Protective Equipment 6. Pressure Gauge 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 1. External heat S/E 3 D S/E 4 C S 4C S/E 4 C S/E 3 D 5 1. DCS interlock - valves to 1. Incinerator not in operation 5 incinerator will open if incinerator 2. Instrument failure 5 is selected, incinerator has run 3. Operator error 5 permissive, incinerator 5 temperature is > 1800 F, pressure on flame arrestor tank is < 15 psig, and fuel gas hi fire permissive is met. 2. Fire Protection System 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Triple valves for isolating flame arrestor from incinerator 447 ABD00037419 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 428. Fuel supply to incinerator combustion chamber Type: Line Drawing: DY-090135-PID-D Design Conditions/Parameters: Pipe spec A2-1 Georgia Gulf Corp Dev Consequences 428.1 Low/No Flow 1. Fire and explosion 2. Personal exposure 3. VCM Leak 4. Shutdown incinerator 428.2 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 428.3 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Flow indication - FIT 4B 5 2. Fire Protection System 5 3. Fixed point monitor 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Valve indication 9. Safety Interlock - Low pressure switch t. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed S/E 3 D S/E 4 C S/E 4 C S 4c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure regulator 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D S/E 4 c S 4c S/E 4 c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Temperature gauge 7. Flame arrestors 1. External heat 448 ABD00037420 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 429. Fuel line to incinerator pilot Type: Line Design Conditions/Parameters: Pipe spec A2-1 Old Module Hazop Drawing: DY-090135-PID-D Georgia Gulf Corp Dev Consequences 429.1 High Pressure 1. Fire and explosion 2. Gasket failure 3. Line rupture 4. Personal exposure 429.2 High Temperature 1. Fire and explosion 2. Line rupture 3. Personal exposure 4. VCM Leak 429.3 Low/No Flow 1. Fire and explosion 2. Personal exposure 3. Shutdown incinerator 4. VCM Leak CAT S L RR Safeguards Causes S/E 3 D S/E 4 C S/E 4 C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 5 4. Operating procedures 5. Personal Protective Equipment 6. Pressure Gauge 7. Pressure regulator 1. Control Valve failure 2. Instrument failure 3. Line blocked in with external heat (thermal expansion) 4. Line plugged 5. Operator error 6. Valve failure S/E 3 D 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor S 4 C 5 3. Flame arrestors S/E 4 C 5 4. general monitor 5. Operating procedures 6. Personal Protective Equipment 7. Temperature gauge 1. External heat S/E 3 D S 4C S/E 4 C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. Flow indication - FIT 4B 5 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 8. Safety Interlock - Low pressure switch 9. Valve indication 1. Instrument failure 2. Line plugged 3. Operator error 4. Valve closed 449 ABD00037421 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 430. Combustion air to incinerator Type: Line Design Conditions/Parameters: Old Module Hazop Drawing: DY-090135-PID-D Georgia Gulf Corp Dev Consequences 430.1 Low/No Flow 1. Fire and explosion 2. Personal exposure 3. Shutdown incinerator 4. VCM Leak 5. Melt down incinerator CAT S L RR Safeguards Causes S/E 1. Safety interlock Fuel & inerts 1. Instrument failure S supply is cut off if blower is not 2. Line plugged S/E running. 3. Operator error S/E 2. Fire Protection System 4. Valve closed S/E 3. Fixed point monitor 4. general monitor 5. Operating procedures 6. Operator training 7. Personal Protective Equipment 450 ABD00037422 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 431. Combustion air to incinerator pilot Type: Line Design Conditions/Parameters: Old Module Hazop Drawing: DY-090135-PID-D Dev Consequences 431.1 Low/No Flow 1. No consequence CAT S L RR Safeguards Georgia Gulf Corp Causes 451 ABD00037423 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 432. Purge air to incinerator combustion chamber. Type: Line Drawing: DY-090135-PID-D Design Conditions/Parameters: Dev Consequences 432.1 Low/No Flow 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 452 ABD00037424 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 433. Process "Quench" water to incinerator Quench Chamber. Type: Line Drawing: DY-090135-PID-D Design Conditions/Parameters: Pipe spec A13-1 Georgia Gulf Corp Dev Consequences 433.1 Low/No Flow 1. Fire and explosion 2. Personal exposure 3. Shutdown incinerator 4. VCM Leak 5. Melt down incinerator CAT S L RR Safeguards Causes S/E 1. Fire Protection System 1. Instrument failure S 2. Fixed point monitor 2. Line plugged S/E 3. general monitor 3. Operator error S/E 4. Heat tracing 4. Valve closed S/E 5. Line insulation 5. Cold weather 6. Pressure Gauge 7. Flow indication - FIT 6B 8. Safety interlock - shuts incinerator down on loss of water flow 453 ABD00037425 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 434. Inerts incinerator Type: Furnace Heater Design Conditions/Parameters: Old Module Hazop Drawing: DY-090135-PID-D Georgia Gulf Corp Dev Consequences 434.1 High Temperature 1. Fire and explosion 2. Melt down incinerator 3. Personal exposure 4. Shutdown incinerator 5. VCM Leak 434.2 High Residual VCM 1. Fire and explosion 2. Personal exposure CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Instrument failure S/E 4 C 5 2. Fixed point monitor 2. Operator error S 4 C 5 3. general monitor 3. Blower failure S/E 4 C 5 4. Operating procedures 4. No water flow S/E 4 C 5 5. Operator training 5. No steam flow 6. Personal Protective Equipment 7. Safety interlock - Fuel & inerts supply is cut off if blower is not running, no steam flow, no water flow, or operator run permissive been given. 8. Temperature indication - 84T143, 84T144 9. High temperature alarm - TAH 5/ 6B 10. Temperature indication - 84T145 S/E 3 D S 4C 5 1. Gas chromatograph 1. High inerts flow 5 2. Fuel gas pressure switch- PSL 3 2. Improper air mixture 3. Steam pressure switch - PSL 5 3. Inaccurate temperature 4. Inerts flow indicator controller - indication 84F102 5. Redundant temperature indicators - 84T143, 84T144 6. Fire Protection System 7. Fixed point monitor 8. general monitor 9. Operating procedures 10. Operator training 11. Personal Protective Equipment 454 ABD00037426 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 435. 1. Notify lead operator tank will be taken out of service. Type: Procedural Step Drawing: proc. VINYL-RM-SD003 Design Conditions/Parameters: Dev Consequences 435.1 No execution of step 1. No consequences CAT S L RR Safeguards Georgia Gulf Corp Causes 455 ABD00037427 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 436. 2. Isolate hot water make-ups to tank. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD003 Georgia Gulf Corp Dev Consequences 436.1 No execution of step 1. Personal injury CAT S L RR Safeguards S 4 C 5 1. Operating procedures 2. Operator training 3. Level indication - 81LI006 4. Drain valve Causes 1. Operator error 2. Valve leaking through 456 ABD00037428 VIIID Hazards Identified - P&ID/Operating Procedures Review Node: 437. 3. Empty charge water tank Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD003 Georgia Gulf Corp Dev Consequences 437.1 No execution of step 1. Personal injury CAT S L RR Safeguards S 4 C 5 1. Drain valve 2 Level indication - 81U006 3. Operating procedures 4. Operator training Causes 1. Operator error 2. Valve leaking through 457 ABD00037429 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 438. 4. Totally isolate tank. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SDQ03 Georgia Gulf Corp Dev Consequences 438.1 No execution of step 1. Personal injury CAT S L RR Safeguards S 4 C 5 1. Drain valve 2. Level indication - 81LI006 3. Operating procedures 4. Operator training Causes 1. Operator error 2. Valve leaking through 458 ABD00037430 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 439. Steps 5 thru 12 Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD003 Georgia Gulf Corp Dev Consequences 439.1 No execution of step 1 Personal injury 2. Personal exposure CAT s L RR Safeguards Causes S 4 C 5 1. Direct reading portable 1. Operator error S 4C 5 instruments 2. Maintenance & operating procedures 3. Personal Protective Equipment 4. Safety control permits 459 ABD00037431 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 440. 13. Prepare tank for service Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD003 Georgia Gulf Corp Dev Consequences 440.1 No execution of step 1. Personal exposure 2 Personal injury CAT S L RR Safeguards Causes S/E 4 C S/E 4 C 5 1. Maintenance & operating 5 procedures 2 Personal Protective Equipment 3. Safety control permits 1. Operator error 2. Valve leaking through 460 ABD00037432 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 441. 14-15. Put tank in service/check for leaks. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD003 Georgia Gulf Corp Dev Consequences 441.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Safety control permits 3. Radio communication Causes 1. Operator error 2. Gasket failure 3. Equipment failure 461 ABD00037433 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 442. 1. Cold water flush using back flush method. Type: Procedural Step Drawing: proc. VINYL-RM-SD004 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 442.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4C S/E 4 C 5 1. Maintenance & operating 1. Equipment failure 5 procedures 2. Gasket failure 2. Radio communication 3. Operator error 3. Safety control permits 4. Temperature indication 81T027 / 82T027 462 ABD00037434 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 443. 2. Cold water flush using fast rinse cycle method Type: Procedural Step Drawing: proc. VINYL-RM-SD004 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 443.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Maintenance & operating 1. Equipment failure S 4C 5 procedures 2. Gasket failure 2. Radio communication 3. Operator error 3. Safety control permits 4. Temperature indication 81T027 / 82T027 463 ABD00037435 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 444. 3. Isolate Decal Tank Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD004 Georgia Gulf Corp Dev Consequences 444.1 No execution of step 1. Personal exposure 2. Personal injury 1 SCAT L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Radio communication 3. Safety control permits Causes 1. Equipment failure 2. Gasket failure 3. Operator error 464 ABD00037436 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 445. 4. Drain Decal Tank Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD004 Georgia Gulf Corp Dev Consequences 445.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Radio communication 3. Safety control permits Causes 1. Equipment failure 2. Gasket failure 3. Operator error 465 ABD00037437 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node. 446. steps 5 thru 8 Type: Positive Displacement Pump Design Conditions/Parameters. Old Module Hazop Drawing: proc. VINYL-RM-SD004 Georgia Gulf Corp Dev Consequences 446.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Radio communication 3. Safety control permits Causes 1. Equipment failure 2. Gasket failure 3. Operator error 466 ABD00037438 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 447. 9. Fill decal tank for pressure check Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD004 Georgia Gulf Corp Dev Consequences 447.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Radio communication 3. Safety control permits Causes 1. Equipment failure 2. Gasket failure 3. Operator error 467 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 448. 10. Pressure check decal tank Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-SD004 Georgia Gulf Corp Dev Consequences 448.1 No execution of step 1. Personal exposure 2. Personal injury 3. Lift relief valve CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures S/E 4 c 5 2. Radio communication 3. Safety control permits 4. Pressure Gauge 5. relief valve Causes 1. Equipment failure 2. Gasket failure 3. Operator error 4. Instrument failure 468 r ABD00037440 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 449. Operation of Module Emergency Shutdown Switch Type: Procedural Step Drawing: proc. VINYL-RM-ESD006 Design Conditions/Parameters: Review of procedure as a whole Georgia Gulf Corp Dev Consequences 449.1 No execution of step 1. Personal exposure 2. Personal injury 3. Fire and explosion 4. VCM release CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures S/E 3 D 5 2. Radio communication S/E 3 D 5 3. Safety control permits 4. Fire Protection System 5. Fixed point monitor 6. general monitor Causes 1. Equipment failure 2. Gasket failure 3. Operator error 469 ABD00037441 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 450. 1-2. Notification Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-EOOI Georgia Gulf Corp Dev Consequences 450.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Plant alarm system Causes 1. Equipment failure 2. Operator error 470 ABD00037442 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 451. 3-4. Activate Fire Suppression (deluge) Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-EOOI Georgia Gulf Corp Dev Consequences 451.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Maintenance & operating S 4C 5 procedures 2. Plant alarm system 3. Fire Protection System 4. Fixed point monitor 5. general monitor Causes 1. Equipment failure 2. Operator error 471 ABD00037443 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 452. 5. Lead operator will choose empty reactor and evacuate. Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 452.1 No execution of step 1. Personal exposure 2. Personal injury CAT s L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 472 ABD00037444 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 453. 6. The lead operator will put pressure on charge water header. Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 453.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 473 ABD00037445 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 454. 7. Put leaking reactor and evacuated reactor in "manual". Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 454.1 No execution of step 1. Personal exposure 2. Personal injury CAT s L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 474 ABD00037446 VIII D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 455. 8*9. Open charge dump valve on involved reactors. Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 455.1 No execution of step 1. Personal exposure 2. Personal injury 3. Line rupture CAT s L RR Safeguards S 4 C 5 1. Fire Protection System S 4 c 5 2. Fixed point monitor s 4 c 5 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 475 ABD00037447 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 456. 10. Lead operator put cooling water on evacuated reactor Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 456.1 No execution of step 1 Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 476 ABD00037448 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 457. 11. Close charge/dump valves. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-EOOI Georgia Gulf Corp Dev Consequences 457.1 No execution of step 1. Personal exposure 2. Personal injury CAT s L RR Safeguards I S 4 C 5 1. Fire Protection System s 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 477 ABD00037449 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 458. 12. The lead operator will flush the charge water lines. Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 458.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S/E 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 478 ABD00037450 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 459. 13-14. Put leaking reactor into auto recovery/ sound all clear Type: Procedural Step Drawing: proc. VINYL-OM-EOOI Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 459.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 479 ABD00037451 VIII.D Hazards Identified - P&ID/Operating Procedures Review Node: 460. Hazards/Discussion Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev Consequences 460.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 c 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 480 ABD00037452 VIII.D. Hazards Identified - P&ID/Operatmg Procedures Review Node: 461. 1-2. Plant notification Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev Consequences 461.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 481 ABD00037453 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 462. 3-4. Activate Deluge/Fire Monitor Type: Procedural Step Drawing: proc. VINYL-OM-E002 i Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 462.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 482 ABD00037454 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 463. 5. Stop agitator and recover (if applicable) Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev Consequences 463.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 483 ABD00037455 VIII.D Hazards Identified - P&ID/Operating Procedures Review Node: 464. 6-8. Prepare to split reactor Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev Consequences 464.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 484 ABD00037456 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 465. 9. Split reactor Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev Consequences 465.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 485 ABD00037457 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 466. 10. Recover split batch reactors Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev Consequences 466.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S/E 4 c 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 486 ABD00037458 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 467. 11. Sound all clear Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E002 Georgia Gulf Corp Dev j Consequences 467.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. Equipment failure 2. Operator error 487 ABD00037459 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 468. Discussion/Hazards Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-E003 Georgia Gulf Corp Dev Consequences 468.1 No execution of step 1. Personal exposure 2. Personal injury CAT s L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 c 5 2. Fixed point monitor 2. Operator error 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system 6. Emergency Power System (UPS & Generator) 488 ABD00037460 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 469. 1. Bump reactor. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-E003 Georgia Gulf Corp Dev Consequences 469.1 No execution of step 1. Personal exposure 2. Personal injury 3. Fire and explosion CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 3 D 5 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system 6. Reactor emergency & manual kill system 7. AMS common header 1. Equipment failure 2. Operator error 3. Line plugged 489 ABD00037461 VIII.D. Hazards Identified P&ID/Operatmg Procedures Review Node: 470. 2. Emergency cooling water Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYI-RM-E003 Georgia Gulf Corp Dev Consequences 470.1 No execution of step 1. Personal exposure 2. Personal injury 3. Fire and explosion CAT S L RR Safeguards Causes S 4C S 4C S/E 3 D 5 1. AMS common header 5 2. Fire Protection System 5 3. Fixed point monitor 4. general monitor 5. Maintenance & operating procedures 6. Plant alarm system 7. Reactor emergency & manual kill system 8. Emergency cooling water system 1. Equipment failure 2. Operator error 490 ABD00037462 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 471. 3. Control reactor pressure. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-E003 Georgia Gulf Corp Dev Consequences 471.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. AMS common header S 4 C 5 2. Fire Protection System S 4 c 5 3. Fixed point monitor 4. general monitor 5. Maintenance & operating procedures 6. Plant alarm system 7. Reactor emergency & manual kill system 1. Equipment failure 2. Operator error 3. High Pressure in Reactor 4. Power failure 491 ABD00037463 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 472. 4. Seal oil units and reactor seals Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-E003 Georgia Gulf Corp Dev Consequences 472.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Operator error S 4 C 5 3. general monitor 3. Power failure 4. Maintenance & operating procedures 5. Plant alarm system 6. Pressure gauge and transmitter 492 i VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 473. 5. Close manual steam stripping valve. Type: Procedural Step Design Conditions/Parameters: ABD00037464 Old Module Hazop Drawing: proc. VINYL-RM-E003 Georgia Gulf Corp Dev Consequences 473.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury 4. Reverse flow CAT S L RR Safeguards S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor S/E 4 C 5 4. Maintenance & operating procedures 5. Plant alarm system 6. Check valve Causes 1. Equipment failure 2. Operator error 3. Low steam pressure 4. Power failure 493 ABD00037465 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 474. 6. Close lip seal water valve on each reactor. Type: Procedural Step Drawing: proc. VINYL-RM-E003 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 474.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S/E 4 C 5 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system 6. Check valve Causes 1. High Pressure in Reactor 2. Power failure 494 ABD00037466 VIIID Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 475. 7. Close spray head flush water valve to each reactor. Type: Procedural Step Drawing: proc. VINYL-RM-E003 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 475.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards S/E 3 D 5 1. Check valve S 4 C 5 2. Fire Protection System S 4 c 5 3. Fixed point monitor 4. general monitor 5. Maintenance & operating procedures 6. Plant alarm system Causes 1. High Pressure in Reactor 2. Power failure 495 ABD00037467 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 476. 8. Isolate catalyst pot on each reactor. Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-RM-E003 Georgia Gulf Corp Dev Consequences 476.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards S/E 3 D S 4C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system 6. Check valve Causes 1. High Pressure in Reactor 2. Power failure 496 ABD00037468 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 477. 9-18. Isolate mechanical seals on VCM containing equipment Type: Procedural Step Drawing: proc. VINYL-RM-E003 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 477.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system Causes 1. High Pressure in Reactor 2. No high pressure service water available. 497 ABD00037469 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 479. Operation of automatic shutdown/isolation system Type: Procedural Step Drawing: proc. VINYL-RM-E004 Design Conditions/Parameters: 1 -3. Description of valve/equipment affected, no operator involvement except for operator activation of the system. Dev Consequences 479.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C s 4C 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 4. Maintenance & operating procedures 5. Plant alarm system 6. Spring return fail close valves 1. Fire in unit 2. Major VCM Leak or Release 3. Loss of instrument air 498 ABD00037470 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 480. Operation of the Halos System in the Vinyl Control Room Type: Procedural Step Drawing: proc. VINYL-OM-E006 Design Conditions/Parameters: Description of valve/equipment affected, no operator involvement except for operator activation of the system. Dev Consequences 480.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury 4. DCS equipment damage CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C S/E 4 C 5 1. Maintenance & operating 5 procedures 5 2. Personal Protective Equipment 5 3. Plant alarm system 1. Fire in control room 499 ABD00037471 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 481. Operation of the Emergency Generator for the Vinyl Control Room. Type: Procedural Step Drawing: proc. VINYL-OM-E007 Design Conditions/Parameters: Discussion of Operation. Georgia Gulf Corp Dev Consequences 481.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury 4. VCM release CAT S L RR Safeguards Causes S/E 3 D S 4C s 4c S/E 4 c 5 1. Fire Protection System 5 2. Operating procedures 5 3. Operator training 5 4. Personal Protective Equipment 5. Plant alarm system 6. Back-up emergency power 1. Operator error 2. Power failure 500 ABD00037472 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Node: 482. Discussion/Hazards Type: Procedural Step Design Conditions/Parameters: Old Module Hazop Drawing: proc. VINYL-OM-E008 Georgia Gulf Corp Dev Consequences 482.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 1. AMS common header 1. Equipment failure S 2. Emergency cooling water 2. Operator error S system 3. Fire Protection System 4. Fixed point monitor 5. general monitor 6. Maintenance & operating procedures 7. Plant alarm system 8. Reactor emergency & manual kill system 9. Bypass valve for emergency cooling water 10. Deluge water can be used for back-up cooling water 11. DCS interlock - Deluge water is diverted to reactors during a power failure 501 ABD00037473 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 483. 1-3. Opening emergency cooling water valve. Type: Procedural Step Drawing: proc. VINYL-OM-E008 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 483.1 No execution of step Fire and explosion Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 1. AMS common header 1. Equipment failure S 2. Bypass valve for emergency 2. Operator error S cooling water 3. DCS interlock - Deluge water is diverted to reactors during a power failure 4. Deluge water can be used for back-up cooling water 5. Emergency cooling water system 6. Fire Protection System 7. Fixed point monitor 8. general monitor 9. Maintenance & operating procedures 10. Plant alarm system 11. Reactor emergency & manual kill system 502 ABD00037474 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 484. 4. Lead operator will determine whether or not a reactor needs more cooling water. Type: Procedural Step Drawing: proc. VINYL-OM-E008 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 484.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. AMS common header 5 2. Bypass valve for emergency 5 cooling water 3. DCS interlock Deluge water is diverted to reactors during a power failure 4. Deluge water can be used for back-up cooling water 5. Emergency cooling water system 6. Fire Protection System 7. Fixed point monitor 8. general monitor 9. Maintenance & operating procedures 10. Plant alarm system 11. Reactor emergency & manual kill system 1. Equipment failure 2. Operator error 503 ABD00037475 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 485. 5. Put emergency cooling water on a bumped/killed reactor. Type: Procedural Step Drawing: proc. VINYL-OM-E008 Design Conditions/Parameters: Georgia Gulf Corp Dev Consequences 485.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 1. AMS common header 1. Equipment failure S 2. Bypass valve for emergency 2. Operator error S cooling water 3. DCS interlock - Deluge water is diverted to reactors during a power failure 4. Deluge water can be used for back-up cooling water 5. Emergency cooling water system 6. Fire Protection System 7. Fixed point monitor 8. general monitor 9. Maintenance & operating procedures 10. Plant alarm system 11. Reactor emergency & manual kill system 504 ABD00037476 VIII D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 486. Discussion and steps & 2. Type: Procedural Step Drawing: proc. VINYL-RM-E009 Design Conditions/Parameters: Operation of Reactor Agitator On/Off/Auto Switch Georgia Gulf Corp Dev Consequences 486.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. AMS common header 5 2. Bypass valve for emergency 5 cooling water 3. DCS interlock Deluge water is diverted to reactors during a power failure 4. Deluge water can be used for back-up cooling water 5. Emergency cooling water system 6. Fire Protection System 7. Fixed point monitor 8. general monitor 9. Maintenance & operating procedures 10. Plant alarm system 11. Reactor emergency & manual kill system 12. Manual agitator switch 1. Equipment failure 2. Operator error 3. Power failure 505 ABD00037477 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 487. Discussion and step 1 (notification of entry) Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 487.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Operator error S 4 C 5 3. general monitor 3. Instrument failure 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 506 ABD00037478 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 488. 2. Flush process water into BWS & strip Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 488.1 No execution of step Fire and explosion Personal exposure Personal injury CAT S L RR Safeguards Causes S/E 1. Fire Protection System 1. Equipment failure S 2. Operating procedures 2. Operator error S 3. Operator training 4. Personal Protective Equipment 5. Plant alarm system 6. Pressure, temperature, and level instrumentation 507 ABD00037479 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 489. 3. Isolate batch water stripper Type: Procedural Step Drawing, proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 489.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 508 ABD00037480 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 490. 4. Close the following manual valves. Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 490.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 509 ABD00037481 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 491. 5. analyze BWS water sample. Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 491.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 510 ABD00037482 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 492. 6-8. Notify maintenance and follow permit and lockout/tag out procedures. Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 492.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 511 ABD00037483 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 493. 9. Blind/disconnect following lines. Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 493.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C s 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 512 ABD00037484 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 494. 10-11. Remove manway and purge BWS. Type. Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 494 1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 513 ABD00037485 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 495. 12. Check for leaks Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 495.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S/E 4 C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 514 ABD00037486 VIII.D. Hazards Identified - P&ID/Operatmg Procedures Review Old Module Hazop Node: 496. 13-14. Set up BWS for Service & place in Auto-fill. Type: Procedural Step Drawing: proc. VINYL-OM-SDOOI Design Conditions/Parameters: Prepare a batch water stripper for entry Georgia Gulf Corp Dev Consequences 496.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor S 4 c 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5 Pressure, temperature, and level instrumentation 515 ABD00037487 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 497. Discussion/Hazards Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 497.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 516 ABD00037488 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 498. 1-2. Notify lead operator and shutdown ERS. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters.' Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 498.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 517 ABD00037489 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 499. 3. Isolate pumps and compressors Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 499.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 518 ABD00037490 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 500. 4. Isolate and recover pressure from ERS. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 500.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 519 ABD00037491 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 501. 5. Isolate and drain cooling water. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 501.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 520 ABD00037492 VIII.D. Hazards Identified P&ID/Operatmg Procedures Review Old Module Hazop Node: 502. 6. Steam condenser Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 502.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 521 ABD00037493 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 503. 7-8. Follow permitting and lockout/tag out procedures. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 503.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s l RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 522 ABD00037494 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 504. 9. Setup for tube cleaning Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 504.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 523 ABD00037495 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 505. 10. Setup for jacket acid cleaning. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 505.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 524 ABD00037496 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 506. 11. After maintenance, Setup cooling water lines and check for leaks. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev j Consequences 506.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C s 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 525 ABD00037497 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 507. 12. Setup condenser lines and check for leaks. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 507.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 526 ABD00037498 VIU.D. Hazards Identified - P&ID/Operatmg Procedures Review Old Module Hazop Node: 508. 13-14. Start-up ERS and notify lead operator that the ERS is back in service. Type: Procedural Step Drawing: proc. VINYL-OM-SD002 Design Conditions/Parameters: Prepare VCM Condenser for Cleaning Tubes/Acid Treating Jacket. Georgia Gulf Corp Dev Consequences 508.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 527 ABD00037499 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 509. Hazards/Discussion Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 509.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 528 ABD00037500 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 510. 1. Setting up recovery system for pressure checking Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 510.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 529 ABD00037501 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 511.2. Add water to recovery system for pressure check. Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 511.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 530 ABD00037502 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 512. 3. Pressure check recovery system. Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 512.1 No execution of step 1 Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 1. Fire Protection System 1. Equipment failure S 2. Fixed point monitor 2. Instrument failure S 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 531 ABD00037503 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 513. 4. Isolate vacuum pumps. Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 513.1 No execution of step 1. Fire and explosion 2 Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C s 4c 5 1. Fire Protection System 5 2. Fixed point monitor 5 3. general monitor 1. Equipment failure 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 532 ABD00037504 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 514. 5. Start water addition to seal water separators. Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 514.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C s 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 533 ABD00037505 VIII.D. Hazards Identified - P&ID/Operatmg Procedures Review Old Module Hazop Node: 515. 6. Draining water from recovery system Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 515.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 534 ABD00037506 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 516. 7. Putting recovery system in service. Type: Procedural Step Drawing: proc. VINYL-OM-NSU002 Design Conditions/Parameters: How to Pressure Check Entire Recovery System and Put Back In Service. Georgia Gulf Corp Dev Consequences 516.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 535 ABD00037507 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 517. Hazards/Discussion Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 517.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S/E 4 C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 536 ABD00037508 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 518. 1-6. Clear and recovery one recovered receiver and all five reactors Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: .Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 518.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 537 ABD00037509 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 519. 7. Evacuate and charge last reactor with one extra gallon of catalyst. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 519.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 538 ABD00037510 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 520. 8. Isolating hot water make-up system Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 520.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 C 4 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor S 4 c 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 539 ABD00037511 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 521.9. Flush FVCM receiver fill line with HPSW. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 521.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 540 ABD00037512 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 522. 10. Fill, isolate, recover, and steam strip receiver to meet receiver opening requirements. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 522.1 No execution of step 1 Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 1. Equipment failure 2. Instrument failure S 4 C 5 3. general monitor 3 Operator error 4. Maintenance & operating procedures 5 Pressure, temperature, and level instrumentation 541 ABD00037513 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 523. 11. Cleaning vcm charge header. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 523.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 542 ABD00037514 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 524. 12. Kill and recover final reactor. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 524.1 No execution of step 1 Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 543 ABD00037515 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 525. 13. Flushing R-300/400/500/600 VCM valves and header into R-700. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 525.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 544 ABD00037516 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 526. 14. When recovering fresh receiver and vcm charge header the following equipment will be recovered. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 526.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 545 ABD00037517 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 527. 15. Recovering VCM charge header, pumps, filter packs, fresh receiver, fresh receiver fill line, and vcm charge valve on R-700. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Dev Consequences 527.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4c 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 546 ABD00037518 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 528. 16. Evacuate and add 5000 gal of hot water to R-300/400/500/600 and then recover. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 528.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 c 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 547 ABD00037519 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 529. 17. Recover between VCM valves on R-300. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 529.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 1. Equipment failure 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 548 ABD00037520 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 530. 18. Recover and steam strip R-300, R-400, R-500, R-600 reactors. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 530.1 No execution of step 1 Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 549 ABD00037521 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 531. 19-20. Dump reactors and notify "A" that reactors are dumping. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 531.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S/E 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 550 ABD00037522 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 532. 21. Evacuate and steam R-300/400/500/600/700 reactor. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 532.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4c 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 551 ABD00037523 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 533. 22. Switch east incinerator to process water. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 533.1 No execution of step 1. Fire and explosion 2. Personal exposure 3 Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 552 ABD00037524 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 534. 23. Set up walk-in catalyst freezers on process water. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Dev Consequences 534.1 No execution of step 1. No consequence CAT S L RR Safeguards Georgia Gulf Corp Causes 553 ABD00037525 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 535. 24. Shutdown 4a 4b cooling tower fans and pumps. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 535.1 No execution of step 1. Shutdown emission system CAT S L RR Safeguards Causes S/E 4 C 5 1. Fire Protection System 1. Equipment failure 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 554 ABD00037526 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 536. 25. Flooding, recovering, and steaming the fresh VCM receiver. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 536.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 555 ABD00037527 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 537. 26. Recover and steam FVCM receiver fill line. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 537.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 556 i ABD00037528 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 538. 27. Recover FVCM filter packs and remove elements. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 538.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 557 ABD00037529 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 539. 28. Recover RVCM filter pack and remove elements. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 539.1 No execution of step 1. Fire and explosion 2 Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3 Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 558 ABD00037530 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 540. 29. Switching inerts venting from old module to new. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 540.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 559 ABD00037531 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 541.30. Clearing old module recovery system of VCM. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 541.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3 Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 560 ABD00037532 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 542. 31. Blinding old module recovery system. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 542.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 561 ABD00037533 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 543. 32. Drain the hot water charge tank. Type: Procedural Step Drawing, proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 543.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 562 ABD00037534 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 544. 33. Blind the hot water tank for entry. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 544.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 563 ABD00037535 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 545. 34. Verify all reactor agitators are off. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 545.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 564 ABD00037536 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Georgia Gulf Corp Node: 546. 35-36. Open reactor lenape lids and move all drummed raw materials to the new module drum storage area. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Dev Consequences 546.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 565 ABD00037537 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 547. 37. Open the following filter packs and remove the used filters and put in the dumpster. Type: Procedural Step Drawing: proc. VINYL-OM-SD005 Design Conditions/Parameters: Schedule Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 547.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 566 ABD00037538 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 548. Hazards/Discussion Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 548.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor S 4 C 5 3. general monitor 1. Equipment failure 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 567 ABD00037539 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 549. 1. Put hot water charge system in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 549.1 No execution of step 1. Personal exposure 2. Personal injury CAT s L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 568 ABD00037540 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 550. 2. Install filters, button up, and put the following filters packs in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 550.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 569 ABD00037541 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 551. 3. Hydo test and dump reactors. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 551.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 570 ABD00037542 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 552. 4. Put RVCM receivers in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 552.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 571 ABD00037543 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 553. 5. Put fresh vcm receiver in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 553.1 No execution of step 1. Fire and explosion 2 Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 572 ABD00037544 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 554. 6. Put recovery system in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Consequences 554.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 573 ABD00037545 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 555. 7. Put normal kill system in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 555.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4c 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 574 ABD00037546 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 556. 8. Put emergency AMS pots in service. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 556.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 575 ABI)'0tJtW7547 't~t VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 557. 9. Start-up 4a and 4b cooling tower pumps and fans. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 557.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 576 ABD00037548 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 558. 10. Setup walk-in catalyst storage freezers on cooling tower water. Type: Procedural Step Drawing: proc. VINVL-OM-SUOOI Design Conditions/Parameters How to Start-up after Scheduled Shutdown/Turnaround Dev Consequences CAT S L RR 558.1 No execution of step 1. No consequence, step no longer valid Safeguards Georgia Gulf Corp Causes 577 ABD00037549 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 559. 11. Switch east incinerator to cooling water. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 559.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 578 ABD00037550 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 560. 12. Check cooling water flow on each reactor. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 560.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 579 ABD00037551 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 561. 13. False charge reactors to check following equipment. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 561.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 5 2. Fixed point monitor 1. Equipment failure 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 580 ABD00037552 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 562. 14. Verify reactor setup. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 562.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 581 ABD00037553 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 563. 15. Fill and flush additive lines. Type: Procedural Step Drawing, proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 563.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System S 4 C 5 2. Fixed point monitor 1. Equipment failure 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 582 ABD00037554 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 564.16. False charge reactor. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 564.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 583 ABD00037555 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 565. 17. Add 5000 gal hot water to each reactor. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 565.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4 Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 584 ABD00037556 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 566. 18. Recovery and steam stripping false charges. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 566.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 585 ABD00037557 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 567. 19. Dumping false charges. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 567.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 c 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 586 ABD00037558 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 568. 20. Sampling dumping of false charge for residual vcm. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 568.1 No execution of step Fire and explosion Personal exposure Personal injury CAT S L RR Safeguards Causes S/E 1. Fire Protection System 1. Equipment failure S 2 Fixed point monitor 2. Instrument failure S 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 587 ABD00037559 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 569. 21. Rinsing reactor after false charge. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 569.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury 1 sCAT L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 588 ABD00037560 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 570. 22. Clean wall reactor after dump/rinse is complete. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 570.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 589 ABD00037561 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 571.23. Evacuating a reactor before charging. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 571.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 590 ABD00037562 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 572. 24. Charging reactor. Type: Procedural Step Drawing: proc. VINYL-OM-SUOOI Design Conditions/Parameters: How to Start-up after Scheduled Shutdown/Turnaround Georgia Gulf Corp Dev Consequences 572.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 591 ABD00037563 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 573. Discussion/Hazards Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 573.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 592 ABD00037564 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 574. 1.-3. Set up HPSW/MSPW pumps. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 574.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 593 ABD00037565 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 575. 4. Lead Operator will close emergency cooling water valves. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 575.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fixed point monitor 1. Equipment failure S 4 C 5 2. Maintenance & operating 2. Instrument failure procedures 3. Operator error 3. Pressure, temperature, and level instrumentation 594 ABD00037566 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 576. 5. Start cooling water pumps Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 576.1 No execution of step 1. Personal exposure 2. Personal injury CAT s L RR Safeguards Causes S 4 C 5 t. Fixed point monitor 1. Equipment failure S 4 C 5 2. Maintenance & operating 2. Instrument failure procedures 3. Operator error 3 Pressure, temperature, and level instrumentation 595 ABD00037567 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 577. 6. Start cooling tower fans. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 577.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 c 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 596 ABD00037568 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 578. 7. Check duraseal units and reactor seals. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 578.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 597 ABD00037569 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 579. 8. Put lip seal flush to reactor seals Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 579.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level Instrumentation 598 ABD00037570 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 580. 9. Start reactor agitators Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 580.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 599 ABD00037571 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 581. 10. Set up seal water on ERS and LRS vacuum pumps and compressors. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 581.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 600 ABD00037572 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 582. 11. Set up seal water to LRS recirculation pumps Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 582.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 601 ABD00037573 VIII.D Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 583. 12. Set up seal water to LRS ring seal water pumps Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 583.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 602 ABD00037574 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 584. 13. Set up seal water to return (collect) pumps. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 584.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 603 ABD00037575 VIII.D. Hazards Identified P&ID/Operating Procedures Review Old Module Hazop Node: 585. 14. Lead operator will start LRS when notified by field operators. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 585.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 604 ABD00037576 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 586. 15. Set up seal water to ERS ring seal water pumps. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 586.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards | Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 605 ABD00037577 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 587. 16. Start-up ERS Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 587.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 606 ABD00037578 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 588. 17. Set up seal water to fresh vcm charge pumps. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 588.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 607 ABD00037579 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 589. 18. Set up seal water to RVCM charge pumps Type: Procedural Step Drawing: proc. VINVL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 589.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 608 ABD00037580 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 590. 19. Line up steam stripping valve to reactors Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 590.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fixed point monitor 1. Equipment failure S 4 C 5 2. Maintenance & operating 2. Instrument failure procedures 3. Operator error 3. Pressure, temperature, and level instrumentation 609 ABD00037581 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 591. 20. Set up steam supply to BWS Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 591.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fixed point monitor 1. Equipment failure S 4 C 5 2. Maintenance & operating 2. Instrument failure procedures 3. Operator error 3. Pressure, temperature, and level instrumentation 610 ABD00037582 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 592. 21. Refill AMS pot. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 592.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 611 ABD00037583 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 593. 22. Check Nitrogen bottles pressure. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 593.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 612 ABD00037584 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 594. 23. Check catalyst day freezers Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 594.1 No execution of step 1. Fire and explosion 2 Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 613 ABD00037585 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 595. 24. Start normal kill agent pump Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 595.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Maintenance & operating 1. Equipment failure S 4C 5 procedures 2. Instrument failure 2. Pressure, temperature, and level 3. Operator error instrumentation 614 ABD00037586 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 596. 25. Check calcium stearate tank agitator. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Dev Consequences 596.1 No execution of step 1. No consequence, wet stearate not used. CAT S L RR Safeguards Georgia Gulf Corp Causes 615 ABD00037587 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 597. 26. Check frick unit Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 597.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 616 ABD00037588 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 598. 27. Check general monitors Type: Procedural Step Drawing: proc. VtNYl-OM-ESUOOl Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 598.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor S 4 c 5 3. Maintenance & operating 2. Instrument failure 3. Operator error procedures 4. Pressure, temperature, and level instrumentation 617 ABD00037589 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 599. 28. Check deluge system. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 599.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 618 ABD00037590 VIIID Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 600. 29. Check fixed point monitors Type: Procedural Step Drawing: proc VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 600.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Persona! injury CAT s L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 619 ABD00037591 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 601. 30. Check centrate system Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 601.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 620 ABD00037592 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 602. 31. Check emergency cooling water valve bottled air pressure. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 602.1 No execution of step 1. Personal exposure 2. Personal injury CAT S L RR Safeguards Causes S 4 C 5 1 Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 621 ABD00037593 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node'603 32. Reset fire water pumps Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 603.1 No execution of step Fire and explosion Personal exposure Personal injury CAT S L RR Safeguards Causes S/E 1. Fire Protection System 1. Equipment failure S 2. Fixed point monitor 2. Instrument failure S 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 622 ABD00037594 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 604. 33. Check pressurization blowers Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 604.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2 Fixed point monitor s 4 C 5 3. general monitor 2. Instrument failure 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 623 ABD00037595 VIIID. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 605. 34. Inject isonox into "normal batch" reactors. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Oesign Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 605.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 624 ABD00037596 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 606. 35. Recover reactor as normal batch Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 606.1 No execution of step 1. Condenser plugged 2. High pressure 3. High temperature CAT S L RR Safeguards Causes S/E 4 C S 4C S/E 4 C 5 1. Fire Protection System 5 2. Fixed point monitor 1. Equipment failure 2. instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 625 ABD00037597 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 607. 36. Split the reactor batch Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 607.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 626 ABD00037598 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 608. 37. Cold recover reactor. Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 608.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 627 ABD00037599 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 609. 38. Re-initiate reactors Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 609.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT s L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1. Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure s 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 628 ABD00037600 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 610. 39. Recover re-initiated reactors Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 610.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D S 4C S 4C 5 1. Fire Protection System 1. Equipment failure 5 2. Fixed point monitor 2. Instrument failure 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 629 ABD00037601 VIII.D. Hazards Identified - P&ID/Operating Procedures Review Old Module Hazop Node: 611.40. Dump power failure batches Type: Procedural Step Drawing: proc. VINYL-OM-ESUOOI Design Conditions/Parameters: Start-up of Old Module After an Emergency Shutdown. Georgia Gulf Corp Dev Consequences 611.1 No execution of step 1. Fire and explosion 2. Personal exposure 3. Personal injury CAT S L RR Safeguards Causes S/E 3 D 5 1. Fire Protection System 1 Equipment failure S 4 C 5 2. Fixed point monitor 2. Instrument failure S 4 C 5 3. general monitor 3. Operator error 4. Maintenance & operating procedures 5. Pressure, temperature, and level instrumentation 630 LIST OF recommendation;* ABD00037603 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP IX. LIST OF RECOMMENDATIONS A. Preliminary Hazard Review 1. PM the deluge system and fixed point monitors more frequently. 2. Identify crane outrigger placement points to avoid sewers. 3. Investigate centralizing deluge valves for unit in one building. 4. Perform a survey to determine if all equipment needing individual fire protection has individual fire protection. B. Human Factors Review 1. Add sections on operator checklists to report piping/conduit needing to be demoed, poor lighting conditions, and poorly labeled pipe/instruments/equipment. 2. Survey local controls to determine if they can and/or should to put on the DCS. 3. Recover dump polishing strainers using ERS system. C. Past Incidents Review No recommendations 631 ABD00037604 IX D List of Recommendations P&ID/ Operating Procedures Review Old Module Hazop Georgia Gulf Corp Recommendations Related Drawings 1. Investigate whether emergency isolation switch gives charge system adequate protection OM-090100-PID-D if valve in this line is open. (See: 9.4) 2. Investigate whether recirculation valve,81xv709, should be interlocked with RVCM & FVCM charge pumps. Valve may need to open before pumps start. (See: 16.1) OM-090100-PID-D 3. Investigate need to interlock valve, 81 hv020, closed on low steam header pressure. (See: 19.2) OM-090101-PID-D 4. Investigate the need for check valve in rinse header flush line. (See: 47.1) 5. Investigate whether BME charge pot drain valve,81H443 & 81H543, should be interlocked not to open if BME charge valves are open. (See: 69.4) OM-090102-PID-D, OM-090103-PID-D, OM090104-PID-D, OM-090105-PID-D, OM090106-PID-D OM-090107-PID-D 6. Investigate possible KO tank DM-027 overpressure if runaway reactor (@ pressure > 150 OM-090108-PID-D psig) is vented to knockout tank. (See: 84.1) 7. Investigate need to house actuated valve solenoids in protected boxes. (See: 84.1) 8. Investigate poly flow tubing use for air line service in hazardous locations (See: 84.1) 9. Investigate relief valve setting and rupture disk rating on vacuum pump VP-501,502settings don't match (See: 103.1) OM-090108-PID-D OM-090108-PI D-D OM-090109-PID-D 10. Investigate the need for relief valves on shell and tube sides of exchanger (See: 124.1) OM-090110-PID-D 11. Investigate feasibility of relocating RVCM condensers to improve maintenance access OM-090111-PID-D ability. (See: 147A.4) 12. Investigate need for system modifications due to the cooler MAWP of 75 psig and OM-090114-PID-D normal seal water pressure of > 100 psig, and coolers have no relief valve. (See: 222.1) 13. Evaluate need for relief valves for thermal expansion on flush line to stripper outlet between valve 91H642 and valves, 91H942, 91H858, 91H664, and 91H631. (See: 350. D OM-090132-PID-D 14. Evaluate need for interlock to prevent valves 91H645 and 91H657 from opening without OM-090132-PID-D rinse pump running. (See: 355.1) 15. Evaluate need for relief valve for thermal expansion between valves 91H630, 91H657, and 91H645. (See: 354.2) OM-090132-PID-D 16. Evaluate need for interlock to prevent valves 91H630 and 91H657 from opening without OM-090132-PID-D rinse pump running. (See: 354.1) 17. Evaluate need for relief valve for thermal expansion between valves 91H641, and 91H652. (See: 356.1) OM-090132-PID-D 18. Evaluate need for relief valve for thermal expansion between double block valves on rinse line to dump strainers (See: 375.2) OM-090134-PID-D 19. Review and update, if necessary, procedure Vinyl-RM-ESD006 and verify that procedure write-up matches DCS programming. (See: 449.1) proc. VINYL-RM-ESD006 20. Review and update, if necessary, the portion of procedure Vinyl-RM-ESD006 pertaining to what rinse valves close on reactor. (No Linked Items) 21. Review and update step #4 of procedure Vinyl-OM-EOOl to include Old Module fire monitor locations. (See: 451.1) proc. VINYL-OM-E001 22. Evaluate the need to developed procedure to dump leaking reactor to dump tank if empty reactor is not available. (See: 452.1) proc. VINYL-OM-E001 632 ABD00037605 IX D. List of Recommendations P&ID/ Operating Procedures Review Old Module Hazop Georgia Gulf Corp Recommendations Related Drawings 23. Review and update step #6 of procedure Vinyl -OM-EOOI to include old module valve proc. VINYL-OM-EOOI references and pump references that now have new module references only. (See: 453. D 24. Evaluate need to include capability to split reactors using closed dump line to split reactors instead of charge water header in procedure Vinyl-OM-EOOl A/inyl-OMESU001. (See: 453.1,607.1) proc. VINYL-OM-EOOI, proc. VINYL-OMESU001 25. Update step #12 of procedure Vinyl-OM-EOOl to include references to Old Module Equipment where as now only new module equipment is referenced. (See: 458.1) proc. VINYL-OM-EOOI 26. Evaluate the need for fixed point monitors to be on emergency power so leak monitoring can continue during power failure. (See: 468.1) proc. VINYL-RM-E003 27. Review step #2 of procedure Vinyl-OM-SDOOI. Batch water stripper fill and equalization proc. VINYL-OM-SDOOI valves may need to be isolated to prevent having to restart procedure if opened. (See: 488.1) 28. Review step#11 of procedure Vinyl-OM-SDOOI. Should batch water stripper be purged proc. VINYL-OM-SDOOI and pressure checked with steam at 20 psig. (See: 494.1) 29. Review step #12 of procedure Vinyl-OM-SDOOI. Verify accuracy of described step. (See: 495.1) proc. VINYL-OM-SDOOI 30. Review step #2 of procedure Vinyl-OM-SD002. If exchanger can be or should be bypassed to keep ERS running while cleaning exchanger, then steps to do so should be added to procedure. (No Linked Items) 31. Review procedure Vinyl-OM-SD002 for proper shutdown and start-up of ERS. (See: 508.1) proc. VINYL-OM-SD002 32. Review and update procedure Vinyl-OM-SD005 for accuracy. Procedure does not cover proc. VINYL-OM-SD005 EXPRESS installed equipment. Include procedure # for all reference procedures. (See: 517.1) 33. Evaluate revising all normal, shutdown, and start-up procedures (where applicable) to permit using hot water for clearing equipment instead of steam. (See: 517.1) proc. VINYL-OM-SD005 34. Review and update procedure, Vinyl-OM-SUOOl for accuracy. Include procedure # for referenced normal procedures and include start-up of any applicable EXPRESS installed equipment. (See: 548.1) proc. VINYL-OM-SUOOI 35. Review and update procedure Vinyl-OM-ESUOOl for accuracy. Include start-up procedures for all applicable EXPRESS installed equipment. (See: 573.1) proc. VINYL-OM-ESUOOI 633 ABD00037606 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP List of Items Needing Further Review No items were identified requiring further review. 634 ABD00037607 APPENDIX B ABD00037608 All Employees Interoffice Communication From: Date: Subject: Kelly Wood March 6, 2000 Employee Participation in the Old Module Hazop Study To comply with OSHA regulations, Georgia Gulf Corporation must perform a hazard analysis on all its existing processes covered under OSHA's PSM standard. Due to the size and complexity of the process unit being considered, Hazop has been chosen to fulfill the process hazard analysis requirement. Soon a Hazop team will begin analysis of the plant's Old Module. Hazop methodology also requires employee participation. To comply with the employee participation portion, the following team has been assembled to conduct the Old Module Hazop. Shea Sargent Craig English A vinyl operations member An instrument technician A maintenance member Kelly Wood To further promote employee participation and to hopefully perform the most thorough Hazop analysis possible, the team is asking you to contact one of the team members if you know of any operability, safety, or environmental issues regarding the project or area you feel needs addressing. Meetings will be held in the plant's Training Conference Room. Meeting times will be 7:45 AM 11:30 AM and 12:30 PM - 4:00 PM daily beginning Wednesday, March 15, 2000. The meetings will continue until the Hazop is completed on or about Wednesday, March 29, 2000. Posting Date Removal Date 3 "<5^ ABD00037609 APPENDIX C ABD00037610 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP Appendix C. HAZOP Pre-Work Material List Process Safety Information Per OSHA CFR 1910.199 (d) I. Hazards Of The Highly Hazardous Chemicals In The Process Item Toxicity Permissible Exposure Limits Physical Data Reactivity Data Corrosivity Data Thermal & Chemical stability Data Hazardous Effects of Inadvertent Mixing Where Found DMS-ABER-Safety-MSDS/Vendor DMS-ABER-Safety-MSDS/Vendor DMS-ABER-Safety-MSDS/Vendor DMS-ABER-Safety-MSDS/Vendor DMS-ABER-Safety-MSDS/Vendor DMS-ABER-Safety-MSDS/Vendor DMS-ABER-Process-Unit Information II. Information On Technology of Process Item PFDs Maximum Intended Inventory Process Chemistry Safe Upper/Lower Limits For Critical Parameters Evaluation of Consequence of Deviation Where Found DMS-ABER-Process-Flow Diagrams DMS-ABER-Process-Unit Information DMS-ABER-Process-Unit Information DMS-ABER-OM-Procedures/Process Operation/Normal DMS-ABER-OM-Procedures/Process Operation/Normal 111. Information on Equipment In Process Item Materials of Construction P&IDs Electrical Classification Relief System Design & Design Basis Ventilation System Design Design Codes/Standards Material & Energy Balances Safety Systems Where Found Equipment Files/DMS DMS-ABER-OM-Engineering Drawings DMS-ABER-OM-Engineering Drawings DMS-ABER-Safety/Environmental/Relief Devises. Not Applicable K: Eng Std DMS-ABER-Process-Unit Information DMS-ABER-Eng.Dwgs-Piping-Firewater Plans/Details ABD00037611 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP Other Information Used Chemical Interaction Matrix for VCM Where Found DMS-ABER-Process-Unit Information Documentation of previous incidents that had a likely potential for catastrophic consequences in the Utilities area. Safety Dept. Files Documentation of previous relevant safety audits that addressed the potential for catastrophic consequences in the Utilities area. PSM File Room Facility Siting Information. Dow Fire & Explosion Index DMS-ABER-PSM Compliance/Facility Siting Operating Procedures P&IDs DMS-ABER-OM-Procedures/Process Operations/Normal DMS-ABER-Engineering Drawings List of Miscellaneous Alarm Points List of DCS Safety Interlocks DMS-ABER-Engineering Drawings DCS Control System Condea Vista Company Corporate Safety & Health Standards, Process Hazard Analysis, PSM-004 DMS-Procedures-PSM Compliance-PHAPSM-004 Plant Plot Plan, GP-F005-42-2-1, DTD. 8/18/82 DMS-ABER-Engineering Drawings PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 721151 721146 701319 721147 701320 722521 781153 701503 722532 Equipment Description PP-020 PUMP: AMS KILL OM PP-107 PUMP: N BWS TRANSFER OM PP-107 MOTOR: 20 HP 3515 RPM FR 256T PP-108 PUMP: S BWS TRANSFER OM PP-108 MOTOR: 20 HP 3515 RPM FR 256-T CP-108 COMPRESSOR: E ERS OM PSV-CP-108 RV: E ERS COMPRESSOR OM CP-108 MOTOR: 100 HP 1780 RPM FR 405-T VP-703 VAC PUMP: W ERS OM ABD00037612 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 700933 781166 722533 700932 781182 720993 722549 720567 700567 720568 700568 720209 700421 510002 720038 701005 721009 701645 721149 701350 721150 701351 721298 702145 721087 700676 721088 700036 721086 700047 491026 701054 720874 700042 721152 701186 721153 Equipment Description VP-703 MOTOR: 40 HP 1180 RPM FR 364-TS PSV-VP-703 RV: WEST ERS VAC PMP OM VP-704 VAC PUMP: E ERS OM VP-704 MOTOR: 40 HP 1180 RPM FR 364-TS PSV-VP-704 RV: E ERS VACUUM PUMP CP-107 COMPRESSOR: W ERS OM CP-109 COMPRESSOR: ERS OM PP-708 PUMP: N SEAL WATER ERS OM PP-708 MOTOR: 40 HP 3540 RPM FR 324-TS PP-707 PUMP: S SEAL WATER ERS OM PP-707 MOTOR: 40 HP 3540 RPM FR 324-TS PP-112 PUMP: ERS KO DRUM WATER PP-112 MOTOR: 7.5 HP 3500 RPM FR 215 TK-313 AGITATOR: BRINE MAKE-UP OM PP-481 PUMP: BRINE SOLUTION TRANSFER OM PP-481 MOTOR: 2 HP 1730 RPM FR 145T PP-483 PUMP: BRINE TANK TRANSFER OM PP-483 MOTOR: 50 HP 3540 RPM FR326TP 212 PP-014 PUMP: E CAUSTIC STORAGE TANK PP-014 MOTOR: 3 HP PP-015 PUMP: W CAUSTIC STORAGE TANK PP-015 MOTOR: 3 HP PP-547 PUMP: OM CENTRATE RECYCLE PP-547 MOTOR: 75 HP 1780 RPM FR 365T PP-230 PUMP: S HOT WATER CHARGE OM PP-230 MOTOR: 75 HP 3560 RPM FR 365-TS PP-231 PUMP: N HOT WATER CHARGE OM PP-231 MOTOR: 75 HP 3560 RPM FR 365TS PP-229 PUMP: RX RINSE WATER OM PP-229 MOTOR: 125 HP 3560 RPM FR 444TS FN-026 FAN: LM SWECO EXHAUST OM FN-026 MOTOR: PP-496 PUMP: E SLURRY DUMP OM PP-496 MOTOR: 30 HP 1770 RPM FR 286TS PP-801A PUMP: E LM SLURRY DUMP OM PP-801A MOTOR: 25 HP 885 RPM FR 326T 801B PUMP W LM SLURRY DUMP OM ABD00037613 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 701187 720033 701098 720034 700958 721021 701019 721239 700034 721243 701238 481000 701633 480001 720044 700044 781306 720800 700800 720011 700268 720010 720891 700041 721014 701341 720953 700953 781406 720954 700954 721089 780009 861021 701104 511137 861012 Equipment Description PP-801B MOTOR: 25 HP 885 RPM FR 326T PP-601 PUMP: RX-700 S SLURRY DUMP OM PP-601 MOTOR: 40 HP 1775 RPM FR 324T PP-602 PUMP: RX-700 N SLURRY DUMP OM PP-602 MOTOR: 40 HP 1775 RPM FR 324T PP-497 PUMP: W SLURRY DUMP OM PP-497 MOTOR: 30 HP 1760 RPM FR 286TS PP-500 PUMP: OM HM DUMP PP-500 MOTOR: 150 HP 1785 RPM FR B445T PP-504 PUMP: OM HM DUMP PP-504 MOTOR: 150 HP 1785 RPM FR B445T GR-601 SCREENER: SWECO VIBRATOR RX-700 GR-601 MOTOR: GR-001 SCREENER: DUMP SWECO OM PP-475W PUMP: WVCM CHARGE OM PP-475W MOTOR: 150 HP 3560 RPM FR 445TS PSV-PP-475 RV: E/W FVCM CHG PMP DISCHG PP-475E PUMP: E VCM CHARGE OM PP-475E MOTOR: 150 HP 3560 RPM FR 445TS PP-011 PUMP: W HPSW OM PP-011 MOTOR: 20 HP 3530 RPM FR 286U PP-010 PUMP: E HPSW OM PP-874 PUMP: S HPSW OM PP-874 MOTOR: 25 HP 3530 RPM FR 284TS PP-134 PUMP: N HPSWOM PP-134 MOTOR: 25 HP 3535 RPM FR 284-TS PP-953 PUMP: N MECH SEAL WATER OM PP-953 MOTOR: 15 HP 3540 RPM FR 254TDZ PSV-PP-953W RV: OU MECH.SEAL OIL PP-954 PUMP: S MECH SEAL WATER OM PP-954 MOTOR: 15 HP 3540 RPM FR 254TDZ PP-276 PUMP: NORMAL KILL SOL OLD MOD PSV-PP-276 RV: NORMAL KILL SOL PUMP OM PP-276 GBOX: NORMAL KILL PUMP OM PP-276 MOTOR: 5 HP 1160 RPM FR 215-T RX-300 AGITATOR: REACTOR OM RX-300 GBOX: SMALL RX AGITATOR ABD00037614 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 700331 510073 860074 700822 510075 861016 700185 510716 861022 700227 511000 860004 701007 722531 701010 781408 721200 700901 781407 720018 780301 700910 722527 780119 722517 700117 781258 722522 781299 700138 720430 700031 721007 701300 720268 701034 721160 Equipment Description RX-300 MOTOR: 200 HP 1780 RPM FR 447TS RX-400 AGITATOR: REACTOR OM RX-400 GBOX: RX AGITATOR RX-400 MOTOR: 200 HP 1800 RPM FR 447TS RX-500 AGITATOR: REACTOR OM RX-500 GBOX: SMALL RX AGITATOR RX-500 MOTOR: 200 HP 1760 RPM FR 449TS RX-600 AGITATOR: REACTOR OM RX-600 GBOX: SMALL RX AGITATOR RX-600 MOTOR: 200 HP 1785 RPM FR 449TS RX-700 AGITATOR: REACTOR OM RX-700 GBOX: RX AGITATOR RX-700 MOTOR: 350 HP 1786 RPM FR 5809-S VP-501 VAC PUMP: A OM VP-501 MOTOR; 75 HP 1175 RPM FR 405T PSV-VP-501 RV: RV ON OM "A" VACC.PUMP VP-502 VAC PUMP: B OM VP-502 MOTOR: 75 HP 1175 RPM 405T PSV-VP-502 RV: VP-502 OM "B" VAC PUMP CP-503 COMPRESSOR: A RECOVERY OM PSV-CP-503 RV: "A" RECOVERY COMPRESSOR CP-503 MOTOR: 150 HP 1780 RPM FR 445TS CP-504 COMPRESSOR: B RECOVERY OM PSV-CP-504 RV: "B" RECOVERY COMPRESSOR CP-506 COMPRESSOR: C RECOVERY OM CP-506 MOTOR: 150 HP 1785 RPM FR445TS PSV-CP-506 RV: OM RECOVERY "C" COMP CP-111 COMPRESSOR: D RECOVERY OM PSV-CP-111 RV: CP-111 RECCOMPOM CP-506 MOTOR: 150 HP 1785 RPM FR445TS PP-489 PUMP: S KO TANK OM PP-489 MOTOR: 7.5 HP 1740 RPM FR 213T PP-490 PUMP: N KO TANK OM PP-490 MOTOR: 20 HP PP-492 PUMP: N SEAL WTR OM PP-492 MOTOR: 7.5 HP 1745 RPM FR 213T PP-491 PUMP: S SEAL WATER OM ABD00037615 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 700028 721083 701638 721029 701642 800001 720001 700003 720003 700232 720878 780326 722504 781327 700237 720136 781251 720137 781252 512000 700000 511126 701257 511130 701258 721250 701284 721254 701294 722541 702182 722544 702185 450806 780295 450811 780296 Equipment Description PP-491 MOTOR: 7.5 HP 1740 RPM FR 213T PP-237 PUMP: HYDROQUINONE METERING OM PP-237 MOTOR: 0.25 HP 1725 RPM FR 56C PP-271 PUMP: RVCM CHILLED H20 OM PP-271 MOTOR: 5 HP 1745 RPM FR 184-T RF-002 CHILLER: OM INERTS REMOVAL PP-110 PUMP: E RVCM RETURN OM PP-110 MOTOR: 7.5 HP 3480 RPM FR 215 PP-111 PUMP: W RVCM RETURN OM PP-111 MOTOR: 7.5 HP 3480 RPM FR 213-T PP-477 PUMP: RVCM CHARGE OM PSV-PP-477 RV: RVCM CHARGE PUMP AT 45012 PP-058 PUMP: RECOVERED VCM CHARGE PSV-PP-058 RV: OM RVCM EAST PUMP ANDY H PP-058 MOTOR: 25 HP 1775 RPM FR 284T PP-279 PUMP: W OM SEAL OIL PSV-PP-279 RV: W OM SEAL OIL DISCHARGE PP-283 PUMP: E OM SEAL OIL PSV-PP-283 RV: E OM SEAL OIL PUMP DM-313 AGITATOR: CALC STEARATE DM-313 MOTOR: DM-075 AGITATOR: OM HM DUMP TK DM-075 MOTOR: 20 HP 1800 RPM FR 256T DM-079 AGITATOR: OM HM STRIPPER FEED TK DM-079 MOTOR: 3 HP 1200 RPM FR 213T PP-511 PUMP: OM HM STRIPPER FEED PP-511 MOTOR: 50 HP 1770 RPM FR 326T PP-515 PUMP: OM HM STRIPPER BOTTOMS PP-515 MOTOR: 50 HP 1770 RPM 326T STRIPPER PUMP MOTOR: 125 HP 1800 RPM FR 444T STRIPPER PUMP MOTOR: 125 HP 1800 RPM FR 444T DM-806 POT: EMERG AMS KILL RX-300 OM PSV-DM-806: RX- 300 KILL POT DM-811 POT: EMERG AMS KILL RX 400 OM PSV-DM-811: RX-400 EMERGENCY KILL POT ABD00037616 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 450808 780297 450809 780298 450780 780281 450310 781046 451030 450200 781049 450201 450801 780235 450802 780951 550002 550004 550311 550351 781011 550376 781283 640050 781109 640051 781108 641057 641058 450026 781290 450308 780269 450309 780255 890004 891104 Equipment Description DM-808 POT: EMERG AMS KILL RX-500 OM PSV-DM-808: RX-500 KILL POT DM-809 POT: EMERG AMS KILL RX 600 OM PSV-DM-809: RX-600 EMERGENCY KILL POT DM-780 POT: EMERG AMS KILL RX 700 OM PSV-DM-780 RV: D-700 EMERGENCY KILL POT DM-310 POT: BME CHARGE RX-600 OM PSV-DM-310 RV: RX-600 BME CHARGE POT DM-311 POT: BME METERING RX-600 DM-200 POT: BME CHARGE RX-700 OM PSV-DM-200 RV: RX-700 BME CHARGE POT DM-201 POT: BME METERING RX-700 DM-801 DRUM: S BATCH WATER STRIPPER OM PSV-DM-801 RV: S BATCH WATER STRIPPER DM-802 DRUM: N BATCH WATER STRIPPER OM PSV-DM-802 RV: N BATCH WATER STRIPPER EX-002 SUBCOOLER: N SEAL WTR ERS OM EX-004 SUBCOOLER: CNTR SEAL WTR OM EX-311 SUBCOOLER: S SEAL WTR ERS OM EX-351 SUBCOOLER: ERS PSV-EX-351 RV: ERS SUBCOOLER ON ROOF EX-376 EXCHANGER: OM ROOF REC SYS PSV-EX-376 RV: OM ERS CONDNESOR ON ROOF FL-050 FILTER: S ERS SEAL WATER PAK PSV-FL-050 RV: S. ERS SEAL WTR FL OM FL-051 FILTER: N ERS SEAL WATER PAK PSV-FL-051 RV: N. ERS SEAL WTR FL OM PP-112 STRAINER: EAT SUCTION PP-112 PP-112 STRAINER: WAT SUCTION PP-112 DM-701 DRUM: ERS KO OM PSV-DM-701 RV: 701 SEAL WATER TANK ERS DM-702 DRUM: N SEAL WATER HOLD ERS OM PSV-DM-702 RV: S. SEAL WTR HLD TK ERS OM DM-703 DRUM: S SEAL WATER HOLD ERS OM PSV-DM-703 RV: S.SEAL WATER TANK ERS TK-004 TANK: S BRINE SOLUTION TK OM TK-114 TANK: CAUSTIC SYS HOLD OM ABD00037617 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 890005 551008 640714 641005 781136 641053 781066 781418 641054 780306 641055 781242 641077 781006 890319 891023 451013 781014 640810 890601 890007 451097 781332 640008 781410 640009 780327 781102 450013 781285 640811 641063 641064 641065 781003 640004 450014 Equipment Description TK-471 TANK: OM CHILLED WATER -VCM RCVRS EX-114 HEATER: CHARGE WATER PIK OM FL-714 FILTER: PIK HTR CHARGE WATER OM FL-002 FILTER: DECAL TANK OUTLET OM PSV-FL-002 RV: DECALF RESIN POLISH FL OM FL-101 FILTER: HOT WATER CHARGE OM SPARE RV: OM MAIN CHARGE WATER FL-101 PSV-FL-101 RV: FL-101 OM CHG. WATER FL-102 FILTER: HOT WATER MAKE UP OM PSV-FL-102 RV: CENTRATE WATER FL OM FL-103 FILTER: RINSE WATR OM NEAR TK-023 PSV-FL-103 RV: OM RINSE WATER FL FL-379 FILTER: DECALCIFIED WATR INLET OM PSV-FL-379 RV: DECALCIFIED WATER FL OM TK-014 TANK: OM CENTRATE RECYCLE STORAGE TK-023 TANK: HOT WTR CHRG TK OM DM-130 DRUM: DECALCIFIED WATER OM PSV-DM-130 RV: DECALCIFIED WATER TANK OM FL-810 FILTER: LOW MOL SWCO PROCESS H20 TK-601 TANK: D-700 SLURRY DUMP TK-007 TANK: 001 SWECO DUMP OM DM-075 DRUM: OM HM DUMP TK PSV-DM-075 RV: RV ON DM-075 OM DUMP TK FL-008 FILTER: N FRESH VCM PAK OM PSV-FL-008 RV: RV ON OM VC FILTER FL-009 FILTER: S FRESH VCM PAK OM PSV-FL-009A RV: S FRESH VCM FILTER PAK PSV-FL-009B RV: S FRESH VCM FL PAK PIPE DM-013 RECEIVER: FRESH VCM OM PSV-DM-013 RV: OU FVCM REC FL-811 FILTER: HPSW PUMP DISCH OM FL-953 FILTER: MECH SEAL WATER OM FL-954 FILTER: MECH SEAL WATER OM FL-134 FILTER: HPSW PUMP SUCTION OM PSV-FL-004 RV: ERS HPSW FLTR UPSTAIRS OM FL-004 FILTER: ERS HPSW FILTER 2ND FL OM DM-014 DRUM: MECH SEAL WATER SURGE OM ABD00037618 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 640795 781063 640040 550321 551019 550356 550330 550329 641131 781243 450300 780095 780096 780312 780318 781133 450400 780089 780090 780230 780314 781039 450500 780001 780091 780094 780325 781171 450600 780087 780088 780225 780313 781040 450700 780282 780288 Equipment Description FL-395 FILTER: NORMAL KILL SOL OM PSV-FL-395 RV: NORMAL KILL FILTER FL-040 FILTER: POLIVIC CHARGE OM RX-500 CONDENSER: RX500 OM RX-600 CONDENSER: RX600 OM RX-700 CONDENSER: RX700 OM RX-300 CONDENSER: RX300 OM RX-400 CONDENSER: RX400 OM FL-130 FILTER: F50 TO RX600/ RX700 PSV-FL-130 RV: F50 FL-W OF RX-700 OM RX-300 REACTOR: VINYL OM PSV-RX-300C RV: RX-300 E RV: 8T10 @ 199 PSV-RX-300A RV: N SHELL RV 8T10 @ 199 PSV-RX-300D RV: RX-300 CONDENSER PSV-RX-300B RV: RX-300 SHELL RV PSV-RX-300J RV: RX-300 JACKET RX-400 REACTOR: VINYL OM PSV-RX-400B RV: W SHELL RV: 8 X 10 PSV-RX-400A RV: N SHELL RV: 8 X 10 PSV-RX-400C RV: E SHELL RV: 6 X 8 PSV-RX-400D RV: RELIEF VALVE: 6X8 PSV-RX-400J RV: D-400 REACTOR JCKT (OM) RX-500 REACTOR: VINYL OM PSV-RX-500C RV: SHELL OU SMALL RX'S PSV-RX-500B RV: OU RX SHELL 8T10-199 PSV-RX-500A RV: OU SMALL RX SHELL PSV-RX-500D RV: OU RX COND RV 6Q8 @ 185 PSV-RX-500J RV: 6Q8 RX JCKT RV RX-600 REACTOR: VINYL OM PSV-RX-600A RV: N RV: 8 X 10 PSV-RX-600B RV: W RV PSV-RX-600D RV: SM RX RV CONDENS PSV-RX-600 RV: E RELIEF VALVE: 6X8 PSV-RX-600J JCKT RV6 Q 8 : 45 PSIG RX-700 REACTOR: VINYL OM PSV-RX-700J RV: JACKET RELIEF VALVE: 3X4 PSV-RX-700F RV: N CONDENSER RELIEF VALVE ABD00037619 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 780289 780290 780291 780292 780293 780294 450065 450067 450066 450068 450778 550005 550006 550340 781411 641061 641062 781298 781301 780120 891008 890003 451100 781255 451101 781256 450027 781416 450028 450129 781041 451010 780133 550008 781284 550009 780329 Equipment Description PSV-RX-700D RV: shell PSV-RX-700B RV: #2 NOZZLE RELIEF VALVE PSV-RX-700E RV: #5 NOZZLE RELIEF VALVE PSV-RX-700A RV: #1 NOZZLE RELIEF VALVE PSV-RX-700G RV: SW CONDENSER RV PSV-RX-700C RV: #3 NOZZLE RV DM-065 POT: CATALYST CHARGE -RX 300 DM-067 POT: CATLYST CHARGE - RX400 DM-066 POT: CATLYST CHARGE - RX 500 DM-068 POT: CATALYST CHARGE -RX 600 DM-778 POT: CATALYST CHARGE-RX 700 EX-005 COOLER: TOP SEAL WATER OM EX-006 COOLER: BOTTOM SEAL WATER OM EX-340 COOLER: KO RECIRCULATION PSV-EX-340 RV: OM VC KO RECIRC COOLER FL-020E FILTER: E RING SEAL WTR :OM RECV FL-020W FILTER: W RING SEAL WTR FLTR OM PSV-FL-020W RV: SEAL WATER FL OM PSV-FL-020E RV: OM RING SEAL WATER PSV-PR-021 RV: REC PUMP RVCM RCVR EQUAL TK-127 TANK: HYDROQ MAKE UP TK OM TK-003 TANK: PVA CHARGE OM DM-017 DRUM: N SEAL H20 SEPARATOR OM PSV-DM-017 RV: S OM SEAL WTR SEPERATOR DM-018 DRUM: S SEAL H20 SEPARATOR OM PSV-DM-018 RV: N OM SEAL WTR SEPERATOR DM-027 DRUM: N KNOCK OUT OM PSV-DM-027 RV: OM NORTH KO POT DM-028 DRUM: S KNOCK OUT OM DM-129 DRUM: HYDROQUINONE STORAGE OM PSV-DM-129 RV: O.U. HYDROQUINONE DM TANK: OLD BPA CHARGE POT E OF RX700 PSV-DM-T2 RV: OLD BPA CHG POT E OF 700 EX-008 CONDENSER: S RVCM OM PSV-EX-008 RV: S RVCM CONDENSER OM EX-009 CONDENSER: N RVCM OM PSV-EX-009 RV: N RVCM CONDENSER OM ABD00037620 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number 550040 550041 550045 781211 781213 781291 640691 781308 781409 781077 450005 450011 780233 450012 780232 641034 641039 891025 890001 450063 450313 551086 781341 551089 641111 641112 641117 641118 641121 641122 641129 881000 781344 781345 452006 781336 452001 Equipment Description EX-124 CONDENSER: S RVCM RECEIVER OM EX-123 CONDENSER: N RVCM RECEIVER OM EX-129 SUBCOOLER: RVCM OM PSV-EX-128T RV: SUBCOOLER TUBE SIDE NM PSV-EX-129S RV: OM GSN RVCM SUBCOOLER PSV-EX-129T RV: RVCM O.M. SUBCOOLER FL-691 FILTER: RVCM PAK OM PSV-PR-007 RV: FRM FL691 TO PP475 OM PSV-FL-691 RV: FL-691 OM FVCM FILTER PSV-PR-020 RV: PIPING ABOVE FL-008&9 OM DM-005 RECEIVER: RVCM COLLECT OM DM-011 RECEIVER: N RVCM OM PSV-DM-011 RV: N RVCM RECEIVER OM DM-012 RECEIVER: S. RVCM OM PSV-DM-012 RV: OM S RVCM RECEIVER FL-113 FILTER: NRX SEAL OIL OM FL-116 FILTER: S RX SEAL OIL OM TK-472 TANK: OM EAST SEAL OIL RESERVOIR TK-473 TANK: OM W RX SEAL OIL RESERVOIR TK-063 DRUM: SEAL OIL OM DM-313 DRUM: CALCIUM STERATE HOLD OM EX-011 EXCHANGER: OM HM STRIPPER FEED PSV-EX-011 RV: OM HM SPIRAL FEED EX TW-002 CONDENSER: OM HM STRIPPING COLUMN FL-030 STRAINER: OM HIGH MOLE POLISH FL-031 STRAINER: OM HIGH MOLE POLISH FL-010 STRAINER: OM HIGH MOLE DUMP FL-011 STRAINER: OM HIGH MOLE DUMP FL-014 STRAINER: OM HIGH MOLE DUMP FL-015 STRAINER: OM HIGH MOLE DUMP FL-128 FILTER: OM HM STRIPPER FLUSH WTR TW-002 STRIPPER: OM HM STRIPPING COLUMN PSV-TW-002A RV: TW-002 OM HM STRIP COL PSV-TW-002B RV: TW-002 OM HM STRIPPER DM-084 POT: OM HM EMERG AMS KILL PSV-DM-084 RV: DM-084 OM HM Kill Pot DM-079 DRUM: OM HM STRIPPER FEED TK ABD00037621 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP PSM Covered Equipment Where Found: DMS-ABER-(Use Folder Search Equipment/Equipment No.) or Project File Equipment Number Equipment Description 781335 PSV-DM-079 RV: DM-079 OM HM FEED TANK ABD00037622 APPENDIX D ABD00037623 INCIDENTS AT CONDEA VISTA'S ABERDEEN PLANT 1. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker got something in his eye while opening bottom reactor manway. February 6, 1987 Insufficient eye protection One eye irritation Eye goggles must be work while opening reactor bottom manways. Herbert Jackson eye injury - March 23, 1987. 2. Incident: Date: Cause: Iniuries: Mitigation: Reference: Near-miss crane accident on 501 blend tank. May 28,1986. Lack of communication and planning. None. A Vista maintenance supervisor oversees all personnel lifting operations. Near-miss accident, 501 blend tank cleaning - June 26, 1986. 3. Incident: Date: Cause: Iniuries: Mitigation: Reference: Worker pinched the skin on his finger while repositioning the global drilling rig on Reactor 745. September 22, 1983. Inadequate procedure for safely setting up the drilling rig. One pinched skin on finger. 1) Install secondary lifting davit on reactor 700 and reactor 745; 2) Discuss incident with employees; and 3) Modify lighting for crane operator visibility. Accident investigation, William Moore, October 14, 1983. 4. Incident: Date: Cause: Iniuries: Mitigation: Reference: Catalyst bottles melted down while in a storage freezer. July 24, 1984. Improper freezer unkeep, freezer location in direct sunlight, and freezer abuse. None. Freezers were put underneath open-side awnings to get the freezers out of direct sunlight; new freezer maintenance procedure. l ABD00037624 5. Incident: Date: Cause: Injuries: Mitigation: Reference: An air hose connected to a jackhammer came loose and as it whipped around uncontrollably, hit a bystander in the knee. April 11,1983. Equipment failure. One bruised knee. Ban all non-locking Thor air fittings from the plant. Lander Keaton injury, April 22, 1983. 6. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker cut finger on rupture disk tag while opening a valve. July 6, 1991 Employee was not wearing gloves and all rupture disks tags have sharp edges. One cut finger 1) Check all safety disks to see if they can be arranged more safely; and 2) Wear gloves while working in the field. Accident investigation report #91-3. 7. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker was loading empty catalyst cardboard boxes in a dumpster. Instead of folding the empty boxes before disposal, the worker was throwing several unfolded boxes in at a time. While doing so, a box knocked his glasses off. In an attempt to catch the glasses, a box flap hit him in the eye cutting the lens. March 2, 1991 The worker was in a hurry to beat the rain. In addition, he did not want his glasses to hit the ground. One eye 1) Fold boxes before disposal; 2) Do not hurry doing a job; and 3) Inform employees and discuss accident. Accident investigation report #91-2. 8. Incident: Date: Cause: Injuries: Mitigation: Reference: Worker pinched a nerve in his back while working on a pump from a squatting position. July 3, 1989 Excessive pulling and straining while trying to loosen some bolts. One, pinched nerve in worker's back. 1) Pump couplings halves are to be sprayed with an anti-seize solution at all subsequent similar maintenance; and 2) if more than normal effort is required to do a job of this nature, the pump is to be pulled and taken to the shop. Herbert Jackson back injury - July 21,1989. 2 ABD00037625 9. Incident: Date: Cause: Injuries: Mitigation: Reference: Reactor 700 evacuation valve failed to close resulting in a VCM release. February 20, 1992 This particular type of actuator and valve stem connection was not properly assembled. The type in question has a recessed valve stem and a transition piece between the valve stem and actuator. None 1) Identify, check all valves of this type, eventually replacing them with valves without recessed stems and transition pieces during shutdowns and downtime; 2) Added an interlock to shut the reactor evacuation valve if more than 8 psig is seen on the reactor; and 3) Add pressure switches and interlocks on evacuation header to look for leaking valves. Investigation of reactor 700 evacuation valve malfunction. March 23, 1992. INCIDENTS AT OTHER CONPEA VISTA PLANTS: 1. Incident: Date: Cause: Injuries: Mitigation: Reference: A 695 lb. release occurred when a threaded pipe spool sheared off an unloading compressor head in the tank farm. May 20, 1996 Fatigue induced by compressor vibration. None Replace Sch. 80 piping with Sch. 160. Include pipe spools in inspection program. C-102 VCM release. 2. Incident: Date: Cause: Injuries: Mitigation: Reference: A reactor was not fully drained after a test and was overfilled during charge. The safety pressure interlock shut down the charge and prevented a release. May 15, 1996 Too many activities in progress at the same time. Panel Operator was distracted and did not answer the DCS question to rerinse or continue. None Evaluate need for low level switch and permissive to ensure the reactor is liquid empty. D-306 charge. 3 ABD00037626 3. Incident: Date: Cause: Injuries: Mitigation: Reference: Near miss accident when operator steamed a line and a valve containing organic peroxide. The organic peroxide rapidly decomposed and split the piping. January 21, 1996 A valve started to open but closed immediately due to low pressure on the HPSW line. A small amount of organic peroxide was trapped between two valves. None Various, such as modifying DCS graphic to show low pressure on the HPSW. F-364 organic peroxide piping. 4. Incident: Date: Cause: Injuries: Mitigation: Reference: Electrical fire in the new control room mechanical room. June 28, 1995 A ground fault occurred at a motor. The surge suppressors were the wrong types for this application. None Remove surge suppressors; follow-up with manufacturer regarding inspection and testing; ensure that the Management of Change System addresses electrical components for future installations and modifi cations. New control room mechanical room electrical fire. 5. Incident: Date: Cause: Injuries: Mitigation: Reference: 46 lbs. of VCM were released to the atmosphere when the antifoam injection line failed and pulled away from the slurry feed line. January 7, 1996 Failure of the weld connecting the antifoam line and the slurry feed line. None Various procedural, design and maintenance actions (see original report). W-622 VCM release. 6. Incident: Date: Cause: Injuries: Mitigation: Reference: A small flash fire occurred while welding on a stripper feed line at the stripper area. July 29, 1996 The piping contained VCM vapor residue, which collected and created a flammable vapor/air mixture. None. Operations personnel to check jobs closer to the actual performance of hot work, permit writers to be aware of long runs of piping which may allow residual vapors to build up, include requirements for accessible flanges and bleeders for long runs of piping. Stripper feed line flash fire. 4 ABD00037627 APPENDIX E ABD00037628 PROCESS SAFETY MANAGEMENT GEORGIA GULF CORPORATION, ABERDEEN PLANT OLD MODULE HAZOP Appendix E. List of Updates and Revalidations 1. Old Module Hazop updated March 2000. ABD00037629 APPENDIX F CERTIFICATE OF EDUCATIONAL ACHIEVEMENT ABD00037630 ABD00037631 OS (Di 360 s Oc <`8 < >> <D Go> .-5 <u *-- n <D +-j on cd e5 iruj >^ cd jC "O G CO cd ^3 *Tn3 'O<u co T3 8C|H O q.) cd 00 CA 3 O <u o -u <d X CO t-< G o oo b0 4> G Q- G 'cd w *0 J2 3O oj a> H S3 8< ox J -O C+-. <D oo 'O +3 G cd <D co c g? B 8*c>d <l) X^ co <D rH TS S +-> C/5 E PU, <2 o Ph ! < E fin sf rH CO G O ~a (D - o 3 TD G O u ABD00037632 APPENDIX G ABD00037633 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Issue Date: Approved By: Process Hazard Analysis July 30, 1998 Harry D. Garrison Manager Safety, Health & Environment 1. SCOPE This standard applies to all existing CONDEA Vista processes covered by the PSM regulation [Reference: CONDEA Vista Corporate Standard PSM-001], It includes provisions that address some anticipated requirements of the EPA Risk Management Programs for Accidental Release Prevention [40 CFR Part 68], The procedure does not include alj potential requirements that may be included in State or EPA regulations. Nor does it include requirements for hazard reviews that may be required or implied by other paragraphs of the OSHA PSM Standard such as Management of Change or Pre-Startup Safety Reviews. 2. PURPOSE This standard defines the minimum requirements for complying with the Process Hazard Analysis requirements, paragraph (e), of the OSHA Process Safety Management of Highly Hazardous Chemicals (PSM) regulation, 29 CFR 1910.119. 3. DEFINITIONS 3.1 Catastrophic Release or Incident - means a major uncontrolled emission, fire, or explosion, involving one or more highly hazardous chemicals (HHC), that presents a serious danger to employees in the workplace. 3.2 Covered Process - This is the group(s) of equipment and systems to which all PSM elements except for the Mechanical Integrity element (which is a subset of the Covered Process) apply. It is possible to have one or more covered process equipment groups. PSM - 004 Page 1 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037634 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 3.3 Process - refers to any activity involving a highly hazardous chemical (HHC) including any use, storage, manufacturing, handling, or the on-site movement of chemicals, or combination of these activities. For purposes of this definition, any group of vessels which are interconnected and separate vessels which are located such that a highly hazardous chemical could be involved in a potential release shall be considered a single process. 3.4 Process Hazards - for purposes of clarification for this standard only, the term "process hazards" means findings resulting from a Process Hazard Analysis that have safety (on-site or offsite), environmental, or community consequences having a scenario ranking requiring mitigation as determined by this standard. 3.5 Flammable Gas - means (a) a gas that, at ambient temperature and pressure, forms a flammable mixture with air at a concentration of thirteen (13) percent by volume or less; or (b) a gas that, at ambient temperature and pressure, forms a range of flammable mixtures with air wider than twelve (12) percent by volume, regardless of the lower limit. (29 CFR 1910.1200, Hazard Communication) 3.6 Flammable Liquid - means any liquid having a flashpoint below 100F, except any mixture having components with flashpoints of 100 F or higher, the total of which makes up 99 percent or more of the total volume of the mixture. (29 CFR 1910.1200, Hazard Communication) Refer to 1910.1200 for definitions of flashpoint. 3.7 HAZOP - A Hazards and Operability (HAZOP) study is a systematic method to identify hazards and operability problems. A HAZOP study involves a systematic, methodical examination of design documents that describe a process. The study is performed by a multi-discipline team. Deviations from the design value of key parameters are studied using guide words to control the examination evaluation. This presumes that the design values of flows, temperatures, and other process variables are inherently safe and operable. 3.8 Highly Hazardous Chemical (HHC) - A Highly Hazardous Chemical (HHC) means a substance possessing toxic, reactive, .flammable, or explosive properties and specified in Appendix A of the OSHA PSM Standard or a flammable liquid or gas on site in one location, in a quantity of 10,000 PSM - 004 Page 2 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies arc uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037635 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 pounds or more. See 1910.119 (a)(1)(A), (a)(1)(B) and (a)(2) of the OSHA PSM standard for exceptions. 3.9 PHA - Process Hazard Analysis (PHA) is a thorough, orderly, systematic approach for identifying, evaluating and controlling the hazards of processes involving highly hazardous chemicals. 3.10 Threshold Quantity (TQ) - Quantity at or above which the OSHA PSM Standard applies. The threshold quantities listed in Appendix A of the standard apply only to pure (or "commercial grade") chemicals unless otherwise specified. 4. PROCESS HAZARD ANALYSIS (PHA) METHODOLOGY Each covered facility shall conduct Process Hazard Analyses (PHA's) on each of its existing covered processes. PHA methods used will depend on the nature and complexity of the process under consideration. 4.1 Each covered facility shall perform an initial process hazard analysis (hazard evaluation) on each of its existing covered processes as soon as possible but not later than the following schedule: 4.1.1 No less than 50 percent of the initial PHA's will be completed by May 26, 1995. 4.1.2 No less than 75 percent of the initial PHA's will be completed by May 26, 1996. 4.1.3 No less than 100 percent of the initial PHA's will be completed by May 26, 1997. A PHA on a process or part of a process should not be delayed even if it is of a lower priority than one where records and documentation are still being generated. 4.2 The initial process hazards analyses will be conducted using the Hazard and Operability Study (HAZOP) methodology and reviews of human factors, facility siting and other hazards common or specific to the location. PSM - 004 Page 3 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037636 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Except as limited by Section 9 (PHA Revalidation), subsequent process hazard analyses may utilize any of the hazard evaluation techniques accepted by OSHA. 4.3 Each facility shall determine and document the priority order for conducting the initial process hazard analyses based on a rationale which includes as a minimum such considerations as: a. The extent of the process hazards, b. The number of potentially affected employees, c. The age of the process, and d. The operating history of the process. 4.4 The documentation shall include a priority order listing of each covered process and a narrative explanation of the rationale for the priority order. A matrix similar to the one presented in Appendix A may be useful in documentation of the rationale. 4.5 If the facility contains large processes with different risk factors within the process, the large processes can be broken down into sub-processes for the priority determination. 4.6 In addition to the considerations listed above in Section 4.3, it may be appropriate for the facility to consider other items when setting the priority for completing PHA's. Some examples are: a. Previous safety studies. b. Potential for off-site impacts. c. Volume of highly hazardous chemicals on site. d. Operating conditions of process containing HHC's. PSM - 004 Page 4 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037637 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 4.7 Process Hazard Analysis Requirements Except as provided in and 4.8 of this standard, all Process Hazard Analyses of existing covered processes in CONDEA Vista require: 4.7.1 Specifically including and addressing each of the following elements: a. The hazards of the process. b. Previous incidents which had a likely potential for catastrophic consequences in the workplace. c. Engineering and administrative controls applicable to the hazards and their interrelationships such as appropriate application of detection methodologies (acceptable examples include process monitoring and control instrumentation with alarms and hydrocarbon or inorganic vapor detection systems) to provide early warning of releases. Other controls include inventory reduction, substitution of less hazardous materials, protective systems (deluges, monitors, foams, etc.), increased separation distances, modification of process temperatures or pressures, redundancy in instrumentation, etc. d. Consequences of failure of engineering and administrative controls. e. Facility siting. An example includes taking into consideration safe distances for locating control rooms based on evaluations of the individual characteristics of equipment involved such as types of construction of the room, types and quantities of materials, types of reactions and processes, operating pressures and temperatures, presence of ignition sources, fire protection facilities, capabilities to respond to explosions, drainage facilities, location of fresh air intakes, etc. Other relevant siting factors such as equipment spacing, equipment spacing from potential ignition sources, and the potential of an incident spreading from one unit to another should also be considered. PSM - 004 Page 5 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037638 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 f. Human factors (the interaction between the process and the employees on the scenarios being evaluated). Examples may include review of operator-process and operatorequipment interfaces, the number and frequency of tasks operators must perform, the evaluation of extended or unusual work schedules, the clarity and simplicity of control displays, operator feedback and communications, clarity of signs and codes, etc. 9 A qualitative evaluation of a range of the possible safety and health effects of failure of controls on employees in the workplace. 4.7.2 The PHA must be conducted by a team of at least two individuals. The team members must have the following expertise: a. Engineering - An engineer must have a minimum of four (4) years of engineering experience. b. Process Operations - The individual filling this requirement shall have at least four (4) years of plant experience. c. Knowledge specific to the process being evaluated. It is recommended that the individual with this expertise be from the unit Operations group. The individual should have at least four (4) years of experience with the unit's operation. d. The team leader must have formal classroom training in the PHA methodology being used. On-the-job training or participation in PHA's is not considered formal training. e. The scope and type of process being studied will determine the make-up and number of the remainder of the team. Typically, representatives from the Mechanical Maintenance group will participate in evaluating processes involving mechanical equipment or piping and those from the Instrument Maintenance group will help evaluate processes involving instrumentation or electrical equipment. Safety Department representation is also typical. Members may be full-time or may participate only on a part-time, as- PSM - 004 Page 6 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037639 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 needed basis as determined by the full-time members of the team. 4.8 PHA's Conducted Prior to Issuance of the Final Corporate Standard If PHA's completed after May 26, 1987 and prior to the issuance of this FINAL corporate standard do not meet the requirements of this standard, facilities must evaluate the PHA's and take appropriate actions to ensure the safety of the facility and compliance with the OSHA PSM standard. Such evaluations shall be conducted by a team satisfying the requirements of 4.7.2 of this standard. The results of the evaluation(s) shall be documented, addressed as required by Section 7 of this standard (if applicable), communicated as required by Section 8 and retained with the original PHA. 4.9 Process Hazard Analysis Pre-work Requirements The following information must be available to the PHA team when they conduct the PHA: 4.9.1 The information requirements contained in 1910.199 (d) - Process Safety Information. 4.9.2 A chemical interaction matrix. 4.9.3 Documentation of any previous incidents that had a likely potential for catastrophic consequences in the work place being evaluated. 4.9.4 Documentation of relevant safety audits or studies in the facility's files that addressed the potential for catastrophic consequences in the work place. 4.9.5 Facility siting information. At a minimum, this will-include calculations for occupied plant buildings using the Dow Fire and Explosion Index. 4.9.6 Shutdown, startup, and emergency operating procedures. 4.9.7 Plant Safety & Health Manual. PSM - 004 Page 7 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037640 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 4.10 Process Hazard Analysis Team Orientation The orientation of the PHA team is a critical step in obtaining a good quality PHA. This is used to set the tone for the PHA and to meet some of the OSHA requirements that are not a direct result of some PHA methods. Attendance records must be kept. All full-time (or core) team members must attend an orientation that includes the following elements: 4.10.1 A review of the purpose and scope of the PHA. 4.10.2 A review of why the PHA method chosen is appropriate for the PHA. Currently, only the HAZOP method is approved for CONDEA Vista's initial PHA's. Unlike most of the other methods, the HAZOP method was developed specifically for chemical plants and processes. In particular, it is an appropriate method for complex processes and when operating conditions are important. 4.10.3 A review of the PHA methodology that the team will use. 4.10.4 A review of all pre-work information. This is not intended to be an detailed review. The intent is to make the team members aware of the resources available to the team. 4.10.5 A review of the process description. 4.10.6 Process or Unit tour (if necessary to ensure all team members are physically oriented and familiarized with the process or unit being evaluated). 4.10.7 A review of the process chemistry description, chemical interaction matrix, and the hazards of the process. The review of the hazards of the process consists of identifying the process chemicals or streams and reviewing the chemical hazards, physical hazards, and corrosion potential for each. This review may result in recommendations to reduce the hazards of the. process. These should be listed but no scenario ranking should be assigned. PSM - 004 Page 8 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037641 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 4.10.8 A review of previous incidents that had a likely potential for catastrophic consequences in the work place. 4.10.9 A review of human factors. If a separate human factors study has not been conducted, the human factors list in Appendix B will be used as a checklist of items that the team should discuss. This review may result in recommendations to reduce the risks associated with the operation of the process. These should be listed but no scenario ranking should be assigned. 4.10.10 A facility siting review. The primary intent is to determine if there are process hazards (as defined by this standard) associated with the facility location/layout that should be examined in detail. If a separate facility siting study has not been conducted, an evaluation of occupied plant buildings utilizing the Dow Fire and Explosion Index as required by 4.9.5 and the facility siting checklist contained in Appendix C will be used to conduct the facility siting study. This review may result in recommendations to reduce the risks associated with the operation of the process. These should be listed but no scenario ranking should be assigned. 4.10.11 A review of the site-specific hazards. This review may result in recommendations to reduce the risks associated with the operation of the process. These should be listed but no scenario ranking should be assigned. This review may also highlight specific areas of focus for the PHA. 5. HAZOP METHODOLOGY FOR PROCESS OR UNIT PHA's. 5.1 Scenario Ranking The team will use the Consequence Rating Table, Likelihood of Occurrence Rating Table, and the Scenario Ranking Matrix included in Appendix D to rate each scenario. Each scenario can receive three (3) separate ratings - Safety (on-site), Economic, and Environmental/ Community (including off-site safety). Each scenario must receive a safety and environmental/community rating. The information in Appendix D can not be modified without the approval of the corporate Manager of Safety, Health and Environment. PSM-004 Page 9 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document C ontrol Procedure. ABD00037642 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 5.2 Team Responsibility The team's responsibility is to define deviations from normal operating conditions that may represent an unacceptable risk level and to identify the problems. The team does not have the responsibility to engineer the solutions; however, it may recommend actions or solutions for consideration in remedying the hazard/risk identified for correction. 5.3 Process Parameters Common process parameters are listed below. The team should review the list and select those appropriate for the process being evaluated. Other deviations may be added by the team if necessary. Flow Level Reaction Frequency Information Separation Corrosion Tube Leak Utilities Pressure Time pH Viscosity Mixing Startup Fouling Tube Rupture Electricity Fuel Gas Nitrogen Temperature Composition Speed Voltage Addition Shutdown Atmospheric Temperature Leak Steam Instrument Air Cooling Water Guide Words and Phrases 5.4.1 Common guide words and phrases for process design and operations are given below: Guide Word/Phrase Meaning No Less or Lower More or Higher Part Of As Well As Reverse Negative of the design intent Quantitative decrease Quantitative Increase Qualitative decrease Qualitative Increase Logical opposite of intent PSM - 004 Page 10 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037643 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Other Than or Sooner/Later Complete Substitution 5.4.2 Common guide words and phrases for procedures are given below: Guide Word/Phrase Meanina Missing A step is missing from the written procedure at, or just before, the step being examined. Skip/Part of The operator skips this step (or some part of it) and performs the rest of the procedure correctly. More The operator does too much of the specified action or does it too quickly. Less The operator does too little of the specified action or does it too slowly. Out of Sequence / As well as The operator performs the steps in a different order than specified by the procedure, possibly as a short cut. Other Than/Reverse The operator performs some action other than the one specified in the procedure, usually because of confusion or haste. 5.5 Study Nodes - P&l Diagrams Each P&l Diagram is divided into study nodes. The study nodes should be as large as possible without the team having to apply the guide words to the parameters for parts of the study node. PSM - 004 Page'll of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037644 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Most utility connections are handled as one part of the study node if the utility is selected as a process parameter. The exception is process generated fuel gas which may involve multiple nodes. These nodes are reviewed as part of the HAZOP. 5.6 Study Nodes - Operating Procedures Emergency, startup (initial introduction of HHC into the unit), and shutdown operating procedures are divided into nodes which are normally defined as the group of sequential steps with one intent. These nodes are reviewed as part of the HAZOP. Other operating procedures are covered as part of the P&l Diagram node. These operating procedures are reviewed when the team believes that it is appropriate. 5.7 Team Process The team will use the following process: 5.7.1 The team selects a study node and reviews the design intent of the study node. If the design intent is not documented, the team can develop it. 5.7.2 The team applies the first guide word to the first process parameter to form a deviation. Guide words and process parameters that have no meaning (such as reverse temperature) are ignored. 5.7.3 The team defines the consequences associated with the deviation assuming that all equipment and procedural protection systems fail. 5.7.4 The team lists all possible causes of the deviation. 5.7.5 The team identifies all safeguards that prevent the deviation. 5.7.6 The team uses the tables found in the Appendix D to define the consequence rating, likelihood of occurrence rating, process hazards scenario ranking. PSM-004 Page 12 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037645 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis issue Date: July 30, 1998 5.7.7 5.7.8 a. Economic scenario rankings can also be generated using the same process. b. If information necessary to define scenario ranking is missing, then the scenario can not be ranked. The team will define an action step to obtain the missing information. If the information can not be found during the HAZOP, then the team will recommend an action step to obtain the information and for the scenario to be ranked at that time. c. The team should not over-state or under-state the risk of the scenario. Making scenarios greater than reality as a method to get faster action or being conservative and playing it "safe" is unacceptable. Down playing the scenario because the solution may be perceived to be politically unacceptable is equally unacceptable. d. To highlight the risk reduction afforded by existing safeguards and/or to evaluate the impact of any additional safeguards, teams may choose to first identify the scenario ranking without (or "before") considering the effects of safeguards and then arrive at a final (or "after") ranking considering all existing safeguards. If teams choose to do this, the final (or "after") ranking will be the ranking reported for mitigation as appropriate. e. In each scenario where various combinations of consequences and probability are possible, only the consequence and corresponding probability yielding the maximum scenario ranking will be reported for mitigation. If there are scenarios that result in catastrophic consequences even though some of the safeguards work properly, these scenarios should be risk ranked. If the team has a recommendation to mitigate the risks, the team should recommend that the person or team responsible for mitigation evaluate that option. Since the team does not take the time to evaluate all options, the team should phrase PSM-004 Page 13 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037646 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 recommendations as "consider" or "evaluate" rather than "do" or "install". 5.7.9 Repeat the process for each deviation until all deviations have been applied to the node. Then repeat the process for each node. 5.8 Scenarios with a Ranking of 1 or 2. Any scenarios with a ranking of 1 or 2 shall be reported to the managers having engineering and operations responsibility for the process being evaluated as soon as possible but not greater than 24 hours of the determination. 6. PROCESS HAZARD ANALYSIS REPORT The report shall contain sufficient detail such that a second PHA team can understand the findings and conclusions of the first team. At a minimum the report shall contain the following items: 6.1 A table of contents. 6.2 Start and end date of the PHA team work covered by the report. 6.3 Issue date. 6.4 The distribution of the report. Please note that either a paper copy or electronic copy must be available to employees affected by the findings and conclusions of the PHA. 6.5 The signatures of the team members and/or the team leader. 6.6 PHA methodology used. This shall include a rationale for the selection of the PHA method. 6.7 Description of the process evaluated. 6.8 The scope of the PHA. This will include a listing of the P&l Diagram(s) and operating procedures that were reviewed. The listing shall include the diagram or procedure number and issue date. PSM-004 Page 14 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037647 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 6.9 A listing of the team members and their qualifications. The documentation shall specify those individuals meeting the expertise requirements of Section 4.7.3 of this standard. 6.10 Attendance records. 6.11 Team orientation. This documentation should identify the steps covered in the PHA orientation and copies of any completed checklists. 6.12 Listing of updates and revalidations to the PHA report. 6.13 Copies of the P&l Diagrams with the study nodes marked and identified. 6.14 Work sheets from the team meetings. 6.15 A listing or index of resources utilized that were not included in the process safety information such as a list of previous incidents considered, technical experts who may have been consulted, research and engineering reports, etc. 6.16 A listing of actions steps requiring further evaluation including identifying nodes which require further evaluation due to missing process safety information. 6.17 Separate listings of the team's process hazards (as defined by this standard) findings and recommendations. This should include any recommendations or findings resulting from the review of human factors, facility siting, previous incidents, or hazards of the process. If economic or operability findings or recommendations are made, then these should be listed separately from the process hazards findings. 7. SYSTEM FOR ADDRESSING PHA TEAM'S FINDINGS Utilizing the clarifications provided in Appendix E, each covered facility shall develop written procedures for the facility's management to address the PHA Team's process hazards (as defined by this standard) findings and recommendations. These procedures shall include the following elements: 7.1 Mitigation Requirements 7.1.1 1 Ranked Scenarios PSM - 004 Page 15 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037648 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 A written schedule for responding to a scenario ranked 1 must be completed within five (5) working days of the managers having engineering and operations responsibility for the process being evaluated being made aware of the finding. If the unit is shut down at the time, the schedule must be completed prior to the unit resuming operations. The written schedule must include a plan for sufficient mitigation to drop the scenario ranking to at least a 3 level. The schedule shall include major milestones and responsibilities. This schedule will be updated monthly. Within ten (10) working days of the managers having engineering and operations responsibility for the process being evaluated being made aware of a 1 ranked scenario, the ranking level must be reduced to a 2 level or that portion of the process must be shut down. Items can not be deleted from the schedule until all appropriate paperwork has been placed in the PHA file. A copy of each schedule shall be placed in the PHA file. 7.1.2 2 Ranked Scenarios A written schedule for scenarios ranked 2 must be completed within ten (10) working days of the managers having engineering and operations responsibility for the process being evaluated being made aware of the team's findings. The written schedule must include a plan for sufficient mitigation to drop the scenario ranking to at least a 3 level. The schedule shall include major milestones and responsibilities. This schedule will be updated monthly. A 2 ranked scenario shall be mitigated sufficiently to obtain a 3 ranking within sixty (60) working days of the managers having engineering and operations responsibility for the process being evaluated being made aware of the item. Exceptions must be approved by the facility S.H.E. Manager and the managers having engineering and operations responsibility for the process being evaluated. Items can not be deleted from the schedule until all appropriate paperwork has been placed in the PHA file. A copy of each schedule shall be placed in the PHA file. PSM - 004 Page 16 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic orpaper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037649 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 7.1.3 7.1.4 7.1.5 3 Ranked Scenarios A written schedule for all 3 ranked scenarios must be completed within two (2) months of the issuance of the PHA report. Scenarios initially ranked 1 and 2 that have been mitigated to a 3 level should be incorporated into this schedule. The schedule shall include major milestones and responsibilities. This schedule shall be updated each quarter. Scenarios ranked 3 should normally be mitigated to at least a 4 ranking within twelve (12) months unless significant engineering design work or a turnaround is required to make revisions. Items can not be deleted from the schedule until all appropriate paperwork has been placed in the PHA file. A copy of each schedule shall be placed in the PHA file. 4 Ranked Scenarios Within two (2) months of the issuance of the PHA report, all 4 ranked scenarios must be evaluated to determine whether mitigation is required, and a written schedule for all 4 ranked items requiring mitigation must completed. Scenarios initially ranked 1 and 2 that have been mitigated to a 4 level should be incorporated into this schedule. The schedule shall include major milestones and responsibilities. This schedule shall be updated each quarter. Mitigation action steps shall be completed within two years of issuance of the report. Extensions to the next scheduled shutdown are permissible if a shutdown is required to implement. Items can not be deleted from the schedule until all appropriate paperwork has been put in the PHA file. A copy of each schedule shall be placed in the PHA file. 5 Ranked Scenarios Scenarios ranked 5 do not require mitigation. PSM - 004 Page 17 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any . other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037650 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 7.2 Documentation of Resolution of Team Findings The PHA file will include documentation of the resolution of each team's findings or recommendations. At minimum, there will be a typed page (or electronic equivalent) summarizing the corrective action taken in sufficient detail that the next PHA team can understand the corrective action that was taken and how the corrective action impacted the scenario ranking. This document can refer to other attached papers such as a Process Design. However, the design alone is not acceptable documentation. 7.3 Tracking System Each facility must have a documented system to track the status of each team's findings. 8. PROCESS HAZARD ANALYSIS COMMUNICATIONS 8.1 Determination of Affected Employees An affected employee is any operator, maintenance employee, contractor, or other employee whose: 8.1.1 Normal work assignment can significantly affect the likelihood of occurrence or consequences of the 1, 2, and 3 ranked scenarios; or 8.1.2 Normal work assignment in occupied buildings takes them within a Dow Fire and Explosion Index radius for more than 2 hours per week. Note: The immediate Supervisor of those individuals defined by items 8.1.1 and 8.1.2 above are also affected employees. 8.2 Pre-Process Hazard Analysis Communications Prior to each process or unit PHA, affected employees and their representatives shall be provided notice of the scheduled PHA. The notice PSM - 004 Page 18 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronie or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037651 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 shall indicate the unit or process being analyzed, the team leader and other team members who will be conducting the PHA, the scheduled meeting place/dates/times, etc. The notice shall also solicit input from affected employees who have concerns or knowledge of issues that the team should consider in its analysis. 8.3 Post-Process Hazard Analysis Communications 8.3.1 Process or Unit PHA findings and mitigation plans shall be reviewed with affected employees within one month of the issuance of the PHA report. Meetings for this purpose are required if scenarios ranked 1 or 2 were identified; otherwise, written communications to affected employees are acceptable. 8.3.2 The affected employees shall have access to a copy of the PHA and the latest mitigation plan. 8.3.3 Documentation including lists of affected employees, date(s) of reviews, meeting attendance records, etc. shall be prepared and placed in the PHA file. 8.3.4 Updates on the status of the mitigation plans for scenarios with rankings of 1, 2 or 3 can be handled through meetings or written communications as deemed appropriate by the facility management. Updates on scenarios ranked 4 or 5 are not required. 8.3.5 Where written communications are used or PHA's are provided to employees, management shall take measures if necessary to make sure recipients understand the information being communicated. 9. PROCESS HAZARD ANALYSIS REVALIDATION 9.1. Initial PHA's performed prior to the issuance of this FINAL standard and not meeting the requirements of this standard shall be evaluated on an accelerated timetable and actions shall be taken to remedy deficiencies as prescribed in 4.8. PSM-004 Page 19 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037652 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 9.2. At least every five (5) years after the completion of the initial process hazard analysis, the process hazard analysis shall be updated and revalidated by a team meeting the requirements of Section 4.7.2 to assure that the process hazard analysis is consistent with the current process. 9.3. PHA Revalidation Team Leaders shall have formal PHA Revalidation training. 9.4. Facilities shall conduct a PHA each time the initial (or subsequent) PHA is revalidated. Generally, the HAZOP methodology is recommended for the first PHA revalidation of a process to ensure a quality baseline PHA has been conducted. If facilities are satisfied with the quality of the initial PHA using the HAZOP methodology, the What If/Checklist methodology is recommended for the PHA revalidation. Any of the methodologies listed in 29 CFR 1910.119 (e) (2) may be used if deemed appropriate for the process or sub-process being evaluated, 9.5. In addition, PHA revalidations shall, as a minimum, include a review of: 9.5.1. Prior determinations of PSM coverage and a re-evaluation of the current PSM coverage. 9.5.2. Previous PHA recommendations and status of actions. 9.5.3. MOCAs and PSI/Procedures to identify any changes since the last PHA. 9.5.4. Any process safety incidents since the last PHA and the investigation recommendations and status of actions to be taken. (Other incidents and their findings known to have occurred at other CONDEA Vista Company locations or in the industry having relevance or applicability to the process being evaluated should also be considered.) 9.5.5. Facility Siting and Human Factors changes since the last PHA. 9.5.6. Applicability of EPA's Risk Management Program (RMP) regulations. 9.6. PHA Revalidation Report shall contain sufficient detail that a future PHA Revalidation Team can understand the findings and conclusions of the current team. At a minimum the PHA Revalidation Report shall contain PSM - 004 Page 20 of 38 This document is i controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037653 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 updated information required for initial PHAs (see Section 6 of this standard). In addition, the following are recommended: 9.6.1. Discussion of differences in conclusions to identified hazards by the PHA Revalidation Team. 9.6.2. Documentation of the status of corrective actions to the recommendations/action items of the initial PHA. 9.6.3. Description of the changes in the process or to equipment since the initial PHA. 9.7. PHA Revafidation Team Findings shall be addressed and managed in accordance with Section 7 of this standard. 9.8. Communications before and after the Revalidation shall occur in accordance with Section 8 of this standard. 10. RECORDS RETENTION Process Hazard Analyses (report and other documentation generated by the team) and updates or revalidations for each covered process and documentation of the resolution of process hazards identified by each shall be retained for the life of the process. PSM - 004 Page 21 of 38 . This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037654 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix A PHA ORDER ANALYSIS MATRIX Each facility shall determine and document the priority order for conducting the initial process hazard analyses based on a rationale which includes as a minimum such considerations as: A - the extent of the process hazards, B - the number of potentially affected employees, C - the age of the process, and D - the operating history of the process. E - other as determined by facility A matrix similar to the one presented below may be useful in documentation of the rationale. The documentation of this chart alone does not satisfy the narrative documentation required by Section 4.4 of this standard. By force ranking the criteria above (and others the facility feel are appropriate) for each of the Processes (or Sub-Processes) for the Unit or Facility and comparing the composite scores, a PHA order may be established. Criteria are ranked from Highest Risk (1) to Lowest Risk (# of Processes being ranked). E XAMPLE Unit/Facility Process A Process B Process C Criteria A B C D E A B C D E A B C D E Rank 1 2 2 1 2 3 3 1 2 1 2 1 3 3 3 Total Order 81 10 2 12 3 . Comments/Remarks PSM-004 Page 22 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037655 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix B HUMAN FACTORS CHECKLIST EQUIPMENT + Labeling equipment clearly labeled, uniform coding Access Operability Layout Uniqueness immediately at hand power-assisted operation well-planned, logical arrangement only component of its kin in area mislabeled or not Labeled hard to reach or access difficult t to operate/change position confusing/inconsistent arrangement several components look similar OBSERVED PRACTICE CONTROLS Labeling Mode Involvement Displays + controls clearly labeled; uniform coding fully automatic; well-tuned operator continually involved clear, simple, representational immediate, unambiguous - OBSERVED PRACTICE mislabeled or not labeled manual operation, many manual steps operator detached from process unclear, complex, non-representational none or potentially misleading DEVIATIONS Alarms Coverage Time Preparedness Last-Resort + first-out; safety-critical alarms dual operator coverage at all times no time pressure for response periodic simulation exercises shutdown not discouraged; fast access many simultaneous or false alarms operator not always present inadequate time to respond no drills or simulation of scenarios shutdown discouraged or unsafe OBSERVED PRACTICE TRANSIENT Procedures Identifying Format Aids + complete, accurate, current, verified ID. location of devices/actions given graphical identification aids checklist or supervisory check - OBSERVED PRACTICE incomplete/too general/out of date ambiguous device/action identification confusing/inconsistent; difficult to read task sequence done by memory = FACTORS BEYOND STANDARD PRACTICE; MAY REDUCE HUMAN ERROR OR INADEQUATE RESPONSE LIKELIHOOD. = FACTORS THAT MAY TEND TO INCREASE THE LIKELIHOOD OF HUMAN ERROR OR INADEQUATE RESPONSE PSM - 004 Page 23 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037656 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix B (continued) HUMAN FACTORS CHECKLIST SCHEDULING Overtime Consistency #of Tasks Task Frequency Intensity + permanent shift assignments tasks, work force, and sills matched routine task regular task at normal pace extreme enough to affect performance inconsistent shift rotations/schedules tasks required exceed time available very infrequent; no expertise base OBSERVED PRACTICE differing tasks in rapid succession COMMUNICATE + Shift Changes Field/Contro! Supervision Emergency status communicated verbally, plus turnover sheet used constant communication with field frequent supervisory communication rapid, unambiguous plant alarm system - inadequate communication of plant status between shifts no communication with field operator little or no supervisory checks no distinction between area, type OBSERVED PRACTICE ENVIRONMENT Noise Level Climate Visibility Lighting + office environment noise level indoors, climate controlled visibility enhancement of some kind - OBSERVED PRACTICE area where hearing protection required temperature/humidity/precipitation/wind extremes often foggy or other visibility limitation inadequate lighting for task "+= FACTORS BEYOND STANDARD PRACTICE; MAY REDUCE HUMAN ERROR OR INADEQUATE RESPONSE LIKELIHOOD. = FACTORS THAT MAY TEND TO INCREASE THE LIKELIHOOD OF HUMAN ERROR OR INADEQUATE RESPONSE PSM - 004 Page 24 of 38 This document b a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037657 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix C (Pages 25 - 32) FACILITY SITING CHECKLISTS AND MITIGATION GUIDANCE Instructions: The team will review each item on the checklist. After evaluation, each item is marked to indicate that the item has been reviewed. Comments and findings are attached on a separate sheet. No scenario rankings are given to the findings. pii Reviewed? '^ 1 ,vrYESn'f^` NO,r. [J'i/iUi i. Location of on-site populations relative to the unit. 2. Location of off-site populations relative to the unit. Location of environmentally sensitive areas. 3. Location of critical and safety systems. 4. Dominant Wind Direction. 5. Climate and water extremes; earthquake; flooding; hurricanes; tornadoes; windstorms. 6. Site topography 7. External hazards and threats (fire, explosion, toxic release from nearby process or facilities; aircraft, subsidence, sabotaqe). 8. On-site traffic flow patterns and clearances. 9. Security and reliability of all critical feeds, utilities, and safety systems. 10. Evacuation routes, emergency exits, safe rally spots. 11. Passive mitigation systems such as dikes, berms, (control spills and fires) and blast walls (protect against explosions). 12. Crane lifts over operating equipment and piping. 13. Barricades between traffic and equipment and piping. 14. Adequate lighting for normal operation, routine maintenance, power failure procedures, evacuation. 15. Communication systems. 16. House keeping - walkways, aisles, operating areas, evacuation routes. 17. Location of railroads to process equipment (derailment, access). PSM-004 Page 25 of 38 Tbis document is a controlled electronic document maintained by tbe Corporate Safety; Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037658 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 REVIEWED YES NO DISCUSSION TOPIC 18. Open ditches, sumps, low points (collect toxic and flammable vapors). 19. Entry into confined spaces during emergencies- Trapped Gases, Hazards, Permit. Buildings 20. Location of occupied building near process units. (Please note that the Dow Chemical Fire and Explosion Index will be used as a screening tool to determine if the building is located sufficiently remote from the process. If the building is not located sufficiently remote from the process, the team should suggest that a more detailed study be conducted.) Control Rooms 21. Minimum occupancy; only essential functions during emergencies. 22. Control Room Construction. 23. Fresh air intake locations/isolation; Temporary safe havens; Access during an emergency. 24. Control room location relative to unit, columns, and pipe bridges. 25. Supply of breathing air in control room. Sufficient for emergency shutdown. 26. Instrument labels up-to-date. Process Facilities 27. Area electrical classification. 28. Accessibility for mechanical integrity inspection and testing. 29. Protection of piping and vessels from vehicles and forklifts. 30. Protection of small bore lines, fittings, from external impact, personnel. 31. Routing of process piping, critical controls cable trays, critical utilities. 32. Vent, drain, and relief valve discharge locations. 33. Remote shutoff valves for feed lines to the unit, accessible, functional in emergency. Loading, unloading, and storage facilities 34. Incompatible materials segregated; storage, dikes, sumps, drains, and waste. PSM-004 Page 26 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037659 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 REVIEWED YES NO DISCUSSION TOPIC 35. Siting, labeling of unloading spots for incompatible materials. 36. Spacing consideration for flammable, combustible, and unstable liquid storage (note use the checklist - "Hazardous Analysis Review for Spacing Considerations for flammable, combustible, and Unstable Liquid Storage") 39. Storage of flammable solids such as wood, paper, rags. Fire Protection 40. Access for fire fighting and other emergency services - trains, vehicle parking, construction. 41. Ignition sources, continuous, intermittent, uncontrolled, hot surfaces. 42. Access to hydrants, monitors, and deluge valves. 43. Grading drains flammables away from storage. 44. Equipment spaced to minimize potential fire explosion damage. 45. Coverage of fire monitors/sprinkler systems. 46. Fire proofing of structures. Accident Mitigation 47. Detection of leaks and ruptures. 48. Emergency shutdown switch locations. 49. Accessibility of isolation valves, size. 50. Potential for fire/explosion in units affecting other equipment. 51. Critical control, mitigation, communication after initial explosion or release. Personnel Protection 52. Passageways, pedestrian traffic patterns vs. hazardous locations. 53. SGBA/respirators locations; accessibility on all shifts. 54. Sufficient escape routes from operating areas, shops, labs, offices. PSM - 004 Page 27 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037660 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 HAZARDOUS ANALYSIS REVIEW FOR SPACING APPLICATIONS FOR FLAMMABLE, COMBUSTIBLE AND UNSTABLE LIQUID STORAGE Instructions: This checklist represents item #36 on the CONDEA Vista Company Facility Siting Checklist. The hazard review team will review each item and mark to indicate a review was completed. Comments and findings are shown in a separate report. No scenario rankings are given to these findings. iStREVlEWEOl MffiSfalNQil ^^li^li^^WPIS<^SSIONiTOPIC. .. ,, . 1. Tanks accessible for fire fighting purposes. 2. Minimum distance between tank and property line or building as defined in paragraph 2-3 of NFPA 30, attached. 3. Outside base tank dike at ground level at least ten (10) feet from property line. 4. Minimum distance between any two storage tanks one third (1/3) of adjacent tank diameters, but at least three (3) feet. If unstable, flammable, or combustible liquids are stored, distance shall be minimum of one half (1/2) the sum of the diameters. 5. Inside base of tank dike at ground level at least five (5) feet from storage tank. 6. Minimum distance between liquefied petroleum gas (LPG) container and storage tank twenty (20) feet. If storage tank operates above 2.5 psig, or is equipped with emergency venting that will permit pressures to exceed 2.5 psig, then Item 4. above applies. 7. Storage tanks not permitted inside buildinqs. 8. When a storage tank is located in an area subject to flooding, the following shall be observed. a. The provisions of Item 8. shall apply only if the maximum flood stage exceeds the elevation of the dike wall. b. Provisions to prevent tank, either full or empty, from floating during rise in water level to established maximum flood staqe. c. Independent water supply facilities available for loading partially empty tanks with water. If filling with water is impractical or hazardous due to tank contents, tank shall be protected by other means against movement or collapse. d. Top of vertical tank extends above maximum flood stage by at least thirty PSM - 004 Page 28 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037661 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 REVIEWED YES NO DISCUSSION TOPIC (30) percent of its allowable storage capacity. e. In addition to Items a., b., c., and d. above, if tank is located such that seventy (70) to one hundred (100) percent of its allowable liquid storage capacity will be submerged at the established maximum flood stage, then the following also applies. i. Is tank raised, or height increased, until it extends above the level obtainable at maximum flood stage a distance equivalent to at least thirty (30) percent if its allowable liquid storage capacity. Submerged part of tank shall not exceed two and one-half (2 Vfe) times its diameter. ii. As an alternate to Item i. above, adequate noncombustible structural guides, designed to permit tank to float vertically without loss of product may be provided. f. Horizontal tanks located such that more than seventy (70) percent of storage capacity will be submerged at the established flood stage attached to foundation of concrete, or of steel and concrete, of sufficient weight to provide adequate load for the tank when filled with flammable or combustible liquid and submerged by flood waters to the established flood staqe. g. For tanks in Item f. above, are tank vents or other openings that are not liquid tight extended above the level obtainable by flood waters at maximum flood staqe water level. Definitions: h. Spherical or spheroid tanks protected by applicable methods specified for either vertical or horizontal tanks as described above. Combustible Liauid. A liauid havina a flash ooint at or above 100F (37.8C). Flammable Liauid. A liauid havina a flash point below 100F (37.8C) and having a vapor pressure not exceeding 40 psia at 100F (37.8C). Unstable Liauid. A liauid that, in the pure state or as commercially produced or transported, will vigorously polymerize, decompose, undergo condensation reaction, or become self reactive under conditions of shock, pressure or temperature. Reference Materials: NFPA (National Fire Protective Association) 30, Flammable and Combustible Liquids Code OSHA 1910.106 PSM - 004 Page 29 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any . other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037662 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 List of Short-term Mitigation Steps for Consideration for Normally Occupied Buildings Inside the Dow F&EI Radius This list is intended to serve as a guide for measures to be considered as short-term mitigation steps for facility siting issues identified. It is not an all inclusive list. MITIGATION STEP 1. Provide a system on the buildings' fresh air intake to detect and alarm when hydrocarbons, smoke, or toxic chemicals are present above acceptable levels. 2. Provide the means to quickly shutdown the building's ventilation system to prevent entry of contaminated air. Locate this control inside the building at a readily accessible location and clearly mark its function. 3.AII sewers, except sanitary sewers, leaving a building shall be sealed by installing a break tank or equivalent in the sewer system. The break tank shall be located outside the building, and must be between the building and any other inlet into the sewer line. There shall be no additional inlets into the sewer between the building and the break tank. Additional inlets into the break tank or into the sewer after the break tank are acceptable. Venting of the break tank shall be routed away from the building to an appropriate place. 4. The exterior surface of the building, at risk including its roof, shall be constructed of fire resistant materials, or a fire suppression system shall be provided to protect these exterior surfaces. 5. All office equipment, supplies, and other materials located within the building which could fall over or become mobile should be removed, relocated, or secured. This applies to all areas except for designated store rooms. Samples, office, janitorial supplies, and other liquids should be evaluated for potential hazards from spills. 6. Interior fixtures, such as ceiling lighting fixtures, wall mounted video monitors, other wall mounted equipment, etc., shall be attached to a building structural member. 7. Exterior windows shall not be permitted unless required for safety or regulatory compliance. If required, windows shall meet these criteria: a. Strength equivalent or better than the building wall, and safe construction that fails in a manner that minimizes risk to building occupants. Examples are 3/8" minimum thickness polycarbonate, toughened glass, laminated glass with internal catch bars. .. b. Window area is minimized. 8. Provide clearly marked utility (gas, electric, steam, etc.) shut-offs inside the APPLICATION Fire Explosion Toxic Fire Explosion Toxic Fire Explosion Fire Explosion Explosion Explosion Fire PSM - 004 Page 30 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037663 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 buildinq. MITIGATION STEP 9. Occupant assignments should be reviewed to determine if individuals can be relocated to buildings that do not fall within the radius defined by the Dow Fire and Explosion Index, unless the building is blast resistant design (BRD). Develop a policy to minimize the use of conference areas in non-BRD buildings located within the radius of concern defined by the Dow Fire and Explosion Index. Non-BRD buildings within the radius of concern defined by the Dow Fire and Explosion Index shall not be used as shelter-in-place facilities for non-operating personnel when there is a potential for fire or explosion impacting such buildings. 10. The building should be equipped with sufficient exits to allow personnel to exit in a direction away from potential fire and explosion sources. Doors shall open to the outside and be capable of resisting at a minimum the same external pressure as the building. The door frame shall support the door on all four sides. The door shall be weather stripped, and have a door closer of sufficient strength such that the door will remain closed and sealed against any positive pressure system that may be present in the building. 11. Other openings in a building shall be sealed to prevent flammable or toxic gases and smoke from entering the building. An opening is defined as penetration of the walls, roof, or floor by a system component. Any system component penetrating the wall, roof, or floor, shall be capable of resisting the same external pressure as the building until the system component is inside the building. Examples of system components that require openings include, but are not limited to, the following: 1) Pipes 2) Conduits 3) Cable trays 12. Each building shall have an emergency response plan for fire, explosion, and toxic release situations. The normal occupants shall be trained in the plan. A brief summary of actions to take in the event of an emergency (evacuation, shelter-in-place,etc.) shall be posted in common areas, such as hallways, and conference or training rooms, so visitors can quickly see what they need to do in the event of an emergency. 13. Occupied temporary buildings will not be located within the radius calculated by the Dow Fire and Explosion Index. APPLICATION Explosion Explosion Fire Explosion Explosion Toxic Fire Explosion Toxic Fire Explosion PSM-004 Page 31 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037664 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 DEFINITION: Normally occupied building The primary function is to house people on a routine basis. Examples of normally occupied buildings include: 1. Control rooms that are staffed during emergencies 2. Offices 3. Laboratories 4. Maintenance shops 5. Buildings designated as gathering points for emergencies Examples of buildings that are not normally occupied buildings include: 1. Motor control centers 2. Electrical substations 3. Temporary operator shelters 4. Compressor sheds, etc. PSM - 004 Page 32 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents.unless managed in conformance with the local Document Control Procedure. ABD00037665 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix D NO INFORMATION IN THIS APPENDIX MAY BE MODIFIED WITHOUT THE APPROVAL OF THE CORPORATE MANAGER SAFETY, HEALTH & ENVIRONMENT. If information necessary to define scenario ranking is missing, the scenario can not be ranked. The team should not over-state or under-state the likelihood of occurrence or consequence of the scenario. Making scenarios greater than reality as a method to get faster action or being conservative and playing it "safe" is unacceptable. Down playing the scenario because the solution may be perceived to be politically unacceptable is equally unacceptable. Note: The Environmental and Community column of the Consequence Rating Table was changed on May 19, 1997. PHAs done after May 19, 1997 should use the table as revised. PHAs done prior to May 19,1997 do not need to be re-rated until the PHA is revalidated. PSM - 004 Page 33 of 38 This document is a controlled electronic document maintained by the Corporate Safety. Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037666 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix D (continued) NO INFORMATION IN THIS APPENDIX MAY BE MODIFIED WITHOUT THE APPROVAL OF THE CORPORATE MANAGER OF SAFETY, HEALTH & ENVIRONMENT. CONSEQUENCE LEVEL CONSEQUENCE RATING EXPECTED RESULT OR IMPACT SAFETY (ON-SITE) ECONOMIC ENVIRONMENTAL AND COMMUNITY (OFF-SITE SAFETY) 1 MAJOR 11 HIGH III MEDIUM IV LOW TO NONE LOSS OF LIFE 4 EQUIPMENT DAMAGE IN EXCESS OF $1,00,000 PERMANENT TOTAL DISABILITY OR 4 RAW MATERIAL OR PARTIAL DISABILITY. PRODUCT LOSSES IN EXCESS OF $1,000,000 HOSPITALIZATION OF 5 OR MORE PEOPLE. MEDICAL TREATMENT FOR FIVE OR MORE PEOPLE. HOSPITALIZATION OF TWO OR MORE PEOPLE. 4 EQUIPMENT DAMAGE IN EXCESS OF $100,000. 4 RAW MATERIAL OR PRODUCT LOSSES IN EXCESS OF $500,000 4 MINOR INJURY OR HEALTH EFFECTS. MEDICAL TREATMENT OF ONE PERSON MULTIPLE EXPOSURES ABOVE OSHA LIMITS. 4 FIRST AID TREATMENT ONLY 4 SINGLE EXPOSURE ABOVE THE OSHA LIMITS 4 NO IMPACT 4 EQUIPMENT DAMAGE IN EXCESS OF $10,000. 4 RAW MATERIAL OR PRODUCT LOSSES IN EXCESS OF $100,000 4 EQUIPMENT DAMAGE LESS THAN 10,000. 4 RAW MATERIAL OR PRODUCT LOSSES LESS THAN $100,00. 4 HOSPITALIZATION OF ONE COMMUNITY MEMBER 4 DAMAGE TO AN ENVIRONMENTALLY SENSITIVE AREA 4 SIGNIFICANT PROPERTY DAMAGE. 4 COMMUNITY EVACUATION 4 SHELTER IN PLACE THE COMMUNITY AND/OR AN OFF SITE INDUSTRIAL FACILITY. 4 MINOR DAMAGE TO OFF-SITE STRUCTURES. 4 INJURY TO ONE OR MORE COMMUNITY MEMBERS. 4 OFF-SITE ENVIRONMENTAL DAMAGE. 4 REGULATORY REPORTABLE EVENT. 4 NO IMPACT PSM - 004 Page 34 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037667 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix D (continued) NO INFORMATION IN THIS APPENDIX MAY BE MODIFIED WITHOUT THE APPROVAL OF THE CORPORATE MANAGER OF SAFETY, HEALTH & ENVIRONMENT. RATING A B C D LIKELIHOOD OF OCCURRENCE RATINGS DESCRIPTION FREQUENT PROBABLE POSSIBLE REMOTE LIKELIHOOD OF OCCURRENCE EXPECTED TO OCCUR ONE OR MORE TIMES WITHIN THE NEXT YEAR EXPECTED TO OCCUR ONCE WITHIN THE NEXT TEN (10) YEARS EXPECTED TO OCCUR ONCE WITHIN THE NEXT 100 YEARS EXPECTED TO OCCUR LESS FREQUENTLY THAN ONCE EVERY 100 YEARS OR IS PHYSICALLY IMPOSSIBLE SCENARIO RANKING MATRIX A 1 11 2 III 3 IV 5 BC 23 23 34 55 D 4 4 5 5 PSM - 004 Page 35 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037668 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix D (continued) NO INFORMATION IN THIS APPENDIX MAY BE MODIFIED WITHOUT THE APPROVAL OF THE CORPORATE MANAGER OF SAFETY, HEALTH & ENVIRONMENT. RESPONSE/MITIGATION REQUIREMENTS FOR SAFETY & ENVIRONMENTAL RANKED ITEMS (See Section 7.1 of this Standard for expanded detail) SCENARIO RANK 1 2 3 4 5 WRITTEN SCHEDULE MITIGATION REQUIREMENT COMPLETE WITHIN 5 DAYS OF NOTIFICATION OF THE MANAGERS HAVING ENGINEERING AND OPERATIONS RESPONSIBILITY FOR THE UNIT BEING EVALUATED (SEE NOTE BELOW) MITIGATE TO SCENARIO RANK 2 OR LOWER WITHIN 10 DAYS OF NOTIFICATION OF THE MANAGERS HAVING ENGINEERING AND OPERATIONS RESPONSIBILITY FOR THE UNIT BEING EVALUATED (SEE NOTE BELOW) OR SHUT DOWN UNIT COMPLETE WITHIN 10 DAYS NOTIFICATION OF THE MANAGERS HAVING ENGINEERING AND OPERATIONS RESPONSIBILITY FOR THE UNIT BEING EVALUATED (SEE NOTE BELOW) MITIGATE TO SCENARIO RANK 3 OR LOWER WITHIN 60 DAYS OF NOTIFICATION OF THE MANAGERS HAVING ENGINEERING AND OPERATIONS RESPONSIBILITY FOR THE UNIT BEING EVALUATED (SEE NOTE BELOW) COMPLETE WITHIN 2 MONTHS OF ISSUANCE OF MITIGATE TO RISK RANK 4 OR LOWER WITHIN 12 MONTHS PHA REPORT OF ISSUANCE OF PHA REPORT COMPLETE WITHIN 2 MONTHS OF ISSUANCE OF MITIGATE (IF REQUIRED) WITHIN 2 YEARS OF ISSUANCE OF PHA REPORT PHA REPORT NOT REQUIRED NO MITIGATION REQUIRED NOTE: SCENARIOS RANKED "1" OR "2" REQUIRE NOTIFICATION OF THE MANAGERS HAVING ENGINEERING AND OPERATIONS RESPONSIBILITY FOR THE UNIT BEING EVALUATED WITHIN 24 HOURS OF DETERMINATION. IF MITIGATION REQUIRES MORE TIME THAN DEFINED ABOVE, A MOCA EXTENSION IS REQUIRED. PSM - 004 Page 36 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any. other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037669 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 Appendix E OSHA GUIDELINES ON ADDRESSING PHA TEAM FINDINGS AND RECOMMENDATIONS Paragraph (e) of the OSHA PSM standard requires that a team with expertise in engineering and process operations conduct a process hazard analysis, containing specific findigs and recommendations for each covered process. The employer is then required to promptly "address" and resolve[ ]" the team's findings, document the actions taken, and communicate these actions to the affected employees. 29 CFR 1910.119(e)(5). OSHA considers an employer to have "resolved" the team's findings and recommendations when the employer either has adopted the recommendations, or has justifiably declined to do so. Where a recommendation is rejected, the employer must communicate this to the team, and expeditiously resolve any subsequent recommendations of the team. An employer can justifiably decline to adopt a recommendation where the employer can document, in writing and based upon adequate evidence, that one or more of the following conditions is true: 1. The analysis upon which the recommendation is based contains material factual errors; 2. The recommendation is not necessary to protect the health and safety of the employer's own employees, or the employees of contractors; 3. An alternative measure would provide a sufficient level of protection; or 4. The recommendation is infeasible. PSM - 004 Page 37 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure. ABD00037670 CONDEA VISTA COMPANY CORPORATE SAFETY & HEALTH STANDARDS Subject: Process Hazard Analysis Issue Date: July 30, 1998 DOCUMENT REVISION HISTORY Revision Date 06/03/96 02/18/97 05/19/97 07/30/98 Comments Original Document. 5.7.6.d. Clarified that teams may choose to rank scenarios "before" consideration of safeguards as well as "after" but that doing so is not mandatory. Expanded and clarified requirements for PHA revalidations (Section 9). Added Document Revision History page. PSM - 004 Page 38 of 38 This document is a controlled electronic document maintained by the Corporate Safety, Health and Environment Department. Any other electronic or paper copies are uncontrolled documents unless managed in conformance with the local Document Control Procedure.