Document pmmZj4JrxNE2Qezbq9GD4EjyE

1995 Consolidated Audit Reactive Chemicals K.J. Kelley April 18, 1995 Review Agenda and Package Contents: I. November 1994 New Superintendent Review Package II. 1995 Reactive Chemical Audit Questionnaire III. Questionnaire Results IV. Interview Results V. Documentation Audit Results VL Misc. Rx Chem Topic Loading Chloroform on Caustic Last Contained Barges VH Wrap Up DO A 032507 CONFIDENTIAL Chlorinated M thanes Plant Pre-Audit fZfi Pi njs-i + 1. There is no reactive chemicals contact person for the Methanes plant. This responsibility should be assigned to someone. 2. Consider developing a reactive chemicals IPT module and include all the major worst case scenarios and lines of defense. 3. Summaries of reactive chemicals reviews including the worst case scenarios and lines of defense should be reviewed with the outside operators and boardmen. 4. Job procedures need information listing the reactive chemicals hazards associated with the particular job to be done. 5. Plant personnel need to be trained on the reactive hazard of inadvertently using a titanium part in dry chlorine service. Most did not know when interviewed. 6. Plant communications book could be an excellent means for communicating current reactive chemical issues. We only found one entry pertaining to reactive chemicals (Sealants database info from Kevin Kelley). Information on the incident involving methyl chloride in a tank car with aluminum baffles could not be located. 7. Worst case scenarios for the various sections of the plant are not included with the procedures. Consider either including them with the procedures or include them in the new Dynamic Data Display system. 8. R-250 procedures for dumping spent catalyst: The specific hazard of spontaneous ignition of organic material on the spent alumina is not listed. The comment in the procedures is "because catalyst is so dry, we need to spray water mist on the catalyst as it is being sucked from the reactor to comply with landfill regulations." 9. PSA carbon change out procedures need to be reviewed and the flammability hazard of dry carbon in air needsto be included. 10. A listing and summary of reactive chemicals data was not available for the Methanes plant. This needs to be done and we recommend that the Tech Center assists. Do ? 3?508 C.0NF T FNTTqi 1995 Consolidated Audit Reactive Chemicals I. November 1994 New Superintendent Review Package A 037509 OONFIDFNTTAI I CMP REACTIVE CHEMICAL REVIEW MEETING CALLED BYjJDonJEaylor DATE: Thu PLACE: Building 4601 Conference Room START TIME: 8:30 END TIME: 10:00 PARTICIPANTS: CMP Staff, Reactive Chemicals Committee PURPOSE: Review Reactive Chemicals concerns in the Chlorinated Methanes Products production unit AGENDA: TOPIC Introduction and review of past action items Ml production unit review M2/M3 production unit review Sealants, reactive chem reports, miscellaneous Discussion and follow-up PREWORK: none FACILITATOR Bruce Miles Steve Ledoux Jim Haney Kevin Kelley Group TIME 15 min 20 min 20 min 20 rain 15 min Do A 033510 confidfntiai' To: KKELLEY CC: To1 Gerald Wagner F Don Taylor Subj: Response to Reactive Chemicals Review Recommenaations 1. Concerning the inadvertent use of titanium parts in dry chlorine: a. Add a statement to the block safety indoctrination package on the reactive chemical hazards of using titanium parts in dry chlorine service. Reply: We are currently in the process of updating our block indoctrination. This will be added to the update Person Responsible: Brian Donatto Due Date: 4/1/95 b. Consider adding a checksheet that addresses this hazard to maintenance procedures for equipment in chlorine service. Reply: This will be added as a check in also advise the area maintenance maintenance procedures. Person Responsible: Barry Young our plant project booklet. We will group to include this in their Due Date: 3/1/95 2. Concerning the reactive chemicals review slides for the Thermal Chlorinator: Add "Evacuation of personnel from reactor area during th lines of defense for avoiding injuries due to a possible de._agration/detonation. startup to Reply; This will be added to the slide. Person Responsible: Jim Haney Due Date: 3/1/95 3. Consider the following scenario and make sure appropriate safeguards are in place to avoid a runaway decomposition D-l tar pot is blocked in and 235# steam flow does not shut off. If the decomposition Temperature is not known, ARC data should be generated. Reply: This will be evaluated Person Responsible: Jim Haney Due Date. 4/1/95 4. R view the materials of construction in the sulfuric acid demister and make sure that they are compatible over the range of temperature and V. sulfuric acid that will be encountered in normal and upset conditions. Reply: This will be reviewed. Person Responsible: Steve Ledoux Due Date' 4/1/95 Respectful ly, Do Taylor Pi t Superintendent Louisiana CMP DO C^TD FNTTAl