Document pp8dL7rBYrwD4D9E5xY1Gmx07

CHLORINATED METHANE PRODUCTS COMMUNIQUE* Review & Initial DATE: FROM: a-In tor_____ ,1995 SUBJECT: P/g*!'- r^A. y/ftn. /Vte-i i A fe~ *>'t <-*.'"< -/X. r*. ' fl P Q3'(\J'? ) to-~//Q<p //'t ( /), (t-~ /^~W^ j JkLLlL / This form is used to insure the attached information is communicated to the appropriate plant personnel INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. PERSONS NEEDING TO REV E\V Day Staff Init. Date Clebert Supervisors SOS's XX tnit. Date Cook J.{_ tt-2s Breaux OS's X . Init. Bishop IT& Date i2h& Loaders Init. Date Armand Haney ___ Dugas $0 &/ti> Beieier O/ii Bourg Doucet Kelley Ledoux McMurray^M pJjflKfc Day Open Bickham (\0^ i^Davis Cook F. /]r .a/9 Cavalier ^ 13/,J Instruments Michel Rizzo Taylor Witt ,ung Donatto Grace Johnson Simonson_ Vavasseur Grant Gravouilla/^/S^O Loonev Neyland. Shankliu Jackson ftSk*4'Voife T)W J3-w-c| Millender^jh /V Metrejeanffif) |zjH DO A 00190? CONFTDFNTTAL Haney, Jim From: To: Subject; Date: Haney, Jim Armand, Luke; Beieler, Brent; Bickham, Clarence; Bishop, Emerson; Bourg, Jason; BDriBedaUuAx, RniiuchidairUdf; C^aavvdaliiecri, Nnceaail,; Cvuowoka, Fnroeududice,; Dwavis, Cvilaaircennwcoe;f Dl/wonmabtvtwo, Bria*n"'*; Doucet, Ken; Ekey, John; Grant, Curt; Gravouilla, Dale; Harrison, Donald; Jack, Oliver; Jackson, Russell; Johnson, Jimmy; Looney, Randy; Metrejean, Darren; Millender, Ron; Wolfe, Dennis; Clebert, Julie; Cook, James; Dugas, Donnie; Kelly, Kevin; Ledoux, Stephen; McMurray, Vic; Rizzo, Gary; Taylor, Don; Vavasseur, Terry; Young, Barry K-1100 DISCHARGE PRESSURE SWITCH - DK396) DEMO Thursday, December 14, 1995 3:43PM The K-1100 discharge pressure switch, DII396), was taken out of service today by disconnecting the wire from the CRJB to the Mod5 can. The switch will be removed from the field at a later date. Also, the graphics bulb for DM396) was deleted. As all of you well know, a problem in the wiring from the switch to the control room was causing a diagnostics alarm to ring on system B, Can 300. Instead of tracking down the problem and fixing it, a decision was made to take it out of service. This decision was made because the switch doesn't provide any useful purpose in the K-1100 control scheme. There are already two discharge pressure transmitters on K-1100 that are used for discharge pressure control and for a high-high discharge pressure alarm (high select between the two). A deviation alarm is written for the two pressure indications. If the diagnostics alarm is still ringing occasionally due to this input, then we'll have to get the Mod5 hardware people involved. Please let me know if this occurs. Jim Page 1 CHLORINATED METHANE PRODUCTS COMMUNIQUE' ( Review & Initidl DATE: Mon, Dec 11,1995 FROM: Rizzo______________________ SUBJECT: See the attached sheets regarding the changes made to E-455 system.___________ Changes were made to alarms 260,261,264.____________________________ AO(202) and AO(212) control was changed. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. TPLOYEE: Please initial and date when you have reviewed and understood the material. PERSONS NEEDING TO REVIEW Coaches X SOS's X CookJ\MlL M-h Breaux \A\h DugaX/U-A Beieler fa pj,,, Day Oper. Bickham tj CookF. ,C nM* Cavalier Init. Date Grant ** Gravouilla jdHj /&M 'Simonson vavasseur Jackson Millender 7\% Metrejeanffio 00 A 031904 CONFIDENT! At c System E-455 Equipment Number 200 Can WARN(260) / (264) Revised the code for this alarm so that if Al(217) fails, the alarm can be activated using Al(207). WARN(261) Alarm 261 has been added to inform operations that a potential non compliance exist for E-455. A 5 minute rolling average, AC(950) has been programmed into alarm 261. It averages Al(206) temperature over a 5 minute time span. When the vent control valve to atmosphere is enabled and open, indicated by DC(1212) becoming true, a timer will become enabled. When approx. 5 minutes goes by the timer will begin. The timer counts 1 minute intervals. When the timer gets 5 minutes it is rezeroed and starts all over again. When the timer reaches 5, DC(223) will become "TRUE". When this occurs, if the average temperature, AC(950) is above the non compliance setpoint, the alarm will activate, indicating a potential non compliance. When the next 5 cycles roles around, if the temperature is above the non compliance setpoint, the alarm will clear and re-ring. This will continue as long as the valve is enabled and the temperature is higher than the non compliance setpoint. Al(206) Wrote failure logic for Al(206) - See DC(225) DO A 031905 CONFIDENTIAL ` ^ V DESCRIPTION OF CHANGE V Sfef c System E-455 Equipment Number 200 Can AO(202) Added the ability to choose between Al(207) and Al(217) for control. Al(217) will be used for control unless the following occurs: See AC(1239) * If Al(217) fails, indicated by DC(1217) becoming true, Al(207) will be used. * If the operator sets AK(217) equal to 207, Al(207) will be used for control as long as Al(207) hasn't failed. * AC(1239) is also used to enable the control valve, instead of just Al(217). (See DC(1212) and DC(510) AO(212) We have revised the code, taking out the seperate control points. It will not be necessary to set AK's to choose between points. When the valve becomes enabled, indicated by DC(917) becoming true, it will immediately go on fixed position control and remain there until AO(202) becomes enabled, at which point it will go on temperature control of Al(206), at AK(553) setpoint. In the event the control valve is enabled to a fixed position, if, after some time period, the vent control valve to atmosphere, AO(202), hasn't become enabled and if the pressur is lower than the setpoint required to enable the valve and if the temperature is below a given temperature, DC(924) will become true, disableing the valve. NOTE: If DK(640) has been used to enable the controller, DC(924) will not become true until the pressure has increase enough to make DC(510) true. DO A 001906 CONFTDFNTT Al.. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Nov 16>1995 FROM: Rizzo SUBJECT: Please review the, following revised procedure*;: They have had reactive chemical concerns added lfl each of them.____________________ _____________ ___ _____ _ MUnad.Doc - Ml loading procedure__________________ Mlttlnad.Dne - Ml Tank Truck l oading Procedure M23lc1od.Doe - M2/M3 Tank Car Loading Procedure This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW / Supervisors SOS's OS's Loaders X lit. Date Cook J. Utft JUI Breaux ^ hiit. I Bishop Armani // /^ Dugas b/tf Beieler /, ,,/,f Doucet Day Oper. x Bickham Cook F. Cavalier Init. Date Donatto Na Grant ___ Ekey ,,,, Harrisoi/^b W/fe Jack Imtnimpntt Grace na Gravouilla lj}7 Looney fU/ ll'fi'ffl Johnson na Jackson flwolfe Simonson_ Vavasseur Millender fyr\ ll/jjQ Metrejean||j/^6 DO A 031907 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Nov 16,\99S FROM: Rizzo SUBJECT: Please review the following revised procedures: They have hart reactive chemical concerns aflflfifl In each of them___________________________________________________________________ Cl 520su.Doc. C200sii.Doc- C2Q2snDnc. C12pad.Doc. Ha7.admat.Doc K55oilcr.DOC. K55su.Doc. Psarchrg.Dnr RnOOsti Dnc R250rech.Dncr R2S0sn A.Dnr, SoIttlod.Dnc V1515SU.DOC_____________________________________________________________________________ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors X SOS's X OS's X Loaders Cook it. Date ^ //-q?/ Breaux Dugas M-jM. Beieler /Jtiit. Date fL_ Day Oper. Bickham /i| ftj^ Cook F. Bishop aIntlt. i*LDate Boure/^o* Davis Ekey /niit Date Armand \ Doucet yx; lustrumnts Cavalier tfC Init. Date Harrisoi Grant Jack GravouillaP^ )| Q Looney 11-20 tnd. Date Jackson /- :5>Volfe Simonson Millender Vavasseur MetrejeanTyv itlfb DO A 031908 CONFIDENTTA! CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Nov 16 FROM: Rizzo ,1995 SUBJECT: Please review the following revised procedures: 159.1 samp Doc. 1750spec Doe. CMPDFMO Doe, Confined One D1 sample One D1 stup.Doc. Distspil.Dne. F.455SU.DOC. filnve.Doc.Offcheck.Di3C,----- PUMPTACi DOC, Qtiartine Doc, R-750 StartnpDoe, Safwlcper Doe--------------------- This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW Supervisors X SOS's X OS'! x \ Loaders / init. Date Breaux Dugas $$ nhl_ Beieler Init. Date Init. Bishop fj%) ^ J///K Bourg Date Init. Date Arnmrfa^\ Doucet . Day Oper. Bickham ^ jijVlj) Davis t^ook F. /f //.4s Ekey______ \-- Cavalier aSC. \ Init./ Date 'C7' Date Donatrp / Grace X Johnspn \ Grants // Gravouilla Jackson Jack CLltZ (Ul Looney lyi/tM EM [Wolfe T)W \\-7H Neylatid, Sh^nklin Simonson Millender ^ $f\: Vavasseur J Metrej eaiTJj^ DO A 031909 CONFIDFNTIAI. CHLORINATED METHANE PRODUCTS COMMUNIQUE This form is used to insure the attached information is communicated to the appropriate plant personnel INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW Supervisors SOS's OS's. Loaders Jnit. Date Init. Date Date I nit. Date Clebert QC Cook J. M# Breaux tOA //M< Bishop icHaney w?n || Dugas ti/j4 Beieler ^ Kelley iyHft* Ledoux rfl ' McMurrawV W/l Day Oper. --- Bickham Cook F. Cavalier /J/c, )).&]!> Michel Rizzo Tavlor K Witt aung Donatto^/" V Mr Grant Jack Ol il-p Neyland. Grace ^ till) Gravouilf5,>-^v jf-ffi Looney fify i\'k'% Shanklin n Johnson Jackson ft) i\voife^r'V[i-io-r Simonson___ Millender Vavasseur________ MetrejeanPW> )t||h Date //*& no a osioio CONFIDENTS Dow Chemical LAD Chlorinated Methanes Products Plant 1995 Written Hearing Conservation Program OSHA CFR29 1910.95 (Occupational Noise Exposure Standard) and Dow Program Requirements for Hearing Conservation (1990) require that any individual with a dose exceeding or equal to 50% of their allowable daily dose must participate in a hearing conservation program. The Chlorinated Methanes Products Plant hearing conservation program fulfills all of the OSHA and Dow requirements and includes the following elements; 1. Evaluation of Noise Exposure 2. A baseline and annual audiogram 3. Annual training covering the following topics: the effects of noise on hearing hearing protection (proper selection, fit, use and care) the purpose of the audiogram (testing procedures and results) 4. Personal Hearing Protection 5. Engineering and Administrative Controls for Noise 6. Record keeping and Audits Evaluation of Noise Comprehensive personnel exposure evaluations were performed during 1992 (2-10-92). Personal noise exposure doses were determined using Dupont Mark II, Quest M15 , and Quest M27 audio-dosimeters. Noise exposure monitoring results were based on OSHA settings of; 80 dBA threshold, 90 dBA criterion level, and a 5 dBA doubling rate. The instruments were checked for calibration before and after each use. Personal noise monitoring results for each job assignment monitored are given on the attached table (Table 1). The results are given as a percent (%) of allowable daily dose with correction for a full shift using the following formula; Actual Shift (hrs.) ------------------------- Monitored Shift (hrs.) X Actual dose = Adjusted dose DO A 031911 CONFTOFNTTAl CMP Hearing Conservation Program Evaluation of Noise (Cont.) A comprehensive area noise survey was performed during 1994. Area sound pressure level measurements were taken with an Edmont-Wilson Sound Level Meter Model 60-510, Serial Number(SN) 2306 using the A-weighting network and slow meter response.. The instrument was calibrated before and after use with an Edmont-Wilson Calibrator Model 60-535, SN 1183. Hearing protection is mandatory in all operating areas of the Chlorinated Methanes Plant except for the Loading Rack (some maintenance activities at the load rack require hearing protectiqf^ ' Attached is the most recent area noise surveys (Tables 2 & 3). Audiometric Testing Baseline audiograms have been determine^ on all employees working in the Chlorinated Methanes Plant. Audiograms will be repeated annually on each employee as required by the OSHA Hearing Conservation Program. Audiogram follow-up will be conducted when medically appropriate. Training A review of the area sound pressure level surveys and personal dosimetry is presented to employees on an annual basis. This program includes; the effects of noise on hearing the proper selection, fit, use and care of hearing protection test procedures and results of the audiometric testing program Personal Hearing Protection Devices Hearing protection is mandatory in all operating areas of the Chlorinated Methanes Plant except for the Loading Rack. All hearing protection chosen shall be able to attenuate below 90 dBA for the noise source and must ensure that the 8 hour time weighted average will not exceed 85 dBA. A combination of earplugs 2 DO A 031912 CONFTDFNTTAI. CMP Hearing Conservation Program and earmuffs may be needed to reach this level of attenuation in certain areas (this increases the attenuation an additional 5 dBA). Personal Hearing Protection Devices (Cont.) Hearing protection devices available are; Type Pro-Max Earmuff Howard Leight Earmuff Val-U-Fit Earplug Expand-O-Fit II Earplugs Howard Leight Max Earplug Noise Reduction Rating 25NRR 27 NRR 25 NRR 30 NRR 33 NRR Many other hearing protectors may be available through different suppliers at different times. Only hearing protection that satisfies the requirements of this program will be acceptable for use. Any other type or style of hearing protection will be evaluated by qualified personnel prior to use. Noise Abatement Plans All new equipment and any changes in the process will be evaluated for noise, and, when feasible, engineered to keep noise levels below 85 dBA. There are currently no existing plans or projects involving engineering controls for noise abatement. Industrial Hygiene Department Date: // MSB:1195 Plant Superintendent Next Review: 11/96 DO A 031913 3 C ONFIDFNTIAl. CMP Hearing Conservation Program Table 1: A Personnel Noise Exposure Survey at the Chlorinated Methanes Plant, Plaquemine, Louisiana during 1992. Job Classification__________________________ % dose* Operations [12 Hour Shift] Operation Specialist / Distillation Operation Specialist / Condensing Senior Operation Specialist / Outside Senior Operation Specialist / Control Board Shift Supervisor 83 58 33 15 10 Non-Operations [8 Hour Shift] Operation Specialist / Project Crew Operation Specialist / Permit Writer Senior Analyzer Specialist Loading Specialist Senior Instrument Specialist Senior Assistant Chemist Senior Environmental Specialist Engineer Safety Coordinator Maintenance Supervisor Training Supervisor Computer Applications Technician Senior Operation Specialist / Project Crew Area Supervisor 45 32 30 20 12 H 11 11 11 10 7 6 5 1 Maintenance [8 Hour Shift] Painter Insulator Pipe-Fitter Foreman Pipe-Fitter Safety Technician Equipment Operator Millwright Laborer 108 Industrial Hvgicne Exposure Guideline Dow Ceiling 50 Personal noise exposure doses were determined using Dupont Mark n, Quest Ml5 , and Quest M27 audio dosimeters. Noise exposure monitoring results were based on OSHA settings of; 80 dBA threshold, 90 dBA criterion level, and a 5 dBA doubling rate. The instruments were checked for calibration before and after each use. DO A 031.914 4 CONFIOFNTTAl CMP Hearing Conservation Program Table 2: An Area Noise Survey Following the Chloroform Expansion Project at the Chlorinated Methanes Plant, Plaqucminc, Louisiana during 1994. Process Area Knock out drum for air compressor North of D-1003, East of D-l 103 West of Knockout drum D-l 100 (near steps facing cast) North of Blower BL-500 West of Pump P-1210 (facing east) West and East of Blower BL-500 West of Reboiler at Pump P-1520 West of the Cooling Tower Water supply and return (facing east) North of Distillation column C-1540 (ten feet away) East of Distillation Column C-1510 (facing west) East of Pump P-752A West of Distillation column C-1540 (standing on grating) North of Pump*1020A (five feet away, facing south) West of Pump P-1260 (facing east) West of Blower BL-750 Northeast Comer of C-610 (standing on grating) South of Knockout drum S-1300 near the Motor Control Center East of Distillation Column C-1500 (facing west) South of the THROX Column C-1500 Middle of the road between the Column and the piperack South of Pump P-1520 South of Pump P-1530 (facing west) Northeast Comer of Pak storage Area Middle of the road between Zone 1 and Cooling Tower West of Knockout drum D-l 140 (facing east) West of Knock out drum D-1110 (facing east) South of the Distillation Column C-1500 (all directions) South of Pump P-1450 West of Analyzer House AH-10 (facing east) South of Compressor K-213 North of Pump P-210B (facing south) On deck near Pump P-1830 (facing east, facing north) West of Reactor R-1300 (facing east) East of Reactor R-1300 (facing west near fence) South of Distillation Column C-210 North Exit of Bldg. 4601 (10 feet from door) South Exit door of Bldg. 4606 (facing north) East Exit door of Bldg. 4606 (facing east) West ofExchangerE-1303 (standing on grating facing east) South of Blower BL-751 South of Pump P-1500A South of Pump P-1250B North of Pump P-1320 (facing south) On grating between Tank T-1830 and T-1555 North End of concrete slab (facing north, facing south) Bottom step inside diked Area near Tank T-1830 Industrial Hvgicne Exposure Guideline Dow Ceiling Sound Level dB(A)* 96-97 96 95 93 93 93 92 91 91 90 89 89 89 88 87 87 87 87 86 86 85-88 85 85 1 85 85 84 84 83 82 82 81-83 81 81 81 80 80 80 80 80 80 78 76 76 73-75 72 90 dB(A) * Measurements were taken with an Edmont-Wilson Sound Level Meter Model 60-510, Serial Number(SN) 2306. The instrument was calibrated before and after use with an Edmont-Wilson Calibrator Model 60-535, SN 1183. DO A 03 5 DONFrOFNTTA! CMP Hearing Conservation Program Table 3: An Area Noise Survey Following the Chloroform Expansion Project at the Chlorinated Methanes Plant, Plaqucminc, Louisiana during 1994. Process Area - Fin Fan Deck Northeast side of Drum D-l 100 (on grating, facing west) North comer of Drum D-l 100 (on first stairdeck) Southeast of Drum D-1710 (facing west) Top Deck of Drum D-l 100 South of Motor MK-1100 (facing north) West side of Drum D-1710 (facing east) North of Motor MK-1100 (facing south) Under Exchanger E-1510 (facing east) Freon lines to South of Compressor K-l 100 (facing north) Under Exchanger E-l 540 (facing south) Under Exchanger E-1420 (facing north) Under Exchanger E-l 550 (facing south) West of Motor MK-1100 (facing east) Near the block valve to the Cooling Tower Water Supply (ground level, north of Drum D-l 100) Under Exchanger E-l 525 (facing south) Stairway Under Exchanger E-1420 West of Pump P-1030A (facing east) Under Exchanger E-1320D (facing east) East of Pump P-1030B (facing west) Industrial Hvgiene Exposure Guideline Dow Ceiling Sound Level dB(A)* 96 95 93 92 91 91 90 89 89 88 88 87 87 87 86 83 83 82 77 90 dB(A) * Measurements were taken with an Edmont-Wilson Sound Level Meter Model 60-510, Serial Number(SN) 2306. The instrument was calibrated before and after use with an Edmont-Wilson Calibrator Model 60-535, SN 1183. DO A 031916 6 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: FROM: (QpT 4^95 /CtStK SUBJECT: ___ I'JeeM.L V fUrt/* <-5h)Af5 -TA/C/ZC /S /f AJST AP T/ftr /'/Z&urtoustc syjTHfH TV-AT m)JLL Sidfor?/Ate . 0*Jct SMSMT#. U/~ qJ/L JtJAP r/f~M oaJ ACt4 /?70fitOAH /V ojL jT at/ICH kJEESiJ. M -me /Mft/J /MeTAfU. . SWT /tup cue*. 0*/ Ctfeciz SHEETS. rt/tTxJ AMCCS? Tflf? /y?/ZXTT u)jc SE 77fE AfDAtT/i jt*rp /'A'fitr stir- rtter c/fzctsti/jurr stM? rtler Pu*4/*s /ma 4em/6Q rtAr r/4rCtSHtreT n AS/tn. h/r u^l t> TTt&Str sdIch /Hoa/pav At), //? u>& A/dvlF S/r/tl /LEAPS ort sntcjt /%3?AcewS t^E CAP SfAUepl/rM /iefA//ZCP. This form is used to insure the attached information is communicated to the appropriate plant personnel INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW Supervisors SOS's OS's Loaders AUiit. Pate Clebert lcfiu Haney QVfy~ IoIm Kelley M> Ledoux r\ McMurra>\M mil Day Oper. Michel rfjl hM Donatto Rizzo __ Grace Taylor *iilA Johnson Witt __ Simonson >ung __ Vavasseur .Initti. Date init. Date Init. Date Breaux f>i Mi Bishop te lov-l Armand Beieler AA /S/?D Bourg 10-& Doucet Bickham tj, Cook F. pc avis Ekev Instruments Cavalier y^1 ZP-affi arrisoiLIum-mM- Grant Us Jack (fcS I&Z Neyland. Gravouilla i))l0'c25~' Loonev W/t-23 Shankliu Jackson (O' r;wolfe flr.w 10-ra Millender Metreiea DO A 031.917 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: FROM: <1995 ________________ SUBJECT: >UZ TO THer A/>/>AD\fAL tP A SUGGEST/6* 77MT til? A/P tfj&/C s/fr*p/,E- b-/7xo /?&>& SuMfrAffc r~t> T-t*ssa; r-- fOLLMsiWG #4S T/ltCCfiJ fmcg ___________________________________ 0 TAe &-I7T9 */eu/> /fe/l>efiL rt r'^/CdO A*Jt> > MS /?^csJ P/SPcaJdecree Mb /f^/AoO A^/tAGts tfrtvr /Ssea/ sk>ST4clc> r7ie />-/7n su#?/* j>wjJ />&c&u/ee- AjtbA c/M*/Gi>. iM~ a/cU CffME- 771e Al/MUriL lS/UvS >~nSO T* r-/SXT /L/AJeZM/9 /MB A/7W /k) /Hrrt> s*j thct F/et>. rfte i/?> s/ztifiv ser -r^ue r/) xr/M-T A/7G0 A*/J> J> nW rt t-/STj?. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. ^AlPLOYEE: Please initial and date when vou have reviewed and understood the material. Day Staff _b^ Jnit. Clebert (Y^ Haney Kelley Ledoux McMurravVM Michel Rizzo Jfy) Taylor Witt oi. ___ ,ung ____ PERSONS NEEDING TO REV EW SOS's OS's Loaders Day Oper. Donatto Grace Johnson Simonson Vavasseur hiit. Date Mnit. Date Init. Date reaux A$ i ilz-J Bishp v$r iopl Armand Beider fa Bourg d^S tplA' Doucet Bickham fc{j, xZ/f-paADavis CP fjiAh: Instruments Cook F. f_ lo-ij) Ekev ^ wt m=- Cavalier Mt /)g& Harrisoi^XskAt Grant ^ Jack CO> [0-23 Neyiand. Gravouilla MAE Loonev ju/ Shankliit Jackson /ty h~l Wolfe^CU/ 10 Millender f^l\ Metrejean D0 A 031 9ie CONFIDENT tai. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT: DATE: njpj, Qcj }% FROM: 6rUn ,1995. fiej/i'ey 4 Ag_ revijeJ >rWI* JetG?rU~i>n(L,hM_ ^rucfJuLnZs, > UP 31? This form is used to insure the attached information is communicated to the appropriate plain personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors SOS's OS's Loaders ,-Jnit. Date Clebert ()C > Op> Haney Qfit Kelley fty. Ic/y Ledoux lejh> McMurray ^ tljl\ Day Oper. Breaux Beieler Ip it. Dite ifBishop Q in Arman Bourg *1 Doucet t, Date /CbM Bickham Davis CP /$<.13 Cook F. Ekey {My $lk7 Cavalier /f/C j&fif Harrisoi^(M l$k Instruments Michel Rizzo Taylor Witt Jt>/u4 ^_ jf}]^ ___ Donatto Grace v/ith Grant ^ Jb'vf-*)?' Jack S_ Jfr/V Neyland 1/19 Gravouilla^ Looney tlk/Lm Shankli JohnsorCX^T ^ Jackson PWJsdl Wolfe lo-i^y Millender /djp, t ^ung ____ MetrejeanUfA DO A 031919 CONFIDENT! Al CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Wed, Oct] 8 FROM: Rizzo ,1995. SUBJECT: Please review the following revised / new procedures: Glove Doc #460637 Confined Space Policy___ # 46Q638_ Safe Work Permit # 460390 NOTH: Product Inrienlifiratinn and Traceability was added In the quality list in the, system The confined space concerns was deleted from the system. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. iMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff x PERSONS NEEDING TO REVIEW Supervisors x SOS's X OS's X Loaders x Init. Date It. Date Clebert fXI h' Cook r,, /O'(9 Breaux Haney di_ Dugas jiffs' /i?A; Beieler lM. Bishop fa Bourg Arman 4&i\ Doucet it- Date 6-7/ Kelley pjL )o/u Ledoux McMurray\M t^y// Day Oper. Bickham ^ rf/lt/g) Davis op idy X Cook F. K lo-IN Ekey Cavalier /Ific Dtftb HarrisoiC $2: Init. Date Instruments X Init. Date Michel Rizzo /dfat Donatto tyf lo/lihS Grants Jack &S Neyland_ ________ Grace jj ^ ^i)b GravouilIa^JD-^_ Looney ^J/' iti'Mt Shanklin Taylor Johnso iVjf Jackson /#-& Wolfe V)W jO-MST Witt Simonson Millender 'oung Vavasseur MetreieaiTDiV^ DO A 001920 CONFTDHNTTAl. CHLORINATED METHANE PRODUCTS COMMUNIQUE* Review & Initial DATE: FROM: /hkr )/ Af\ /^dl' ,1995 M-n e-*rO f'4- i /y>s.s>u.a>/ O/l L- lA> A^O ( -+o \f-feyO __ Ok Oof) A / tlr\ - 7/n j Av*1**/' to--i * bn* "Ao .ry*/ o<P -A/ \ Jp->~^'/o____ v> /-. lb i /A- &7-/e.r t Al<< ^ /-* AAt. A/** - /tel l dt *** OfC*r->< C.*\Al oAol.'sif S LCr. /s'Cf AAb /7/tv. ou i ^4-A ^ .'<w Afo(3cjiT T. Arts' **. ^ , s S-. ~ s, s AA-~ This form is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff Init. Date Clebert Haney QJty //? PERSONS NEEDING TO REVIEW SOS's X- 0 Init. Date Breaux Beieler Kelley Jp/jo Ledoux O K McMurraW^l Day Oper. Bickham #4 tejn?l CookF. ft ih-i'sjE Cavalier Michel Rizzo Jd/uf Donatto Grace Grant ^ Gravoouuilillak^__A_ ^_____ Taylor ^ Witt________ I -oung Johnson Simonson Vavasseur Jackson U A /;-7)|Wolfe ?KMiMnai . . Millender Metreiean~TlW\ ^ Loaders Init. Date Armand Doucet Instruments Neyland. Shanklin /Q'^ D0 A 031921 oonftdfnttai. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Oct 5,1995 FROM: Rizzo SUBJECT: Please review the attached sheet explaining the mod v changes in distillation. _ 1. AOf3Q51 filter hv pass control valve - new addition 1. Revised the P-1541 pump logic - Took out the bump code logic____________________ 3. Revised alarm 308 and 345 . taking all of the references to the shroud temperature-out __ since they rm longer exist_____________________________________________________ 4. high vent flow for V-.175Q filter beds to atmosphere.______________________________ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors X SOS's X OS's Loaders Clebert Haney Init. Date Q// flh Kelley Stf) /('Ac Ledoux tfns'nfi? MpM,,rrav\u Kt McMurrayv"'- Djil Michel /V. Rizzo Date CookJi^L /,- Breaux Dugas`^7^ Beieler *Init. Date, Init. &/$ Bishop -Bourg Bickham jo/y Day Oper. CookF. fC -- Cavalier AtfS- Init. Date Donatto Grant ias /= Davis Ekev Harrison Jack Grace Gravouillafti l\~^- ? f Loonev Taylor Witt Johnson Simonson Jackson \JiXlK Wolfe Millender fyt /djr Date Init. Date Armand Doucet Instruments -- Init. Date Neylanri Shanklin------------- Young Vavasseur MetrejeaiTjV^- A 0319?? CONFIDENTIAL CHLORINATED METHANES MOD V ItJ DESCRIPTION OF CHANGE gf S] D System PSA'S Equipment Number 400 Can Added alarm 461 for system D the alarm will activate when the vent flow to atmosphere from the psa beds exceeds the high flow setpoint and the beds are in one of the many adsorbtion steps. These alarm are used to indicate a possible problem with the vent valves on the tanks. A high vent flow could indicate excessive venting or the vent control valve has failed and is wide open. DO A 031923 CONFIDENTIAL CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE SZf S] D System C-1540 Equipment Number 300 Can AO(305) - V-1540 By pass Positional Control Valve AO(305) is a positional controller which will either run wide open or closed. When V-1540 isn't online, the control valve will be disabled and wide open. When the board operator is ready to place the filter on line, the board operator can initiate a DK function, DK(109), which will enable the control valve, DC(379), and begin ramping the control valve closed at a ramp rate set by AP$731), until the controller output reaches AP(732). This will force all the bottoms product through the filter. When the board operator needs to take the filter off line, the DK can be zeroed, which will disable the AO and begin ramping the controller open, to an output based on AP(730). DK(109) will be autozeroed if not in step(304). do A CONFl 031^24 pFNTI Al. CHLORINATED METHANES MOD V 0 DESCRIPTION OF CHANGE Qf Ml D System C-1540 Equipment Number 400 Can | DO(327) & DO(337) Took out all the bump start logic for these pumps. Left the DC to enabled the pump. The reason for this is that when performing the upload we won't have to place the pumps in manual or hand. REQ(308) Took out DC(1063) and DC(1037) high shroud temperature alarms. Took out DC(1539) and DC(1540) high temperature differential alarms. Warn(345) Took out DC(1077) & DC(1078) High differential temperature alarms. Took out DC(1412) & DC(1416) Low Low Amp alarm. 00 4 031925 CONFIDENTIAL I CHLORINATED METHANE PRODUCTS COMMUNIQUE Review & Initial SUBJECT: __________ /!/ a/ T DATE; FROM: C TOC'/4lL 0(A T~ *1995 This fonn is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors ySOS \yOS's Loaders Init. Date; flhfif- Date Init. Date Init. Date Init. Date Clebert Cf, ,n(# Cook Breaux vdUMlbi Bishop__________ Armand Haney Kelley Ledoux Jiff l^j/Q DugasA)A Beieier Day Oper. Bickham (ty Cook F. fC Bourg Doucet McMurray \)<^ ffl/l Cavalier Michel A/fri Donatto fyfP HI KIZZ&- ________ Grace $ 7b Taylor tyj itjvift Johnson Grant *-' /*> -i'?* Gravouillaffi Iq4 r ?^|Loonev Neylaud. Jt'H | Shanklin Jackson ^/oi?-s,r J [Wolfe *j)W 1(H& Witt________ Simonson Millender I oung Vavasseur MetreieariJ^Vf\ A 0319?6 conftofnttai. PLANT INSTRUCTIONS FOR CONTRACTOR CALL-OUT CONTRACTOR CALL-OUT POLICY PLANTS ARE TO USE THE FOLLOWING GUIDELINES WHEN IT IS NECESSARY TO CALL-OUT CONTRACT CRAFTSMEN. 1-INITIATE A GEMTS WORK ORDER REQUEST THIS IS NECESSARY FOR CHARGING TIME AND ORDERING MATERIALS/EQUIPMENT THRU MSMS OR PURCHASE ORDER. 2-BE PREPARED TO ANSWER BEFORE CALLING: IS THIS A PRODUCTION LOSS? IF NO,WHY IS THE CALL-OUT NEEDED? IS EQUIPMENT CLEARED AND TAGGED? IF NOT,WHEN WILL IT BE READY? IS SCAFFOLDING NEEDED? IS A RIG NEEDED? ARE OUTSIDE SERVICES NEEDED? 3-CALL THE CADM CALLOUT PERSON(S) FOR WEEKDAY (MONDAY-THURSDAY) CALL FROM THE PROVIDED LIST FOR YOUR PLANT. FOR WEEKEND (FRIDAY-SUNDAY) CALL THE WEEKEND CALLOUT PERSON PAGER 352-3600 SEE LIST FOR PERSON AND HOME NUMBER 4-HAVE SOMEONE AVAILABLE TO INDOCTRINATE THE CRAFTSMEN COMING OUT.CTHIS MAY NOT BE NECESSARY) 00 A 031977 CONFTDFNTT Al CADM WEEKEND CALL pager SUPV/FOREMAN 352-3600 1995 OCT. 7-8 LARRY DONALDSON 261*0714 PFA PFA MW OCT. 14-15 RICKY DUPONT 687-0499 PFA PFB MW OCT. 21 -22 MIKE LANEY 774-1119 PFC WELDER MW OCT. 28 - 29 KENNY BOUTTE 687-0698 PFA PFA MW NOV. 4 - 5 PETE TALBOT 261 -0303 PFA WELDER MW NOV. 1112 RONNIE ROSHTO 261-5654 PFA WELDER MW NOV. 18 -19 GARY ROBILLARD 383-8200 PFA WELDER MW MW NOV. 23-26 TIMMY QUATREVING 687-4255 PFA PFA PFA MW DEC. 2-3 ERIC SWANSON 627-9500 PFA WELDER MW DEC. 9-10 CURTIS STELLY 318-585-731 PFA WELDER MW DEC. 16-17 STEVE LANDRY 749-3611 PFA PFA MW DEC. 23-24-25 C. J. BOUDREAUX 627-4044 PFA PFB MW DEC. 30-31 JAN. 1 LARRY DONALDSON 261-0714 PFC WELDER MW JAN. 6 -7 RICKY DUPONT 687-0499 1996 PPFFA PFA MW DO A 0319?B CONFIDENTIAL ;ALROST.XLS SS 9/29/95 i CADM WEEKDAY CALLOUT WEEK DAY CALLOUTS(MONDAY-THURSDAY) MECHANICAL CHLORINE RONNIE ROSHTO 261-5654 KENNY BOUTTE 687-0698 ERNEST TATE 664-9603 MAC MCCRAINE 751-3629 CA-2/CAUSTIC CJ BOUDREAUX 627-4044 MIKE LANEY 774-1119 LARRY DONALDSON 261-0714 FLOYD CAMPBELL 749-3254 BEAU DUNN 683-5004 METHANES ERIC SWANSON RICKEY DUPONT JOHN MEEKER GREG FUENTES 627-9500 687-0499 654-3833 749-2969 VINYL-2 CURTIS STELLY STEVE LANDRY JOHN MEEKER GREG FUENTES 318-585-7317 749-3611 654-3833 749-2969 SOLVENTS/EDC GARY ROB1L1ARD PETE TALBOT ERNEST TATE MAC MCCRAINE 383-8200 261-0303 664-9603 751-3629 RELIABILITY JIMMY GRISSOM STEVE FOLSE MAURI SCHOBY 752-7838 687-4327 387-5921 PV/PSV / GEMTS TODD HEBERT 749-2063 CADM SUPT. DAVE DUPUY 261-1569 MAINTENANCE SUPPORT (DOW EXTENSIONS-DO NOT USE 8787) HOME PAGER CAT. CHEROKEE SCAFFOLD 4084 4066 4085 CONTROL ENG. SOFTWARE 4465 ELECTRICAL(WEEKENDS) 4090 4091 IBM-3306 4599 INSTRUMENT 4092 4093 INVENTORY MANAGEMENT 4460 4466 HUMAN RESOURCES 4453 4455 MAINTENANCE(DIVISION) 8963 8956 HARDWARE SUPPORT-MOD5/ 4778 4779 PRODUCTION PLANNING PURCHASING 4773 4775 4774 4778 RADIO/PA/COMPUTER 4066 SHIPPING/DISTRIBUTION 4772 4771 TELECOMM/NETWORK 6418 6415 9/29/95 DO A 0319?9 CONFIDENTIAL Review & Initial SUBJECT CHLORINATED METHANE PRODUCTS COMMUNIQUE' DATE: 36 ,1995. FROM: ^.a &(le^ Vv4^ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. PERSONS NEEDING TO REVIEW Day Staff Supervisors SOS's X XX Init. Date Init. Date init. Date Clebert Cook J.jgg? /bX Breaux xU> ihh? mjskHaney QttJzk. Dugas Beieier Kelley Ledoux Day Oper. Bickham Cook F. /? f\\ McMurrayVJH IjJlM" Cavalier \0 1 Loaders X .Init. Date Armanff A-'X Doucet Instruments tfi. Michel Atf, Donatto |p/ic Rizzo __________ Grace j. j? Taylor 4^ Johnsoi{ V-/ M>l Witt aung L 0 Simonson^ Jbl Vavasseur Grant /o-t Neyland- Gravouilla Sltifi Looney ft fW Shanklin Jackson fyf IWolfe MHIender^fa ikL MetreieanT^y. I Oh 00 A 031930 CONFTDFNTT At CMP EMERGENCY DRILL o Back "nrTrTM-TnPnn?""| Notesl^'J'^flRecordl Dons o Next Drill Date - 9/28/95 Record # ASL Actual Emergency B Emergency Drill NOTE: The Safety Team must get Supervisor'* approval to use an actual emergency to fulfill drill requirements. Safety Team Conducting Drill Safety Team Working on Drill Date F Team r Team Drill Topic -- Personnel Involved in Drill: List Names of People Responding to Drill ACUTES HEM1CALEXRQSURE TQ.AMYLEML Luxe flrmana, uaie uravpnuna. uonaio -Harrision, jnurj. Grant. Jason Bourg. Tavlor Best (Security! Security List Groups Participating tn Drill SECURITY. MEDICAL. CMP OPERATIONS, CMP_ STAFF. "E TEAM" DRILL COORDINATION _ Drill Critique (Give description of actions taken in response to the emergency and the deficiencies noted during the emergency.) Simulated Emergency Scenario: An employee, while, passing through an .area of the slant. Jotlcea_a-----drip In an unusual place. He looks up as the tubing on the amvlene M-methyl -butenes -injection tubing to the Chloroform product line "hlows out" He Is sprayed by liquid, and staggers, to -the. safety.shower _ near T-1555A/B. fin the process, he blocks in the, line preventing, further solllaaeJTH1S IS NOT A SEILL SITUATION! Inside, the SS simulates^ .amvlene ilow_deviation alarm, and tails, the hoard SOS ahouL 1L_ Immedlately after, the "exposed'' rings the safety shower and the drill begins. The exposed person. when visited bv the responder will he staggering awav from the site. He will complain of Irritated. eves^_ belnq very sleepy, and will Insist on vomiting because he has swallowed some of the chemical. -----------Emergency Response: 0:00 start drill. 1:00 Curt calls Dale and Donald on Intercom. 1:30 Dale, and------Donald arrive from different areas, calls control room for ambulance. Curt calls 8888 for _anhu lance. Immediately they push Luke under shower and ave_wash_to make sure -he's, flushing, hla eve&-_ Dale-------calls Curt to tell him that Luke ha* amvlene In his eves and mouth. Luke Is complaining about being____ sick and feeling dlzxy, ?:40 Dale sends Donald to meet ambulance and continues to hold Luke under shower. 3:30 Curt calls to find out If amvlene Is blocked In or do we have a sollL It Is not a solll 5-40 DO A 031931 CONFIDENTIAL CMP EMERGENCY DRILL O Back O t--- .L-l -- -- Next Curl calls outside to see If ambulance Is there vet.It Isn't so he calls BBSS aaflln_to see.Wfaat.Jhe IQld up Is. There wai minor confusion about whether nurses should respond or not. Amhulancfi la en-routn 7;30 . 1st guard shows up at scene. 1:38:30 ambulance arrives on scene. Drill personnel ..ask_auar.d------ what his response. Is. He asks what happened. Instructs to keen him under shower, and will flak what-- chemical It la. Savs ha will call the gate to get the MSMS on the chemical. OpfiratlonS.ln.fQrma.hlm.lt la amvlene. Drill coordinators and operations discuss the .fact_that amvlene Is a common name_aniLthe----- g-methvlbutene-2 Is the chemical name fhow_the_MSD5_ls .written L -Drill concluded. _ ---------- Critique Meeting for Developing follow up: Outs1de_operator response and-llmlna. was very..quick and------ totally correct. The board man called BB88 Instead of. 333. a-Common evsnLdurlna.drllls. ^The board____ man called the responders on the Intercom and didn't make a plant page tor a safety.-shower.response__ The coordination to receive the ambulance and follow un bv_board man to make the .second Phone call was very good. The fact that g.methvlbutene-2 la. the_reaL name that "Amylene" Is listed as In the MSDS was not known by all the parties Involved. The ambulance resonded with only_1 puard-no_mirse&-or medical personnel (may have been since they knew It was a_ drill). _ _ -------- -- _ -- Follow up added to CMP action register:-------------------------------------------------------------------------------------------- ------- -- 1. Discuss the results of this drill at tailgate safetv .meetings. Include focus on uslna MSDS streets, and the real name of amylene. tCook/Duoas bv._ 10/13/9.51---------------------------------------------------------------------- 2. Contact Medical to ensure that they responded with one guard because It was only a_drlU--------------- L KfiYlrLJKellfiV.il/2aZ95).-----------------------------------------------------------------------------------------.----. 3. Put drill results In communique book----- (Kfillei ,3129/SS.)------------------------------------------------------------------------ MD30M4 DO A 03193? GONFTDFNTTAl CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Tue, Sep 26 FROM: Rizzo *1995 SUBJECT: Please review the attached MOD V code, changes They concern the PSA filter beds high vent flow alarm. AT.Mf6121 nn System C andEJJ20. Master Temperature Limit. ACf247)-------------------------------------------------------------------------- This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors X SOS's X OS's Loaders Init. Date Clebert _________ Haney (pi uli Kelley Ledoux jf^r~ Cook j Breaux Init. Date Bishop Dugas Beieler ^ y&y Bourg/^^5y# Day Oper. Bickham pj- Davis //QP toL Cook F. ftCfi-tb Ekey Init. Date Armand Doucet Instruments McMurray^r/ kyC Init. Michel fjjl, /<>M Donatto Rizzo Grace Cavalier Date AiZ'P/z/k Harrison Init. Grant *" Gravouilla J^ck Neyland. |l ooney & t5_ Shanklin Date Taylor Johnson Jackson to-ttft Wolfe Witt Young Simonson Vavasseur Millender Metrejean^Lvs DO A 031933 CONFTOFNTT At CHLORINATED METHANES MOD V _J_j DESCRIPTION OF CHANGE szfa A System Alarm 612 D-1250 Equipment Number 600 Can | This alarm has been changed to look at the total Ml flow not just the virgin Ml flow to R-1300. D0 A 03^34 COMF10FNT'IW' CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE S] C/D System PSA'S Equipment Number 300 Can Added alarms 360 & 361 to system C and 461 for system D the alarm will activate when the vent flow to atmosphere from the psa beds exceeds the high flow setpoint and the beds are in one of the many adsorbtion steps. These alarm are used to indicate a possible problem with the vent valves on the tanks. A high vent flow could indicate excessive venting or the vent control valve has failed and is wide open. DO A 031935 CONFIDFNTIAI CHLORINATED METHANES MOD V __\Bl\ DESCRIPTION OF CHANGE gf HI B System E-1320 Equipment Number 200 Can E-1320 Fans Master Output - AC(247) Added code to AC(247) which will prevent the output from continuing to ramp down when the Master Integral, DC(1023) is false. The Master integral goes false when the fans are running at max. or min. output. DO A 031936 CONFIDENTIAL., CHLORINATED METHANE PRODUCTS COMMUNIQUE Review & Initial DATE: Mon, Sep 18,1995 FROM: Rizzo SUBJECT: Please review the attached shoot explaning the MOD V changes to system C & D. This form is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. X PERSONS NEEDING TO REV] EW \ l^ay Staff ^ Supervisors X SOS's X "y OS's Loaders \ Init. /date Clebeitt / Haney \ / Kelley \ / \ Ledoux \ McMurrayX Michel / \ Rizzo / Tavh/r \ \ CookJteM Breaux ^ $$6. , \ Init. Date' Uiio, Date Bishop \ / ArmancK \ ao Duaas/<$^$ 7/h? Beieler ^ TB>ourg \\ // Day Oper. Bickham i/lti Davis CookF. f/ f/z! Ekey \^ \/ /\ Instruments V- / Init. Donatto Grace \ Johnson \ Cavalier /U Date Grant Gravouilla^^J^ Jackson Harrison/ Jack / \ \ Init. Date Npyylan"H lnl - Loonefy_________ . ShankUn------------- Wolfe /" Witt/ Youne \ Simonson Millender Vavasseur________ MetrejeanjV' Ijf^ DO A 031937 CONFIDENTIAL CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE gf H] C/D System PSA'S Equipment Number 300 Can | In the below list alarm, the low nitrogen flow alarm setpoints which were AP's were replaced with AC's . These AC are the calculated flow requirements based on the pressure of the filter bed. System C * Warn(355) and (356) System D - Warn(460) RATE OF CHANGE ALARMS - 321,347,447 Added a minimum temperature to activate the rate of change alarm for each bed temperature - Bottoms bed 80, mid and top 30-35. A 031938 CONFIDFNTTAI.. i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: FROM: f//<r _ ,1995 Abbeys______ SUBJECT: qC / e. _____________ PltittK _.4y?e * /> /> /**<. r2; Pos- -/Xt /? >-0 LAJof'c, L//? Pl-d-cA. Pz Lc~- z. 6-<f- />, Pt-i-ek $ '*1 /n PO p}/- p/u. i/AX ' -Pasty . P/e** c_ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day^St^ff PERSONS NEEDING TO REVIEW Supervisors SOS's. Loaders Haney Kelley Ledoux Date Init. Date C Cook jjjgl 9-JU Breaux Qj1j!i Dugas Beieler iST S Day Oper. Bickham CookF. f.( V McMurray\M \ Cavalier AC. Michel Rizzo /Uh /p/U / Donatio 1 y Grace / Grant f-}f", Gravouill5^^^_ Taylor John /on Jackson . Witt Sirrtonson Millender ! aung ____ Vavasseur MetreieaiTDw IS Init. Date Armand Doucet Instruments Neylaud. Shanklin DO A 001909 CONFIDENTIAL. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Fri, Sep 15>1995 FROM: Rizzo SUBJECT: Please review the following revised procedures- 1 1 531 sample doe # 460694 2. psarchrg.doc #460127 RnnOcscl.doc___ OfiOISti ^S.tsamhea.Doc___&,460273 5 SUM1SYS.DOC #460042 This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Clebert __j>_ Haney\ C/77f Kelley Ledoux McMurray' Michel PERSONS NEEDING TO REVIEW SOS's X Loaders Breaux Beieler Bickham flQ v//j Cook F. __ 9i 1 nit. Date Armand / D^ucet IInns^ttrruments Cavalier /v/z. Jnit. Date Grant f-Jpi Jack Q^> %lte> Neylarid__ _y Gravouift^S'Ml. h Looney fcj)' l'h'% Shanklii Jackson W-5^ [Wolfe 1-K-15! Millender^ ____ MetrejeanT)^ A 3t9l? o _ t At c OMF10 CHLORINATED METHANE PRODUCTS COMMUNIQUE' ( 'MPLOYEE: Please initial and date when you have reviewed and understood the material. DO A 031941. CONFIDFNTTAI. CHLORINATED METHANE PRODUCTS COMMUNIQUE* Review & Initial DATE; /**$ FROM: PUG-AS ~r SUBJECT: _______ C~600 lVE e*I T/%U te j/jjMfte Z^e/Arr 4995. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supejrrvviissoops SOS's OS's aders Cook J.v SA Dugas 00 Date 2-QH Breaux / t/XI Beieler Day Oper./' Bickham Cook F. 4nit. Date %/$ pc Cavalier /jiC Z)#)j Jnit\ Date Armand Doucet truments Grant , Nevland Gravouilla flk M ^ Looney $2' 8**^3 Shanklii Jackson Clh h-Wv Wolfe / Simonson___ \ Millender fa.il Vavasseur MetrejeahX>V^ DO A 00194? CONFTDFNTT At. C--600 LEVEL CONTROL C-6GC' it no a being level controlled using the same level control that L-610 used The cascade control scheme to CA2 and CWT is the same as it was formerly The level control 'loop near C--600 is blocked in on each side or the control valve and the bypass is wide open Tins is the way it will be lined up under normal operations. The C-6G0 level recorder controller (LRC-2B07) is the old C-610 controller and is located in I DC Group 11) slot 1. It is also located in Group 119, slot 3 This is the working level controller. The level control valve near C-600) controller LRC-45015, (which is bypassed) is located in TDC Group 119) slot 6. You won't have to do any f r, i no u< i ~ h this one under normal operating conditions. The ,.-t)00 sample point has been relocated to the diked C--610 area and is on t-"c '.pstream bleed valve on the level control loop Ijcil. ., c .. j i t be able to send acid to CWT and.-'or CA2) along with acid to T -1 1'. ? 'he same way that we used to do it. " *' . - - , s any quests.11'-, s- tali- to James or Donnie. D-'D/L" : DO A 031943 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Tue, Aug 22 FROM: ,1995 SUBJECT: Please review the attached sheets for an explanation of the changes made to the PSA syslem. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors X SOS's X OS's Loaders \ Clebert Init. Date / Breaux Init. Date \ Init. Date Init. Date Bishop \ Armand Beieler ourg ___ / Day Oper. \ Bickham (Q-. f/zg Davis Cook F. ft wj Ekey X X\ Cavalier 'y Itilt. Date Harrison___ Donatto / _ V' Grace , \ Johnson Grant ^ Jack Gravouilla Lui i Looney Jackson tWo/fe rf-if-'k ___ ___ Doucet Instruments \ t. Date A Nevland__ : Shankli 'oung ___ Simonson Vavasseur Millender Metre.jeanTSl'n ? V) CO A 031944 CONFIDENTIAL CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE m PSA'S Equipment Number 300 Can 1 RAMP RATE ALARM Req(321) - Each temperature point on V-1770 has a high rate of change logic written. Example for Al(363) The way it works is that when the seq enters the adsorption step 304, if Al(363) raises above the previous cycles temperature, AC(746) by a given amount set by AP(1424) , a DC will become trueDC(1059), which in turn, activates another DC, DC(1093), which will activate the alarm. When this occurs, AC(746) will begin tracking Al(363) value until leaving the adsorption steps, where it will trap its last value. When the alarm activates, another AC, AC(748), will track the highest value for that temperture until the alarm clears. Upon leaving this step, DC(1059) will become false. The next time the sequence comes back through the cycle, one of the following control actions will take place: * Upon entering the adsorption step, if the temperature, Al(363) increases above the trapped value, AC(746), from the previous cycle, by an amount greater than the previous cycle AP, DC(1059) will become true again, clearing the alarm and then re-activating it, Indicating a continual increase in bed temperature during the adsoption cycles. * If the temperature is above the previous temperature, AC(746), but below the deviation AP setpoint, the alarm will remain active. The alarm will not re-ring. * If DC(1059) doesn't become true and the temperature, Al(363) Is below the previous cycle temperature, AC(746) upon leaving the step, DC(304) will become true and AC(746) will be made equal to A!(363). This is used to eventually clear the alarm. When the temperature from cycle to cycle begins to decrease, and when there is no longer a deviation between the trapped value, AC(746) and the highest value attained during the alarm condition, AC(748), by an amount set by AP(1407), the alarm will clear. - See DC(1093) I DO A 031945 CONFIDENTIAL. CHLORINATED METHANES MOD V |__ | DESCRIPTION OF CHANGE |gf O c System E-1760 & E-1770 PSA'S Equipment Number 300 Can This controller has been changed from a freon back pressure controller, to a cascade drain temperature to pressure controller. See AO(303) & AO(323) When the slave controller becomes enabled, if the local pressure setpoint AK's are set to (0), and the drain temperature transmitter hasn't failed, the master controller will become enabled, adjusting the pressure setpoint to control the drain temperature. If the drain temperature shoud fail, the master controller will become disabled and the slave setpoint will maintain its last good value. If the pressure transmitter fails, the controller will hold its last good output. If you need to adjust the controller you can place the valve in manual. REQ(329) This alarm detects a high oxygen concentration on the discharge of K-1770 DO A 031946 CONFIDENTIAL 1 CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Fri, Aug 18 FROM: Rizzo ,1995 SUBJECT: The Following Procedures Have been Added To the System: Please Read These Prncedure. *C-600 Emergency Procedure - #460626 *C-600 Shut Down - #460627 *C-600 Startup -#460628 * Unplugging Amvlene Additnn Lines - 460624. PSA Valve Replacement #460631 * OS TOR description- Resource Form * V-1540 Filter Element Replacement - 460629. * V-1540 Back Wash Procedure - #460630 This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV FAY Supervisors X SOS's X OS's X Init. / Date Clebert / Haney / \! Kelley Cook Init. Date flffK Breaux Beieler Bickham ^ Bishop Bourg / -J/ Davis vA Cook F. jZ tjvb Ekey Cavalier Harrisi Grant S'-' Jack jfpl Gravouilla Hi y-1^: y Loone (Ul Jackson Wolfe Voting ___ Simonson Millender 1c\U $ m I Vavasseur_________ Melreieaihy. Loaders Init. Date Armand Doucet / Instruments Init. Date Neyland; ShankliiS CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Fri, Aug 18 FROM: Rizzo SUBJECT: The Following Procedures Have Been Revised- Please Review Them * C-1540 Drain Procedure - 460072 * C-1540 Shut Down - 460073 C-1540 Start up - 460074 * R250 Start Up Procedures - # 460007. 460009, 460010 &. 46001L T-102(LEill JJ6QQ96- ,1995. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. '.MPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff Young ___ PERSONS NEEDING TO REVIEW SOS's X OS's X Loaders Breaux Init. Date /Init. Date Armand Beieler //j, Bickham (C^ Cook F. fC Ekey Djiucet _______- Instr^urmments Cavalier /fc Grant V S'* Gravouilla Harrisopf Init/ Date tJack Neyland^l. Looney <21 ttOL Shanklin- Jackson S-tyUIwolfe Millender M etrej ea n"j2)[[>_y|V]j DO A 031948 OONFTDFNTIAL i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT: A-/3Qq PAeMs^t DATE: FROM: 8 /IS?. ,1995 This fonn is used to insure the attached information is communicated to the appropriate plant personnel. |NITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV Supervisors \ Init. Date \M, mlClebfert_________ cook j Dugas^^ Haney\ Kelley \_________ Ledoux ^_________ McMurravy^ C^S Day Oper. \ Bickham ^ Cook F. pc (/'ll Cavalier /fc. tf-MV Michel ___ ' Donatto \ Rizzo _________ Grace _\ / / Taylor__________ Johnson Witt /" Simonson_ , *ung ___ Vavasseur Grants Gravouilla^' l' < )j Jackson f,\ Wolfe MillenderftAA tfftl Metrejeanl)lr) ___ Loaders \ (nit. Date Armand DO A 031949 conftofnttal CHLORMETHANES R-1300 MODIFICATIONS Changes in the R-1300 program are now being implemented as the '<nit has been shutdown. In order to ready the plant to accept up to AS J. MMlb/day of chlorine feed, the large flow transmitters on the vapor recycle stream from the distillation train have been reranged (from 207920 lb/hr to 250000 lb/hr). The scale factors have been reassigned for all variables associated with the flows, and literals employed in the reactor mole balances have been redetermined. Also, .the HC1 flow to the inlet nozzle is no longer used for temperature control of the nozzle. The purge flow setpoints for the controller are now the only adjustments available. Simulation of these changes is now complete and the upload is slated to occur on August 17th. The recycle flow transmitters will need to be reranged before R-1300 startup. One issue still requiring resolution is the value, KB (193), used to allow the swap from small to large recycle flowmeters to occur. Typically, there is a deviation between the two meters while feeds are increased during startup. The meter flows equalize shortly before the swap is triggered by DC(138). As a result of the rescaling, this converging may take place at a higher flow than that currently set in the program. AP(193) may need to be increased, so the small and large flows should be monitored to determine if a new value is necessary. old DO A 031950 CONFIDENTIAL I I* Review < Initial CHLORINATED METHANE PRODUCTS COMMUNIQUE' DATE: FROM: ,1995 I fell This form is used to insure the attached information is communicated to the appropriate plant personnel. lNITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors SOS's Loaders Init. Date Clebert Q, hr~ Cook J. Date V 9, i Breaux Haney 1lf^{ Dugas/J^? 7/tf Beieler fyb sPfe Kelley Vi? Ledoux McMurrav\jltV Dav Oper. 4* Bickham (jij gjt Cook F. fC tzrt Cavalier pMCs J*2% U Michel ///?/, /OftH' Donatto _______ Grant ?'l Rh*o- ___ Grace lin Gravouilla ack DU ' Looney AH /Mi Taylor ___ Witt " J . oung Johnson Simonson Vavasseur Jackson Millender ^ ^ Wolfe 2lt MetrejeanT^ *7, DO A 031951 CONFIDENTIAL OPERATIONS COMMUNIQUE' K. KELLEY Date: 7/27/95 Topic: Ordering liquid nitrogen for T-455. The "Liquid Nitrogen Order" procedure has been revised to make things a little easier from a paperwork standpoint. The procedure has been updated on the commons. We now have a standing PO# with Air Liquide, so you will be able to call them directly and schedule the truck when you need it. See Julie or myself with questions. Kevin Kelley DO A 03195? OONFIDFNTT AL i CHLORINATED METHANE PRODUCTS COMMUNIQUE Review & Initial SUBJECT: 44 DATE: FROM: 7//7 ,1995 M7/ic . s- <b'( --i*>z'" /-'eu-'&i. y'Oj-' r /* 'Zv ----'.-i /*--> c_ ~>-t . ?J u, 7/ _ ^ 77*.~ -/Tl* yC_. /?/. ---- . This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW SOS' OS's Loaders Clebert Init. Date Init. Date CoOk J. MC` Breaux Init. Date Lb 7hW B J2 Init. Date Armand Haney gfcjMfyt* W# Beieler A6_2L m. Doucet Kelley Ledoux "ihh i/a. Day Oper. Bickham ftp Cook F. fc 1 rtU Instruments MeMurraytM <sli7 Cavalier /#?-- 7~f)& Michel $'/?'}< /o/*H Donatto Rizzo Taylor A/& ____ Grace MU "jpM Johnson Grant Jack pp> '?77-<? Nevland. Gravouilla|j^~H*') V Looney 7~//'^ cShanklii Jackson iVolfe DWth^ jr Simonson w Vavasseur Millender MetrejealTJiVfv "ijli 00 A 031953 confidential / CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: 7/7 ,1995. SUBJECT: " 1 r 1-- fl-/^OO /-t/feA /lt TrC-tS--> cktC P) ftZ'C . '/k:> <? /> * klP-- /Z**~*t C-J-, <k*-e-cA 7/k > ScJ'm t/'*1 / 4*. *r "<J%. -JP*- C-&-4 . -Ao r<~ h.j, fid, Q.PA- r <0$ yc> ^ frk sto , f P>r~ /4rUf/2- 0) , /j? r^o /c7 s9*,. , t** %> -s----,y jZ~k~ ~ j This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day^Staff PERSONS NEEDING TO REVIEW Supervisor? SOS's OS's Loaders Jnlt. Date Clebert Cook Haney Kelley ^ fai Ledoux McMurray^ `ftVvV Michel Rizzo Taylor tefn ________ 0^ Witt ->ung V4? 'V Breaux it. Date Bishop 7jWi Beieler Bourg/jfe Bickham (Jr llrfhf Davis CookF. Ekey L *11$ Vl> init. Date Armand Doucet Instruments Cavalier fa. ikarris Grant ^ 7'#^ Jack as.H. Neyland GravouillaQ& .jjjtf Looney jllL'E'P Shankli Jackson @JK_ 7-/0-V Wolfe `DW 1-%-V Millender Metrej % 00 A 0.-51954 C0NFIDENTlfll Review & Initial O iaOKI.NATED METHANE PRODUCTS COMMUNIQUE' DATE: Fri, Jul 7,1995 FROM: Rizzo This form is used to insure the unueiicd information is communicated to the appropriate plant personnel. INITIATOR: Place a cheel< inui is by li.e emup(s) needing to review. D0 a 031955 C0NF10FNTT Al CHLORINATED METHANE PRODUCTS COMMUNIQUE Review & Initial DATE: FROM: -t/s ,1995 rs To r' t4> ic-ck r->^ 3 5 b j.o _v hr,, l- L. J~i> O * * -1^ / * e/-^ >ec 0 ^/'<, H'ib / /'/p, 7- -* ^-7/ / &-<Jl br -.0 ^ This fonn is used to insure the attached information is communicated to the appropriate plant personnel. T^ITlATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. PERSONS NEEDING TO REVIEW Supervisors SOS's OS's Loaders Init. Cook J, I___ /____ Dugaw^ffi Date Breaux l/ir Beieler Afi> Bishop Bourg /?/ 7IV Init. Date Armand Doucet Day Oper. Bickham ek-j/m Davis Cook F. Q._ Ekey C$ ifcr lltS. Instruments Cavalier HarrisoiilXt^ 7ftf Donatto Grant fr^/72Grace ~V2 Gravouilla Johnson Jackson ^ Jack Neyland- Loonev ^ Shankliiv kolfe T)W ~VH5 Simonson Vavasseur MillenderM) 7/kL 1I MetrejeanTlrTi 1 ___ T**T--* DO A 031956 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Wed, Jul 5*1995 FROM: Rizzo SUBJECT: Please review the attached shirts which explain the rnrie modifications thal were done on system CD)------------------------------------------------------------------------------------------ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors X SOS's X OS's Loaders Init. Date Anit- Date Clebert_________ Cook J.i/Ce 7 to Breaux /In it. Date Init. Date Init. Date ihks Bishop________ Armand Haney (jflf *//f Dugas J$) j/b Kellev vil I?-' Ledoux nj^l Day Oper. Beieler /& Bickham ^ CookF. Bourg ________ 6savis CSL oh 77^ Ekey________ Doucet Instruments McMurraV^ <l\v\ Michel fhftl. *jjS Rizzo Donatto Gri.ce Cavalier Init. Date > < Grant cy j(~\u27 Gravouilla Harrison 1 Jack________ Looney ________ Taylor l)(f& Johnson Jackson fy nj0,oflWolfe Init. Date Neyland Shankli Witt - V' '7oung ^ Simonson Vavasseur Millender 7ft Metrejeanpjpn ijtf A 03]957 confidential CHLORINATED METHANES MOD V _I "_I DESCRIPTION OF CHANGE gf D System ALARM(460) PSA'S Equipment Number 400 Can Alarm (460) was added to system D. This alarm will activate when the Nitrogen flow to the beds, Al(425) drops below the minimum N2 flow setpoint, AP(462) and in step(434) or (440). The intent of this alarm is to notify to board operator that the flow is to low to properly regenerate the beds, possible causing an organic break through. this alarm may become a nuisence alarm because the timer, DT(413), is set to low. If so, monitor the N2 flow when first entering a regen step and time how long it takes before an actual flow is indicated. fifQiyA'] A 031958 CONFIDENTIAL CHLORINATED METHANES MOD V _It_J DESCRIPTION OF CHANGE gf SI D System C-1540 Equipment Number 300 Can 1 AO(322) When the feed valve to C-1550 is requested to open, the slave setpoint, AC(1097), will go to zero as will the valve output. The slave setpoint will then be ramped back to the original tracked setpoint, AC(1060) preceded by the master returning to full control. If, during this process, a sufficient feed flow, as set by AP(7Q5), hasn't been established to C-1550, by the time the control valve output exceeds AP(704) value, DC(705) will become "TRUE", indicating a possible problem with the feed AOV. When this occurs, the AOV to D-1525, DO(303) will open and the feed AOV, DO(322) will close. The control ramp setpoint will be given a value of zero for one second, closing the control valve and then ramping the setpoint back up to the feed that it had prior to the swap. The same function occurs if C-1550 would enter the shutdown step and the feed aov would close. If DO(303) opens but a flow isn't indicated, the feed AOV to C-1550 will re-open. DO(303) & DO(322) In the event that DO(303) is requested open by the mod and a sufficient flow hasn't been established by the time the control valve output reaches AP(704), DC(704) will become true, opening DO(322) back to T-1500. This is an indication that there are problems with the AOV. If a condition exist where the feed aov, DO(322), to C-1550 is requested open and a di/do mismatch occurs in the process, or if the feed control valve AO(322) becomes greater than the setpoint to establish a flow and the feed flow to C-1550, AI(314), is less than AP(705), DC(705) becomes true, indicating a possible problem with the feed aov . DO(303) will become enabled, the reason for this action is to protect the P-1541 reflux pumps from dead heading. WARN(330) This alarm activate if DC(704) or DC(705) become true, indicating a possible problem with the swapping of AO(322) or AO(303). DO A 031959 CONFIDENTIAL CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE g( g] D System C-l 510/20/40 Equipment Number 100 Can WARN(158) Re-wrote Alarm 158. Took out the logic that required the level to be above a certain limit before enabling the alarm. When the alarm activates, P-1511's will trip and will not re-energize until the alarm has cleared. WARN(220) Re-wrote Alarm(220). Took out the logic that required the level to be above a certain limit before enabling the alarm. If the alarm activates, indicating a low leve, the reflux pump will trip. The pump will not re-energize until the alarm has cleared. DC(960) Changed the latch from DC(919) to #ALM(220). This has the same affect since DC(919) goes false when ALM(220 activates). 00 A 031 960 CONFI OF NT I Al CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE M D System T-1500 Equipment Number 100 Can | AUTO ZEROING AK(890) placed a one second blip in the CALL AKZERO(AK890) logic. Upon entering STEP(263) AK(890) will be autozeroed. Once it has been set to zero, the operator has the option of re-setting the AK to begin feeding C-1510 again. DO A 031961 CONFIDENTIAL i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT: P DATE: M5o |___________ FROM: ,1995. This form is used to insure the attached information is communicated to the appropriate plant personnel. fNITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. PERSONS NEEDING TO REVIEW Supervisors j/_ SOS's OS's Loaders Uiit. Date Cook J^22 lit Breaux mliLDugas Beieler Dav Oper. V Bickham Cook F. Cavalier (nil. Date 7 t f ,mm fC 7-3 Air nji. Date Bishop f iff Armant Bourg/_ Doucet &Q ?//$ Davis 'Kjb ih Ekev fhiliL. Instruments HarrisoiQtfL Id- Donatto M l/Sk_ Grant ^^`j&ck /fc 7V Grace 'i') Gravouillal^ Looney ~1'3 Neyland. Shanklin Johnso SSiimmoonnssoonn"jC'/ VavasseufM^ Jackson ^ 7-1 Ufa Millender'^// Metrejean Wolfe DO A 031962 CONFTDFNTT Al. OSHA'S NONE DOW WEEK OF 06/12-06/18 DAYS SINCE LAST DAWC = MANHOURS SINCE LAST DAWC= 6/19/95 233 2,592,042 DO A CONF1 03"i OE-NTT At CONTRACTOR OSHA INCIDENCE RATE OSHA'S NONE CONTRACTOR WEEK OF 06/12-06/18 DAYS SINCE LAST DAWC= MANHOURS SINCE LAST DAWC= 6/19/95 18 240,970 DO A 031964 CONFIDENTIAL SITE OSHA INCIDENCE RATE w h jo> r n o z r a o dec! 6/19/95 DO A 031965 GONFTDFNTT AL DOW OSHA RECORDABLES (CUMULATIVE) 1995 OSHA RECORDABLES SEVEN 6/12/95 DO A 03196)6 CONFIDENTIAL 16 x 14 -12 -10 -- LEIGH'S AREA DOW OSHA INCIDENT RATE N_ soc <^r <- j-- W2 C Lu <1 ChH C L2l ao o ........ ......... .............. .... ...... ua.14.21 m m {y 0) it o u. tv ft 2 m w O. < > * 2 IS A C 3 " IS A *3 -> IS IS AA O l 3 < (A CM A T> O IS (71 > O Z <s 01 6 o Q f "jo/95 DO A 0 3 1 9 6 8 C O N FTO fN TTAl 12 T LEIGH'S AREA CONTRACTOR OSHA INCIDENT RATE UCL 10.35 0-Cm>)0ujbm.)0251Jj: < 2 NN 0) k 0 0) OOI*) O N 01 >O Z rj at O> a r0t) ce rrtt iui. 0> e 2 o o> o a < > a 2 ro>t "c3> rat 3 rt 0) r01t r0t) <3a a u> o O rt 0> o> Z rt O) 6 0 o *0) 0") < 0) 1JO1j. 0<0 0 2 0) a < <0) 0 2 *0*) 3 *n3 * 03ar) < 0 a 00 *00 O O *rt >o Z O^) Q6 O) 1ce t0l*) Ui) I0A> i0A) i2i 3< rt 2>* 6/"' '95 LAD REACTIVE CHEMICALS INCIDENTS (CUMULATIVE) Z O -Q 1 U Z I-M 1995 INCIDENTS MAY NONE 6/12/95 c^rVr9`9 DO A 0 3 1 9 7 0 C O N F T D F N T IA L 1995 Contractor Injuries by Body Part Finger/Han d/ Wrist Leg/Knee/Foot/Ankle Back/Neck Hernia/Internal Abdomen Head Arm plu 6/95 DO A 0 3 1 9 7 1 C O N F ID E N T ! Al. 1995 Contractor Injuries by Contractor JEM NMC HBT S&S Cat Tech Gemco Rust Wyatt Westgate Tech Comp Srv 0 10 No. of Injuries 20 30 % of Injuries 40 50 XJ % of Manhours plu 6/95 (50 A 0 3 1 ^ 7 2 C O N F ID E N T IA L 1995 Contractor Injuries by Job Function Maintenance i Construction Operations Services plu 6/96 1995 Contractor Injuries by Manager Area Accountable Cole htolmes Leigh Sticklen Masey Bernat 6/96 No. of Injuries jii 25 30 35 % of Injuries % of Manhours 40 1995 Contractor Injuries by Time in Class < 12 mo 12 - 24 mo 25 - 36 mo 37 - 48 mo 49 - 60 mo > 60 mo plu 6/95 No. of Injuries % of Injuries 40 c o n fid e n tia l uu A 031975 c o n fid e n tia l 1995 Contractor Injuries by Type of Contact Struck By/Against i Body Reaction Caught in/on/between Fall/same level Temperature Exp. plu 6/95 No. of Injuries % of Injuries i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT: _ Ppr/n & 4, ^ <AgA>i DATE: FROM: ,1995. D flr<^-S*6zr- 'Tsir.UiXji <> C&2-SCS.Z. f^y7 2?^r-f-^r> / ifL. frf / qy /g/ tW PrJctUc 1 J^_ This form is used to insure the attached information is communicated to the appropriate plant personnel. tNITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. PERSONS NEEDING TO REVIEW Supervisors OS's Init. Date Init. Date Clebert Of; lo Cook J</RlO/ Breaux /init. Date (,fa Bishop Haney Kelley Ledoux ^Ikl Dugas /$ c/a? Day Oper. Beieler /j^_^ Bourr;g Bickham ^ Davis Cook F. a 3-^ Ekey McMurravMK Ipffy Cavalier h arriso Armand Doucet dn- Instruments Michel fah M Donatto Rizzo Grace M.!^L Taylor Johnson Grant Gravouilla^ J- T Jackson j Jack 0\ Neyland- Looney bi i-im Shanklin Wolfe i!8 Is Witt Simonson Millender'j^ ^ oung Vavasseur. MetrejeanpVY\_^ 2cj 0 A CNF^FNTj^ e /etc.) :rom aring the aring the id details Dieted by e Plant approval side with ted with d, either .menting orrected a for 12/15/94 Page 258 Attachment X Topics for Possible Review at Pre-Startup Audit (Brother's Keeper Pre-Startup Audit form acceptable for R&D Projects) Item Procedures are complete for: startup shutdown normal operations emergency operations line/equipment openings confined space entry lockout / tagout sampling filter changes spill containment loading / unloading decontamination other emergency (freeze, power loss, etc.) Other (specify) Consequences of deviation defined Training Modules/Tests Complete Training Conducted or Scheduled Pressure Testing Plan in Place or Done Dry Run/Simulation Conducted Critical Instruments Frequency ID'ed | Fail Safe Positions/Interlocks Verified | Instruments Calibrated Yes N/A Expect By Assigned To J \// 4 iv// Jr y/ J, y y / f y / J y /s J / (J3.1* hr \J / >4 i ys Safety & Loss Prevention Standard S-333, Pre-Startup Safety Audit y DO A 031977 CONFTDFNTT AL 12/15/94 Page 259 Item Instruments Loop Checked Plant IH Manual Updated new MSDS's Area Maps PPE listing Hazcom Program CPAI Other (specify) Monitoring Plans in place for during and after startup Yes/ N/A Expect By \J /* Sy / y y y y j J Assigned To Mechanical Integrity Programs updated: Pressure Vessel Relief Device / / Piping Inspection Vibration Lubrication v/ / J PM Program updated List of Glass Devices Updated /J Pump Rotation checked Necessary Spare Parts Obtained Equipment Inspected for Compliance with Design Specifications V/ J/ J Safety & Loss Prevention Standard S-333, Pre-Startup Safety Audit DO A 031978 CONFIDENTIAL 12/15/94| Page - "Tf* Attachment 2 Items to Observe for During Walk Through Personal Safety Safety Showers/Eye Washes Exposure to Temperature Extremes (number and access) Intercoms Lighting Fire Extinguishers Ventilation (number and access) Hazard Signs (Noise, CSE, PPE, etc.) Sprinkler System Exit/Egress Routes Waking/Working Surfaces Level/Non-slippeiy Drainage Clearances in Walkways/Aisles Fall Protection Equipment Tripping Hazards Ladders Guardrails/Barriers (gates/obstructions on climbing Stairways (non-slip, well lit) side/overhead obstructions/etc.) Support/Hangers/Shoes Markings/Labels Sample Points Plugs on Open Ended Valves Joints Aligned Valves & Piping Drain/Vents to Safe Location Insulation Valve Location & Orientation (access to operate & maintain) Markings/Labels Accessibility to Relief Devices Vessels & Tanks Direction of Relief Guards in Place Accessibility (operate & maintain) Seal Flushes Start/Stop Stations Labeled Grounding MCC's Electrical Labeling (switches, starters, JB's) Miscellaneous Hoses Flammable Storage Utility Stations Compressed Gas Cylinders (labeling, access, connections) Glass Devices Radiation Devices Control Room Instrument Layout Safety & Loss Prevention Standard S-333, Pre-Startup Safety Audit DO A 031979 CONFIDENTIAL 12/15/94 ^ Appendix A Pre-Startup Audit Action List Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation: Action Item: Responsible: Expected By: Actual Date: Observation:____________________________________________________ Action Item: Responsible:Expected By: Actual Date: s-f*.fy & Loss Prevention Standard S-333, Pre-Startup Safety Audit D0 A cm^eo CONFIDENTIAL 12/15/94 Page 262 *- 0 e rc DO A 031981 CONFIDENTIAL. H PUMP RELIABILITY PROJ METHANES inOMAVtNC ISSUE RECORD* ma A &CK2CM *8121 w n*1 * 03/Si 1 fttlt wpm ^ym77z*I~ms' mPuxm WOtVCTM?__ ft DRAWING LIMITS I DC DRAWING LIMITS A L &0 A 03198? CONFIDENTIAL PIPING C0cf O' m <r, z C lci; <[ t-> Ll oz O Co SECTION *R-R* LOOKING MHTH B4-9W1 il-l*-n)6-*l L' n | 1 0EVLI1QN t " 1 "1 "1 t rr 1 l--T-- TT^ i owing iisue rccoro lit |____ |a<SSsOM XBI21 0)/t) h"---- r|m""--1-f-1-"-"--"--------1I THE DOW CHEMICAL < Training & Development Procedures Chlorinated Methanes CMP PROCEDURE VENTING PUMP SEAL OIL POTS TO THE DRY VENT HEADER PROCEDURE # PURPOSE To provide the operator with the necessary information to properly vent a seal oil pot for a tandem sealed pump to the dry vent header. SCOPE This procedure covers all steps to safely vent a seal oil pot to the dry vent header. RELATED PROCEDURES STARTING AND SWAPPING MODV OPERATED PUMPS - #460206 DEFINITIONS Seal Oil Pot - drum that stores the seal oil which circulates through the seal for any tandem sealed pump. SAFETY CONCERNS & EQUIPMENT Always wear monogoggles and chemical resistant gloves when draining oil from a seal oil pot. If the primary seal is leaking, then the oil will more than likely have process material in it. ENVIRONMENTAL CONCERNS All oil that is drained from a seal oil pot must be discarded in the waste oil drum in the oil storage area. DO A 031904 CONFIDENTIAL Revision # .0 Dow Confidential Revision Date- 6/22/95 This procedure is valid for 24 hours from the date viewed, 06/23/95 09:29 AM Training & Development Procedures Chlorinated Methanes VENTING PUMP SEAL OIL POTS TO THE DRY VENT HEADER SPECIAL CONCERNS When venting seal oil pots which have internal cooling coils, extreme caution must be taken to ensure that water hasn't leaked into the seal oil pot due to a coil failure. Venting a seal oil pot that has water in it will cause significant corrosion to the dry vent header and will ultimately lead to pipe failures. jvh 6/23/i- seuotl.doc 00 A 031985 CONFIDFNTIAI, Training & Development ProceduresChlorinated Methanes VENTING PUMP SEAL OIL POTS TO THE DRY VENT HEADER PROCEDURE SEAL OIL POTS WITHOUT COOLING COILS Step Action 1 Inspect pressure gauge on seal oil pot and make sure it is working property. Replace if necessary. 2 If pressure is greater than 10 psig, then proceed. If pressure is less than 10 psig, then it is not necessary to vent the seal pot. 3 Open vent valve to the dry vent header. Monitor seal pot pressure. It should drop to approximately the same pressure that the dry vent header is running. 4 Allow pot to vent for approximately 5 minutes, then close the vent valve. 5 Monitor seal pot pressure periodically. If it increases slowly over time, then the primary seal is OK. If it increases rapidly, then the primary seal has failed and the pump will have to be shutdown for seal replacement. jvh 6/23/95 sealoil.doc DO A 031986 CONFIDFNTTAl Training & Development Procedures Chlorinated Methanes VENTING PUMP SEAL OIL POTS TO THE DRY VENT HEADER PROCEDURE SEAL OIL POTS WITH COOLING COILS Note: This procedure applies to the following pumps only: P-1320 C/D P-1541 C/D Step Action 1 Inspect pressure gauge on seal oil pot and make sure it is working properly. Replace if necessary. 2 If pressure is greater than 10 psig, then proceed. If pressure is less than 10 psig, then it is not necessary to vent the seal pot. 3 Varify that there is no cooling coil water leaks to the seal oil pot by inspsecting the following: A. Check seal oil level by inspecting the sight glass. If level is unusually high or at the top of the sight glass, then water or process liquid may have filled the seal oil pot. B. Sample the oil in the seal oil pot and check for water. Iftwo distinct liquid layers are present, then the oil is contaminated with water (water layer will be on the bottom). 4 If water is present in the seal oil pot, then swap pumps and tag out the pump with the contaminated seal oil pot so that the pot can be repaired. Do not open the vent valve to the Dry Vent Header. 5 If water is not present, then break seal on valve to the dry vent header and open fully. Monitor seal pot pressure. It should drop to approximately the same pressure that the dry vent header is running. 6 Allow pot to vent for approximately 5 minutes, then close the vent valve. Install new seal on vent valve. jvh 6/23/95 seaJofl.doc A 031937 confidential Training & Development Procedures Chlorinated Methanes VENTING PUMP SEAL OIL POTS TO THE DRY VENT HEADER 5 Monitor seal pot pressure periodically. If it increases slowly over time, then the primary seal is OK. If it increases rapidly, then the primary seal has failed and the pump will have to be shutdown for seal replacement. jvh 6/23/95 sealoii.doc DO A 031988 CONFIDENTIAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE STARTING AND SWAPPING MOD V OPERATED PUMPS PROCEDURE # 460206 PURPOSE To provide the operator with the necessaiy information needed to properly start, swap and restart a MOD V operated pump. SCOPE This procedure covers the steps necessary to safely start up mag drive pumps at CMP. RELATED PROCEDURES All start up procedures DEFINITIONS Mag Drive- A pump that is magnetically coupled such that there is no need for a mechanical rotating seal for separating the dry and wet ends. Arc Valve- Automatic recirculation valve. Designed to maintain a minimum flow (based on its design). When the discharge end is blocked, a bypass line opens and allows a bypass flow. As the forward flow increases, the bypass closes. NEVER BLOCK IN AN ARC VALVE!!!!! SAFETY CONCERNS Not filling the pump bowl with liquid prior to starting & EQUIPMENT WILL damage the pump when energized. Minimum block standards for swapping. Scott -ovista and rubber gloves to drain pumps. Never rotate a pump by hand unless the main switchgear is racked out ENVIRONMENTAL CONCERNS A chemical release due to a malfunctioning seal SPECIAL CONCERNS Monitor discharge pressure to ensure the pump is stable. The process pressure of the suction side of the pump must be equal to normal pressure during operation. Without that pressure, the pump will cavitate, vapor lock, and wreck. Revision# 2 Dow Confidential Revision Date- 6/22/95 This procedure is valid for 24 hours from the date viewed, June 23, 1995 9:45 AM D0 A 031989 CONFIOFNTIAI. Training 8l Development Procedures Chlorinated Methanes STARTING AND SWAPPING MOD V OPERATED PUMPS PROCEDURE NOTE: If this pump is a mag drive pump, monitor amp and pressure. If amps and pressure are swinging, the pump may be cavitating. To prevent damage to the pump, swap pumps and shut down. If the amps are low and the pressure high, the pump may be dead headed. I. Lining up a MOD V operated pump Step Action 1 Clear any red tag masters. Close and blind any bleed valves on the pump. Ensure a working pressure gauge is installed on the discharge. 2 Line up the suction, discharge, arc valve, and recirculation, (check for leaks) 3 For Tandem Sealed Pumps Only - Line up cooling water (if applicable) and recirculation linesfor the oil sealpot. Bleed down any pressure on the seal pot to the dry vent header, then close vent valve. For P-1320 CID and P-1541 C/D, install seals on the vent valves to ensure they are not inadvertently opened. 4 Check oil mist system to ensure the bearings are being lubricated. 5 Check low point on the pump casing to ensure an oil level hasn't collected. 6 With the switch gear still racked out rotate the pump shaft by hand, ensuring that the pump rotates freely and there are know indications of nibbing, knocking or pinging coming from within the pump 7 With the field switch in the OFF position, energize the switch gear. 8 Cool down cold service pumps to prepare them for starting (P- 1450's, P-1250's) 9 Contact the board man to ensure adequate level is in the vessel. If there is no level, leave the pump in the off position. 10 Bump the starter (on then back to off)- This will fill the bowl up with liquid and help eliminate damage to the pumps (MAG DRIVE'S). Watch the motor shaft and ensure the pump comes to a very gradual stop. If it doesn't there is something wrong and the pump will wreck quickly. GR S/92 rev 6/22/95 DDVPHMP.DOC DO A 031990 CONFIDENTIAL ( Training & Development Procedures Chlorinated Methanes STARTING AND SWAPPING MOD V OPERATED PUMPS 11 If both pumps are available for operation place the (A) pump field switch in the "AUTO" position first, then the (B) pump field switch. (When the switches has been placed in the auto position it will indicate to die MOD and the BOARD OPERATOR that everything is O.K.) The MOD will start up the following pumps automatically, when the right conditions exist and the field switches are in "AUTO". A P-1250 A/B B. P-1260 A/B C. P-1320 CID D. P-1450 CID E. P-1500 A/B F. P-1511 A/B G. P-1520 A/B R P-1521 A/B I. P-1525 A/B J. P-1530 A/B K. P-1540 A/B L. P-1541 C/D M. P-1550 A/B N. P-1710 A/B 12 The following pumps will have to be started by the board operator initiating a (DK) function. t A. P-1750 * DK(150) B. P-1760 = DK(100) C. P-1770 = DK(102) D. P-1813 = DK(120) GR 8/92 rev 6/22/95 DO A 031991 CONFIDENTIAL MODVPUMPr' ( Training & Development Procedures Chlorinated Methanes STARTING AND SWAPPING MOD V OPERATED PUMPS Note II. SWAPPING MOD V OPERATED PUMPS AND PREPARING PUMP FOR MAINTENANCE. In the event the pump that is presently on-line needs to be swapped, it will be necessary for the board operator to initiate a (DM) function to energize the off-line pump. The off-line pump must have the field switch in the "AUTO" position and already be lined up in the field/NOTE: THEIR ARE A FEW PUMPS WHICH WILL HAVE TO BE PLACED IN MANUAL TO SWAP, USUALLY ON THE TANKS)The following is a list of the pumps that will AUTO START when their (DM) values are set: A. P-1250 A/B * DM(210) B. P-1260 A/B * DM(214) C. P-1320 C/D - DM(136) D. P-1450 C/D a DM(134) E. P-1500 A/B a DM(IOO) F. P-1511 A/B = DM(107) G. P-1520 A/B = DM(130) H. P-1521 A/B = DM(133) I. P-1525 A/B a DM(131) J. P-1530 A/B = DM(135) K. P-1540 A/B = DM(150) L. P-1541 C/D = DM(153) M. P-1550 A/B = DM(155) N. P-1710 A/B DM(216) GR 8/92 rev 6/22/95 DO A 031992 CONFTDFNTTAL. MODVPUMPDOC I Training & Development Procedures Chlorinated Methanes STARTING AND SWAPPING MOD V OPERATED PUMPS PROCEDURE Step Action 1 Ensure the pump is properly lined up. Energize the pump by initiating the proper (DM) function 2 If the board operator feels he has good control and the outside operatorfeels the discharge pressure is adequate, then shut down the other pump in the field by placing the field switch in the "OFF' position. This should be done within 10 seconds ifat all possible to keepfrom running a pump back on its curve (Mag drive pumps only). NOTE: If you are making a weekly or monthly pump swap, then set the pump up in the back up mode. If the pump is in need of repair move to item # 3 3 Block in the suction, discharge and recirculation valves. 4 Bleed down using both bleed valves (suction and discharge bleed valves after the ARC valve). BE SURE TO ROD OUT THE BLEED VALVES TO MAKE SURE THEY ARE NOT PLUGGED. If the CONTENTS are CHLORINATED HYDROCARBONS, you need to depressure the pump to the throx unit through the collection header.(Do Not Depressure D-1525 Or C-1540 Reflux Pumps To The Collection Header Because Of Chlorine Content 5 Tag out the pump and check the field switch. (THE FIELD SWITCH WILL BE CHECKED BY THE OPERATOR WHO WILL ISSUE THE SAFE WORK PERMIT AND THE MAINTENANCE PERSONNEL WHO WILL BE WORKING ON THE PUMP 6 Once the pump has been repaired, pressure it up and then follow the line up procedure. GR 8/92 rev fi/22/95 DO A 031993 CONFIDENTIAL. modvpumpjxx: CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT \l\Q DATE : ,- ,1995. FROM: (Lr,k / Cu<jA OwJl fi=LCK\\ V WftWoCs^ This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW Supe:rrvvjisscors SOS^ Loaaddeps Clebert Hanev Init. Date bill Cook J Date (rPI Breaux Dugas \ljgW_ Beieler Init. Date mm M k/p/k Kelley \eh-\ Ledoux jLLfa Day OUppetr. Bickham ^ Cook F. fc j-iy '^key Armani Doucet Inssttrruumpients McMurray_________ Cavalier b-2}% Harriso Michel aV/- bjii/ Donatto^jT C>Jvk Grant C~t /. rk a^_ Rizzo __________ Grace Gravouilla Ify (W^Loonev Neyland_______ Shankli .4m Taylor (VW Johns Jackson fyf I'W Wolfe $)V( L'33 ^lillender ^ jung ] Vavasseurftl 'iffi Metrejeari^W ufej DO A 031994 CONFTDFNTTAL , r i- =; V t 1 o ' X \ ' 3*i 1 " 1 L i : . t V l> -- ' *i- \ r'i: j i i, 3 ( " V ^1 l l 1 sr ^ i ` : j. i . Vi-' t ,, ; .. 1 ' - i : r r t r - i ` l ' * i 3 * i " ~d z = : s'"? t vio l? ti ii S i r , > + r " vicla i'V5/ it is r ? v i o u f i - -> i ' i - t tz 1 i ' 4 x ~ r < D'"' f ,,i1 ti ? ^ t * i l s . tii 5 - r i 3 o = s ci i vf ii or i : !_ - '(.' *j r -V : / / ?' r - ( r z " c * s - ~r y v = ,.cr' . V j * v i r 1 t i 1" ' - rr not 11 ? t y " ' i _ c ;- -j ir "ijr irT. T * i' i - ; - i-; ^ f* f '.(. i ^ ^ ,^'j t iv *i . : i i ".v i i l i ` v + ' j \ 3r^ ^ 4 " ! j t i or i - t 1 - ^ + j *. i ` ill r*? DO A 03199S CONFIOENTTAI f CHLORINATED METHANE PRODUCTS COMMUNIQUE* Review & Initial SUBJECT: DATE: A- 3. ,1995 FROM: , )uu<' Qcjeser't________ lAoJ ; SH 1 j~C Cs/JUla^-c^ / j --=7 .0J?AS~fi,.cL- T~- <47k A This form is used to insure the attached information is communicated to the appropriate plant personnel. lNITIATOR: Place a check mark by the group(s) needing to review, EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW SOS's Loaders JL Init. Clebort . Date JC Jiyt. Date Breaux /LI Cfifo Bishop _x ArmandJM.K ^ Haney QVfr l.frfof Kelley W [hW- Ledoux McMurraytlM itflft' " Day Oper. X Beieier ^ (J^ Bourg /O //L Bickham Davis SA Cook F. ft ffff Ekey Cavalier rfC'U-tt'6 Harriso^ Doucet *}//? Instruments Michel Rizzo Taylor Witt oung /}<(*" iDonatto^ jjyj^ Grant ^ _________ Grace {k4 lift(tf Johnso Jf^ Gravouilla ^ Jackson C^/z rf^S LLhS Neyland. till Loonev Shankliu ITs.. . * ^ , .. Wolfe T)W t>-\yq Simonson^ Millender ib- mfc' YavasseurtV 7j^f Metrejea^f\_U/j r^r DO A 031996 CONFTDFNTIAl. VULCAN METHYL CHLORIDE TANK CARS TO CELLULOSE "THE RUN" The time has finally arrived - we will begin offloading the Vulcan tank cars to Cellulose on Sunday, June 4th. These are the cars that are contaminated with R-12. There are 15 cars Cellulose's use rate will be about 75,000 Ibs/day. Once we begin with this product we'll continue until it's all gone. Several meetings have been held to insure everything goes well. Here's hoping!!!! To begin this, Saturday night we will need to top off Cellulose's T-12 with "good" Ml and empty their T-42 into T-261. Sunday morning Ken and Luke will be in to complete the piping for offloading the railcars to Cellulose and for emptying T-42 into T/T's-T/C's. We need to be ready to offload around midday. Beginning Monday, transfers will be made to Cellulose first thing in the morning and last thing in the afternoon. T-42 will be emptied when the level reaches 75%. We will only load/offload on days. Cellulose is aware of this. Ken/Luke will monitor tank levels at Cellulose to determine transfer timing. Once all cars are empty, we will send "good" Ml to flush all lines and continue to transfer T-42 to T/T's until all samples show NO FREON. We will hold a tailgate safety meeting first thing Sunday morning to insure everything is in place. If you have any questions/concems, give me a call or holler at Steve or James. Thanks in advance for the help and cooperation. If we all work together on this, I'm sure this project will be a success for CMP (no Freon contamination) and Dow (taking this product from Vulcan means extra product (Ml and 1,1,1) in an already tight market and extra $$$ for the Company). Julie DO A 031997 CONFIDENTIAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE Preparing Piping to Unload Wide Spec Methyl Chloride Tank Cars PROCEDURE # PURPOSE To prepare lines, tanks and load rack to take Wide Spec Methyl Chloride Tank Cars. SCOPE Install Blinds at D-1813 and on the M-l vent header at Load Rack. Install spool pieces at T-261. DEFINITIONS Wide Spec Methyl Chloride - Methyl Chloride that meets Cellulose Raw Material Specs but is outside of CMP's normal Production Specs. SAFETY CONCERNS & EQUIPMENT Standard block safety equipment is to be on person at all times in the loading area. Regulations of the D.O.T. are to be followed as well as the block and division regulations. 5 - 2" X 150# Slip Blinds 1 - 3" X 150# Blind Flanges 1 -2"X 150# Blind Flanges 1 - 1 1/2" X 150# Blind Flanges 1 - Spool piece between Cellulose T-42 line and T-261 1 - Spool piece between T-261 & M-l to Cellulose Meter Run 1 - Spool piece between T-261 & Load Rack PreWork Prefab 2" spool piece between Cellulose T-42 line and T261 Prefab temporary loading line to 3" Cellulose line. Prefab spool piece between Spot #5/6 line and the Cellulose Meter mn. Sample and Empty D-1813 (Make sure supervision looks at analysis prior to transferring) Have Cellulose pump T-42 to T-261 (Since it might be a couple of days that their line might be out of service, have them empty their tank) Lower T-261 level. (We will still be able to pump out of T-261 but we will not have the recirculation line for a D0 A 031998 couple of months) confidfnttai Revision # 1 Dow Confidential Revision F ,,- 3/95 This procedure is valid for 24 hours from the date viewed, 3/7/95 10:00 AM Training & Development ProceduresChlorinated Methanes Preparing Piping to Take Wide Spec Methyl Chloride Cars Procedure Step Action Isolate the DME Header going to the T/C Rack Hook nitrogen at Spot #5/6 on the DME line and blow the DME Loading header including the spool piece under T-261 to T-261. Flatten the DME Loading Header to the Low Pressure M-l Vent Header. Hook up nitrogen at D-1813 pump discharge and pressure DME load header to nitrogen header pressure and flatten the DME Loading Header to the Low Pressure M-l Vent Header again. 3/1/95 Red Tag the Header. 1. T-261 Bottoms valve under middle of the tank. 2. 3" valve to Cellulose. 3. T-261 Recirculation line. 4. D-1813 pump suction 5. T/C DME line to D-1813 at top of D-1813 6. T-261 line to D-1813 at Throx header. 7. D-1813 pump recirculation. 8. Bleed open at Spot #5 at load rack. 9. Air to M-l vent valve at Spot #5 10. Nitrogen to M-l vent header at Spot #5 11. Low pressure header on M-l vent at Spot #5 12. Bleed open at M-l vent spot #5 13. Air to M-l vent valve at spot #6 14. Nitrogen to M-l vent header at Spot #6 15. Low pressure header on M-l vent at Spot #6 16. Bleed open at M-l vent spot #6 DO A 031999 OONFIDENTTAI Install slip blind (2" 150#) under valve at D-1813 to DME load rack/T-261 line. Preparing for Wide Spec T\Cs Training & Development Procedures Chlorinated Methanes Preparing Piping to Take Wide Spec Methyl Chloride Cars Procedure $ Install slip blind (2" 150#) on top of valve (T/C DME line to D-1813 at top of D-1813) 9 Install slip blind (2" 150#) under valve (T-261 line to D-1813 at Throx header) 10 Install slip blind (2" 150#) on Spot #5 M-l vent header under where Low Pressure ties in to Vent Header. 11 Install slip blind (2" 150#) on Spot #6 M-l vent header under where Low Pressure ties in to Vent Header. 12 Remove spool piece under T-261. 13 Install temporary spool piece (T-42 to T-261) 14 Blind Flange goes here | [Temporary piping goes here Remove this spool piece 2" line to T/C Spot ##55L M| 3" 300# line from Cellulose 1 1/2" Recirculation Temporary spool piece (T-42 to T-261) 3/1/95 DO A 032000 OONFTDFNTT Al. Preparing for Wide Spec T\Cs Training & Development Procedures Chlorinated Methanes Preparing Piping to Take Wide Spec Methyl Chloride Cars Procedure 15 Put blind (1 1/2") flange on recirculation line where spool piece was. 16 Pressure test the lines and blinds. 17 Hang Red Tags on the blind flanges. When the Vulcan Tank Car Arrive 18 Block in the Cellulose meter run and use niotrogen to blow the M-l back to T-814. Isolate the meter run and depressure. 19 Block in (T-42 to T-261) spool piece, blow the spool piece to T-261 with nitrogen. Red tag, and remove spool piece. 20 Put blind (3") flange on bottom of T-261 where spool piece was. 21 Connect new temporary loading line to 3" Cellulose line. 22 Connect the Spool piece between Spot #5/6 line and the Cellulose Meter run. 23 Install a Blind (2" 150#) flange under the M-l to Cellulose line at the meter run. 24 Pressure test the lines and blinds. 3/1/95 DO A 037001 CONFIDFNTIAl Preparing for Wide Spec T\Cs CHLORINATED METHANE PRODUCTS COMMUNIQUE Review <6 Initial SUBJECT: C* ~r\ >* f DATE: FROM: S r* r&~/*7 J>*/ iv ~7~ ______ 4995 f1#'* Ter A-/3QO_____(c_4" /ec 3 This form is used to insure the attached information is communicated to the appropriate plain personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. PERSONS NEEDING TO REV EW Day Staff Supervisors SOS's OS's Clebert 2C JL Init. Date Init. Date Cook J. Breaux Anil. Date cK Bishop Init. Haney /OVlr Kelley Ledoux Ptisas M 6/3 Dav Oper. f Beieler aZ/A^ Bours Diuvnaiu (`Jj, unp* Davis Cook F. MX Ekev McMurray\J/v\ Cavalier /&C- C`)l& Harrison Michel -- -- Donatto Grant C*/e-' Stick Rizzo Tavlor Qwi Grace / Johnson Gravouilla Jackson ^ If' Loonev 1 -Us Wolfe Witt 1 -oung Simonson Vavasseur Millender^fft- (Jf I /, Metre jea*?^^ U ^ Loaders Date Init. Date Armand Doucet Instruments -- Nevlaiwl SI h n n 1/ 1 S 11 A 032002 ^onfidfntiai CHLORMETHANES R-1300 MODIFICATIONS A major change in the R-1300 program is now being impl mented since the unit has been shutdown. The R-1300 thermal chlorination reactor uses a vapor recycle stream from the distillation train to reprocess unreacted methyl chloride. The spec sheet for the transmitters installed during the expansion utilized an incorrect density obtained from CRPROP, resulting in a decrease in the compensated flow measurement. The scale factors have been reassigned for all variables associated with the flows, and literals employed in mole balances have been redetermined. Other program alterations have been made. A ramping function was attached to the chlorine load setpoint to allow a more gradual change of without operator intervention (initially set at 200 lb/min). Another ramp will be used to make larger load cuts should the differential pressure fall too low. In addition, the recycle flow control setpoint is limited based on the control valve position. If the valve opens greater than 80%, the setpoint is reset to the current flow. Also, liquid injecion will not ramp off in the event of a low chlorine to R-1300 differential pressure. Finally, the temperature selection logic has been adjusted to limit the change of position of the control point within the bottom section of the reactor. Simulation of these changes is now complete and the upload is slated to occur on Friday, June 2. The recycle flow transmitters will need to be rescaled at that time. DO A 032000 CONFIDFNTIAl CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Jun 1 FROM: Rizzo ,1995 SUBJECT: Please review the attached MOD V Change sheet. Twn alarms were added to the system C They are WARNH55) anH WARNH^fiV They alarm -- when the N2 flow to the filter beds drops helow the low flow setpoint and il is in the regeneration, .step--------------------------------------------------------------------------------------------------------------------.-------- This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW Supervisors X SOS's X OS's Loaders Init. Date Init. Date Clebert Cook J.______ _ Breaux ftHaney Hifa' Dugas MS Beieler /j'M'h ^ Bourg Init. Date Init. Date Bishop Armand ___ Doucet Kelley Ledoux Day Oper. Bickham CookF. ft Davis Ekey ___ ___ McMurrayJfft Mr Cavalier Init. Date ?-//% Harrison___ Michel $ M, Donatto Grant 4 "S* Jack ___ Rizzo ___ Grace GravouillallA jjj jp Looney ___ Instruments Init. Date Neyland. Shanklin Taylor ___ Johnson Jackson Wolfe Witt ___ Simonson Millenderjpfy - voung ___ Vavasseur Metrejeanffil Is J DO A 032004 OONFTDFNTTAl CHL0R1NA TED METHANES MOD V DESCRIPTION OF CHANGE m. c System Zone 1 Equipment Number 500 Can Changed the pumps code on Zone 1, 3 and the Shot pond Zone 1 and the Shotpond Pumps Took out all the automatic swapping logic from the code and went with the same convention we have on other pumps in the plant. Since Zone 1 and the Shot Pond are 3 pump systems, the small pump was made the primary pump. This will require less energy consumption during normal operations. The small pumps will energize if it is in the automatic position in the field and there is sufficient level. In the event the primary pump doesn't energize within a specified time frame the (A) pump is designated to energize next. If the (A) pump doesn't energize within a specified time frame the (B) pump will energize. In the event a high level alarm condition occurs and the primary pump is running, the (A) pump is designated to energize. If A high - high level condition exist then all 3 pumps will be energized, if in auto in the field. In the event all 3 pumps are running and if the control valve goes closed, the (B) pump is designated to de-energize first, then the (A) pump. If only 2 pumps are running and the control valve closes, the primary pump will remain energized. See the following code: D0(501), DO(511), DO(521), DO(502), DO(512), DO(522) Zone 3 This is a 2 pump system with the (A) pump designated as the primary pump. The (A) pump will energize if it is in the automatic position in the field and there is sufficient level. The (B) pump is designated to energize if the (A) pump hasn't energized within a specified time frame. If a high level alarm condition exist, the pump that is off line, will energize. See the following code: DO(513) & DO(523) 03?005 DO A CONF'^1 c System CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE W " ii -- 1J Zone 1 500 Equipment Number Can All ZONES & SHOTPOND Revised the code for all of the recirculation AOV's. The AOV's opening are no longer dependent on the level. The AOV's will be open the pumps aren't running or if the control valves are at their minimum position. See the code for all the recirculation AOV's ZONE 2 Revised the stepping logic for moving back to STEP(522). The old code stated that if a high high shotpond level existed, indicated by ALM(541) being true, Zone 2 stepping logic automatically moved the sequence back up into STEP(522). This prevented Zone 2 from being able to do directly to the outfall if there was a problem with the Shotpond. The above mentioned code was taken out. You will only move back to STEP(522) if high organics are detected or analyzer failure or if requested by the operator performing an AK/DM function.* DO C-Ot^F *03^006 TOfNT7a/ CHLORINATED METHANES MOD V _I__5_l_I DESCRIPTION OF CHANGE SfS) c System PSA'S Equipment Number J300 Can WARN(355) This alarm will activate if the N2 flow, Al(325) drops below the low flow setpoint, AP(353) and one of the PSA 1760 beds is in the regeneration steps, STEP344 or STEP(340) Once activated the alarm will remain on until the N2 flow is above the unlatch setpoint, AC(l043^. WARN(356) This alarm will activate if the N2 flow, Al(305) drops below the low flow setpoint, AP(372) and one of the PSA 1770 beds is in the regeneration steps, STEP304 or STEP(310) Once activated the alarm will remain on until the N2 flow is above the unlatch setpoint, AC(1040). DO A 033007 cnfidea,Ttal Review & Initial SUBJECT: CHLORINATED METHANE PRODUCTS COMMUNIQUE' DAT1 E: MAh 2.L FROM: C Srw.________________________ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REV EW Supervisors SOS's Clebert Haney -*r Init. Date Cts g'Ht Cook ji/jffi 5~-?7 Breaux Dugas1^? fefofc/ Beieler gap* ^ Kelley Ledoux '' Day Oper. Bickham to4^ cookF. fy. McMurray l/fti Cavalier A/t-i^^jH Loaders lnit. Date Armand Doucet Instruments Michel .-W^' Itlii Btwralto Rizzo_________ Grace ilk 0(1 Taylor JulllliOII -- Grant Gravouilla Jackson Neyland. ///Ift ooney hfa t>r$ ^^ Shanklin Wolfe ftWJKM Simonson Millender ioung Yavasseur Metrejeanj)\y\ _ 00 A 03?008 CONFTDFNTTAJ Page 1 Note tor Kelley, Kevin From: Date: Subject: T: Kelley, Kevin Fri, May 26,1995 7:52 AM E-455 Performance Kelley, Kevin May 25,1995 E-455 continues to be a thorn in our side. It appears that we are beginning to have problems maintaining temperature control during barge offloads. This is due to one of three possible problems: 1) Higher offload rates than expected, 2) Mechanical problem inside exchanger allowing flow to bypass exchanger core, or 3)Higher outside, river water (and therefore methanol) temperatures. The only one of these we can affect is #1. Until the plans listed below are put in place, please have the Docks adjust their offload rate to allow the exchanger to control the vent temperature at -20 to -30 as needed. We need to do this in order to minimize emissions from the system. It is very well understood that this system has been anything but the dream vent recovery system as we were lead to believe initially. The newest plan for the exchanger system is as follows. We are pursuing adding in a second heat exchanger that will run in series with E-455. Both exchangers will be installed in the horizontal position in order to allow condensed liquid to drain through a seal leg back to the tank. A demister will be installed downstream of the exchangers. In addition to some inherent physical problems with liquid nitrogen as a heal transfer fluid, it seems the design basis for the exchanger was a little conservative. The plant's position with this system is this: We are going to make one more, best faith effort at using the liquid nitrogen technology. Both CMP and Air Liquide have agreed that we will install the best possible system this time, sharing the costs of the additional equipment. We don't want to scrap everything that's been done and start all over again until we put the best possible system in. If it works, everyone will be beyond happy. If it doesn't, back to the drawing board. We plan to finalize design of the additional exchanger and demister by the end of next week and place the order then. In the four to six weeks it takes to get here, we'll be engineering the necessary piping and structural steel modifications needed. If everything goes as planned (which would be a first for this project) the final version of the system should be in by August. One final, unrelated note. E-455 will be moved to system C in the middle of June in order to prepare for the installation of C-600 on can A-500. Thanks for your continued patience with this trying issue. DO A 033009 OONFTDFNTXAi I CHLORINATED METHANE PRODUCTS COMMUNIQUE Review <6 Initial DATE: Fri, May 19,1995 FROM: Rizzo SUBJECT: Please, review the following procedures * evnppnmp repair - #460215 * TDC policy -J46QSa6 ... * R-750 shutdown # 460141 * Lah procedure #460336____________ * mnr policy_________________________ * procedure approval policy #460384 This form is used to insure the attached information is communicated to the appropriate plant personnel. 'N1TIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors SOS's X Loaders /J/t't; Date CookJ/PC 5*g Breaux Dugas/y^ff Beieler fe S/nM Day Oper. Bickham ^ CookF. Jp lnit. Date Armand Doucet Instruments Cavalier Init. Date Grant ?*'* Jack Gravouilla S~ S> Looney 10 b Init. Date Neyland. Shanklin Jackson ^ /m woife S)]^/ S'31 Simonson_ Millender Vavasseur MetrejeanQlnfl ^T/l' DO A 032010 CONFIDENTIAL i 4 ' CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT: O 15 00 DATE: MA^J 1*7 FROM: ([ ,1995 This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff, PERSONS NEEDING TO REVIEW Supervisors v/ SOVS' ' OS's Loaders Clebert Haney Kelley Ledoux Init. Date ^ Cook J. Breaux ffkjtnfti 0jjn(pL&. /P11as Beieler nte Bickham gft #(?/< Davis Day Oper. CookF. ft 5-0 Ekey MfU-- Init. Date Armand Doucet Instruments McMurra>{|/|f\ Cavalier Michel Donatto oYikl 4/z* Grant Rizzo AkGrace if111K Gravouilla Taylor of ililki Johnso Jackson HarrisoftipKt/- atk 05. Neyland. Looney Shankliit JVVolfe fiVj/ ^)1-y Witt Simonson Millender jung Vat jjjiui Metrejean I i OPERATIONS COMMUNIQUE' K. KELLEY Date: 5/17/95 Topic: C-1500 Leak Clamp Installation A leak damp will be installed on the bypass on the C-1500 feed control valve in the next day or so. The clamp is being installed to stop a small leak out of an alien screw on the body of the valve. The alien screw is used to maintain the compression of the seats against the ball on the inside of the valve. This is the same problem that was seen on the T-1500 AOV and the other valve on C-1500 that's clamped. TBV has changed their design, but we still have a number of similar valves throughout the plant. There will be an evaluation of where likely future occurances are and what we can do to ward them off. Please continue to be on the look out for this type of leak. Good job to A shift for catching it this time. K.K. CHLORINATED METHANE PRODUCTS COMMUNIQUE Review & Initial SUBJECT:: DATE : FROM: It, f/t &J(t &7C7 dcrj+si 'Rest, Ms ,1995 This form is used to insure the attached information is communicated to the appropriate plant personnel INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors SOS's OS's Loaders Init. Date Init. Date Clebert Qfc_ Cook J.____ Breaux Haney Kelley Ledoux tfok) Dugas____ $K_ $hk Day Oper. Beieler Bickham Cook F. McMurrav\j/V\ b(xife Cavalier nit. Date Vl7/ B __ Davis f},\ 7^ Ekev arriso Init. Date Armand Doucet Instruments Michel A/ff< 6/ft Bonatttr Rizzo ________ Grace- Taylor tff -Johnson Witt Simonson Grant * Gravouilla fl] Jack Neyland. Looney fit- f-vdShanklin Jackson y L0-" yVolte T)W 5-I7 V Millender^, yy jung Vavasstur MetrejeaiTpify^ DO A 03701,3 CONFTDFNTTAl. 1995 Hog Body Contest K. Kelley, Official Statistician Fat Old Sows Name F. Cook In B. Young R. Jackson T. Sensat C Davis F. Simonson D. Metrejean Out 230 229 211 233 240 239 227 Piglet Bodies % change Name In 218 5.22 D. Taylor 224 2.18 K. Kelley 208 1.42 J. Clebert 231 0.86 S. Ledoux 240 0.00 J. Haney 239 0.00 L. Purdy 229 -0.88 Out 193 204 142 203 177 137 % change 179 7.25 190 6.86 138 2.82 202 0.49 177 0.00 137 0.00 The Official Results are in. Darren Metrejean, who said in January "let's make it bum and make the contest longer this time" was the only contestant to gain. Better luck next year D. Don Taylor and Freddie Cook win the prize of $ 131.00 each. Personally, I feel cheated. Only 1 more pound and 1 would have beaten Don. That's the way the cookie crumbles (or is eaten, in my case), '/jic TSoSS A1"S tx)i a) . Thanks for a good contest. Now, start gaining for next year!! Kevin Kelley zMn o > 'oTl o z--HA c\O>o J> -- Confidential 5/9/95 Pagel Fat Old Sows -Weight Loss Results Piglet Bodies- Weight Loss Results l % change] 00 A 03?015 C0NFTDFNTTA1 Confidential 5/9/95 Page 2 i Review & Initial SUBJECT : CHLORINATED METHANE PRODUCTS COMMUNIQUE' : S/tshi DATE f)FROM: ,1995 AiiehJ/ Ehlj'/y t * b? Ccnh'rtJ This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors SOS OS's Loaders f nit. Date Init. Date A Init. Date Clebert ip Cook j nee. g.\s? Breaux <fb qrm Bishop f Haney 9jlty Dugas Beieler ^ Kelley fL Ledoux * McMurravl//K ltl}\ fa Dav Oper. V Bickham ^ g*/f Cook F. k_.l!2 Cavalier Ai?-% Michel &/}$ Donatto^- Rizzo _________ Grace LU ^2 Taylor tyff Johnso>^4 -- Wvf IitItI _______ Simonson, t ^ung________ VavasseurJ, Grant ^ -TV, ack Gravouilla^ 1L oonev Jackson MM. Wolfe MMillender l Metrejean^i/ir ^VI ArmandllZAl^lZ/JI Doucet b J//% Instruments ^7-16 Neyland. Shankliu 0 A 032016 confidential RECEIVED R404 U434031 3129 422 DONATIO PEEBLES? R L (RODDEY) DONATTO B D (BRIAN) 5/03/95 5/03/95 U434031 042 U432195 HADECD (U434031 ) (F-'LAGjM F'ROH : TO: NAME : U4321 95 <U4321 95eLARNDC(?MRGATEGUSMV2> U434031 SIBMGi FROM- LACSDC::UCIE 9" 3-MAv~1995 07-53:49.07 TO - CD IS:BEUPI CO: US IE SU.vJ : SAFETY ATTENDANT ENTRY INTO CONFINED SPACES' A 5:F ETY 'TTE<-IDi .NT IC ALLOWED TO ENTER A CONFINED SPACE (REMEMBER, ENTRY IS DEFINED AS PASSING ANY PART OF THE BODY PAST THE OPENING O'" THE SP.-CF). HE SAFETY ATTENDANT MUST NO I ENTER THE CONFINED SPACE UNLESS EI.IFVE.O OF THEIR DUTIES AS ll-IE ATTENDANT.. IT IS UNDERSTOOD THAT THEY MAY AT TIMES HAVE TO CALL IN AT THE OPENING TO COMMUNICATE WITH THE ENTRANTS BUT SHOULD NOT HAVE TO "ENTER" THE SPACE TO P E R F n r< y, ] H j, $ c C ' M M LIN IC A T T t' ti. REMAL! OUTSIDE THE SPACE AND AC I AS THE LINK BETWEEN THE PERSONS INSIDE AND THE ACTIVITIES OUTSIDE. THE SAFETY SJPEF IfVTt NDIINTS RECOMMEND USING THE CONFINED SPACE ENTRY CHECK IN/OUT ROSTER AVAILABLE FROM STOCK (DOW CODE NUMBER 3 5 71ST 0 - VIA TROXCLA.TR PRINTING). THIS CARD HAS A SPACE AT THE TOP FOR THE ATTENDANT'S NAME, SEPARATE FROM THE LIST OF AUTHORIZED ENTRANTS. IT ALSO HAS THE RESPONSIBILITIES 01- THE ATTENDANT LISTED ON THE FRONT AS A REMINDER. THIS LIST HAS BEEN RECENTLY CHANGED AND NEW CARDS WILL BE AVAILABLE IN THE NEAR FUTURE WHICH SPECIFY THAT THE SAFETY ATTENDANT "DO NOT ENTER YOURSELF UNLESS RELIEVED OF ATTENDANT RESPONSIBILITIES AND PROPERLY SIGNED ON TO ROSTER, RED TAG MASTER, SAFE WORK PERMIT, ETC." PLEASE COMMUNICATE THIS 10 THE APPROPRIATE PERSONS WITHIN YOUR ORGANIZATION (PERSONS ISSUING CONFINED SPACE ENTRY PERMITS, PERSONS 'WHO MIGHT ACT AS ATTENDANTS. ETC.) IT WILL ALSO BE ...OKMUNICATED TO CONTRACTORS IN AN UPCOMING WEEKLY SAFETY MEETING PAM L. US IE S A!" E T Y S U P E RIN T E N D E N T FROM: PEEBLES FODDIIY PEEBLES DO A 032017 CONFIDENTIAL CHLOR-ALK ALI /DER I VATI VES BLDG 1 SOI CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial :kkDATE: ___ 5 FROM: ^J>;M SUBJECT: A)2 w C,c*./U P'lSrfl 0 ,1995 This form is used to insure the attached information is communicated to the appropriate plain personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors SOS's OS's Loaders Init. Date nil. Date Clebert Cook J Breaux Haney_________ Dugas 'Beieler Kelley P&L %Jp, Ledoux 7^ Day Oper. Bickham Cook F. McMurrayjftV Cavalier Init. Date f/jfa Bishop pl Sk ^ $ Init. Date Init. Date j-l1) Armand Doucet Instruments L' Donatto Grace Grant Gravouilla Nevland. Shanklin^L * Johnson Simonson_ Jackson Millender Wolfe ^ 5-8-<S Vavasseur MetrejeanJ^K *> ' DO A 032018 conftdfnttai Communique Subject: P-1541 D (New sealed pump) From: Jim Haney Date: 5/4/95 The new sealed P-1541 was started up in place of P-1541 B, the mag drive pump, on 5/4/95. The tag for this pump is P-1541 D. After P-1541 A is replaced with the new sealed pump, which will be tagged P-1541 C, the "A" and "B" designations will no longer be valid. The Mod5 graphics will be changed after P-1541 C is on-line. The Mod5 code will be changed during the next Distillation upload. Also, the tags on the pump field switches and the stencils on the foundations will be changed to "C" and "D". The other sealed pump will be installed during the week of 5/8/95 provided their arc no problems with P-1541 D over the next few days. D0 A 032019 C0NFTDFNTIA1 CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Tue, May 2 FROM: Rizzo SUBJECT: Please review the following procedure revision MOD V PUMP #460206 ,1995 Tbifform is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. Day Staff PERSONS NEEDING TO REVIEW Supervisors X SOS's X OS's X Loaders Init. Date nit. Date Clebert_________ Cook J.AV S-ti Breaux Jnlt. Date t. Datf Init. Date .L BishopfjE&T Q. '< Armand Haney Zfoki Dugas Beieler Doucet Kelley Ledoux McMurrayj^^jJft Day Oper. Bickham Cook F. Cavalier Init. Date Michel Donatto Grant rQ H'l'fA rK-^-% Harrison<& Jack -&. Rizzo Grace Gravouill Looney 5'2> instruments Init./Date Neyland A Shankli Taylor Johnson Jackson S~iv Wolfe T)\a/ S-t-V Witt Simonson^ Millender voung Vavasseur MetrejeanilTi \ DO A 0320P0 conftdfnttal CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Tue, May 2 FROM: Rizzo SUBJECT: Please review the following lah procedure revisions # 460326. #460^27. #460^29 #460^0. ft #460616 ,1995 This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. 'MPLOYEE: Please initial and date when you have reviewed and understood the material. PERSONS NEEDING TO REVIEW Day Staff Supervisors SOS's \. Init. Date init. Date Ciebert Cook J. \ Breaux Haney______ Dugas \ Beieler Kelley %_lK\ Ledoux ___ Day Oper. Bickham Cook F. Init. Date McMurray____ Michel Rizzo Init. Donatto Grace \ Cavalier fiC->1ft Harri^dikpijy( Date Grant Jack Gravouilla4. hl Looney `p'3 Taylor / Witt Johnson Simonson \ Jackson jlj) ' ,5. / 0 Wolfe DW Miliende Young ___ Vavasseur Metre!ean"[jf<^ Loaders X Armand^l^l Doucet /s> S'/f Instruments Init. Date. Neyland Shankli cnftof nTta/  CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Tue, Apr 25 FROM: Rizzo SUBJECT: Please review the following revised procedures: Sampling outfall 15^1 -#460494 Sampling outfall 1541 -#460615 ,1995 This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. \ Day Staff PERSONS NEEDING TO REVIEW \Sup ervisors SOS's Init. Date Init. Date Clebert Clj. d/3# Cook J.____ Breaux --------- T" Init. Date Haney_________ Dugas____ Beieler Kelley U Ledoux jr/u. \Day Oper. Bickham Cook F. C~C fa# McMurray________ Michel ^ * r Rizzo ________ Init. Donatto\ G^race / / \\ Cavalier Date Grant Gravouilla W UK Taylor Witt .oung ________ ___ ____ ________ Johnson Simonson_ Vavasseur Jackson ICfd Millender Metrej.eanT^fl f(ft OS's X Loaders Init. Date Armand Doucet Instruments Init. Dale Neyland. Shanklin DO A 002022 CONFTDFNTIAl CHLORINATED METHANE PRODUCTS COMMUNIQUE' EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW, ^ Day Staff Taylor McMurray ` Bourne - -jjjp ^Kelley lianev Witt Young Michel fi / Clebert 4 Rizzo Supervisors ^?(^Cook/J. X[ XSOS's b Breaux ^^''Xrant ^S^Lugas Beieler -^Bickhamook F. ^^Cavalier i) K Gravouilla Jackson Millender'TlY^ Metrejean ^^Bishop1^^*!--?Bourg .'DW Wolfe c. jeuUiarrison 0^ Jack Day Oper. ___ Donatto____ Grace itU^cLonney V-fl Davis ^----- Johnson '-^^Simonsoh____Vavasseur Ledoux Loaders ___ Armand -C__ UOlicet ------... Instruments ^T^vland ___ Shanklin Do A 0320P3 CONFIDFNTTAI. TOPIC: METHYLENE CHLORIDE -- AMYLENE INHIBITED TO: OPERATIONS cc: Julie Clebert FROM: TERRY VAVASSEUR DATE: 04/21>95 The lab is setup to analyze Methylene Chloride with Amylene as the inhibitor. We will log the sample into the Lab Computer using sample code #53. The appropriate test and specifications are asigned. The main thing to keep in mind is that the GC analysis is ran on channel 1 (M3 GC) not channel 3. I have modified the autosampler so that when we run a Methylene sample after a Chloroform sample there is no cross contamination of products. When logging in a Methylene sample please indicate the tank ID by using the LOT entry. This way we can use one code for all tanks until we make a complete swap to all amylene inhibited product. If anyone should have a problem with this analysis please give me a call. Thanks, Terry V. DO A 03?0 CONFIOFNTT I> *0 $ - HF N :}x enrolcal COMPANY PI; ODUC r :c o.. t t IT ". T - i . 4 " '> ` . 1 '' f> r "aodlm: T " - r- , ", n - EI-" l-'tTI I V i," QIJAL. :c r v' OF EC-IF IC A 'I i'. K.f >v i? Apr- '7* SUPERf-L Dir:19 AG CO RAN CL LAI E : l06 MAR '*5 r,t ' hv !..fnl i;; v- r- * ) e.:c.-; ;'J CAL - e; : hi-r^ic", <>. i U A ME DICHL drometh-ANi'.: i*--v* rG-ut-`` . , 'OK - 1, Ar-'-.AFLL , \ \ N T ILE , AMD color;. .EOS LlC .'ID ,, F i`\i: t, Of' set- ;m[f/.NT hMI) CUG ELM) ED M AT TER i * * , / * Af.'r ; D- s 7 0 i ;re: 'K AC!"!S MIL" 0 6 9'90 > 11 OL'"\* ,r:'7 ` pr TA -........ 1 ' ;"r, .............- - ............. . ; .......*.............. . ; N 'i. ' 1 I P.F :' ->...... ............ ............ ...... .......... ^ -.............- " ---- ` ' " ....... .. ' .......... UN T THAI i:- . - a;: ri ... ,1v.1 /'i '> M c' l M. E 2 0 3 l 210':.; ; L 'ML Y V) F'F'h AtM : 1 0 L< i - L :r l. *( n . ASIA L-L;'c.'v `t,*t.|.' >' ; Vv.'. none: ;r. : :sr .. .. }-, i N ^ i - :>L!590C GAG CHRAMA'' '.G 'A f.;l;la : : : ' - 0' ` -1 I ' r;N ; i; ;;?F,'2r 7 iAUDII , :>'? , j U: - 0 > ,, Z i ' A * \j A*.. -1 1 DLL C AS IF D-107-! ASTM D- 21 i 1 A XC f 1 "...UROF URL . 2* DlCriLCAUL ! MYLLv-iL vr iyl] r.p->:r c: : f r.i *>r. 1 00 ' 200 1 00 MAX Ko,\ r ax -'PM PPM PPM 1C GC GC 7 : MYL PH!. C IDF MLTUVL CM! CRT. re i 00 20 MAX MAX PPM F`PM r- f~U' . GC , " > ^ OO- ' 1F-' W* 'T K OF THE DOM CHt: MICA! CO MPA':V -ii y- K r J v. {1 N 1 I It F N T I A l \ -x ANO P -IFF PAGE re`..LOW.: 00 A 032025 CONFIDENTIAL E MIC m . -s..'-1'I!1 V PRODUCTION SPECIFIGAT TON (3UAL IT Y ASSURANCL Oi- !' T, ' A Cv E ` 0 Z rjrvULL, ,';LTi-'vL LNF C. HL..OF 3 :)l , TECHN i.CAL - P ..................... ...... .................... REQU.T Pi". KENTS (CONTINUED)--------- i, n, limit uk:it METHOP ' ;i. Cl L. 0. I DC. JJNHIBITOP < 1 ) : REGULAR GRADE-AMYLENE < 2-MF.THYL" BUTENE-2> 1G May 40 - 60 PPM PPM GC cc : 207 700 PPi. GC - -...... ............... pt.y-M ; : VOV PPM r" - - - ' CGMr'Oi- J 1 f.C/i'j- - ----- -........ . - - ... ......... .......... A i i' v 'r U N I`T CAS AO* ... ' .. . !_ ' ; . /.... L v J,, - b' i yi. X L'T, 0*000"' T '(,,,v 1 <: CO ) : 32- /' " ` - ' : ' 1 (. >' 2 l: t .* O0O!" j :t 3p-: 1 i `. "Vi. /i, J-* **' 000064 - 7-5 :-------- - - -....................................... ......... -RAC MATERIALS- ------------------- ................... ---------------- - ; COMPONENT AMOUNT UNIT RM SPEC CAS NO * .ni.nRins: . 1.1uuj!i . HYL CLOLIDF VP. i 16273-R003 007782- 50 5 31O92-R0O1 000074--87-V 1 8696-P.002 0001 1 e- ' , A I - A I A Mil. OAR!- or TIL: 1)01 CHEMICAL. COMPANY ')< * }. ^ j: : v f A 1 J A L * > * -.NOTITI; ' PAGE YD-...LOW DO A 032026 CONFIDENTIAL *1 . -1' >- L COMPANY . pot or: spec if...or. 7 tun QUALITY ASSURANCE :; L PAGE r '7 0 . HNIwAl. - II ........ LAW HAT EPt TAI..L ( CON''. IrlULP > l;C AMOUNT UNIT Rii SPEC CAS NO. ' IY L AL.UOiK)!. SI) A 2G 29839-ROG1 OOOSuA *-5 11' H!: I Cl-:'. 5.`52 '2 -a'Tv> 1 QbOJ',2-3?-- . Nn"'ES" :"Tir,i '.H.IT E ',01)IISi n proi'u; >!!. ST A).5.11. 1.7 i "I: r. - ART A. CODE 'IFFTtf POL C Til UHEXANE c : sep !-; > - 2 1 IL ric H !' ! ltd 7 r-.XAc FI A PP f.DUC ING K- PY 'LL A C- A PKOI'i. . ; <>., I/ 1< '1 IQ}'.1 *.V lit 'i \ J t ] r_. y : i r r- y '1 O'"1 ' J . 1.1. E i' PR i n..'Mc,7 on . f Iu date: T. I A Pu\ '' S- QA EQAR PR0; LITIUM/QC 7 EX PR;- ' I.IC.'] TON/QC AL v-'- . /.: 1 ' C i_. 21 rib 1 & F !:, i niY <?- : approvers ; unction r. . oi'i.H:' KOI MEETING THIS S r v- i r .[CATION MUST NOT BE SHIPPED |UNLESS t TPOR DIED T V SALES AND P fl. 01) U C T10 : h A N A G EM ENT V (' iv 0 >> C a N -r 1 P E N T T A L *** !. --S'l AGE DO A 032037 CONFIDENTIAL. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Tue, Apr 18,1995 FROM: Rizzo SUBJECT: A Non Communique Training Records Fnnn has heen developed and placed in a ring hinder ffll lhe bookshelf. The purpose of this form is to document training whichbsn'Lcovered hy 1PT modules, hut is also .tofrompheated for a simple roi-mrmnique------------------------------------------------------------------_ When all required personnel have signed the form, place it my mailbox This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW/ Day Staff na Taylor McMurray ___ Bourne X na Witt /^V^Ybung __ a- Supervisors X , Cook J. i^^Dugas Michel j_ficeTley :yi Clebert Haney ^^^Ledoux ___ Rizzo SOS's Bredux ^Beieler j2^Bp>kham *^-Cook F. /^Siavalier tA/ Grant Gravouilla //^Jackson ^^tMillender '~DV`N Metre jean OS's l^raBishop/^-^Bourg ( ]S|t/^Mnarrisoit P.^Jack Day Oper. ___ Donatto ____ Grace ^^-Eliey Wolfe ^j-ZcLonney CkKDavis ___ Johnson ____Simonson ____ Vavasseur Loaders ___ Armand ____ Doucet Instruments ___ Neyland ____ Shanklin D A 03po?a conftofnttal ------------------------------ ^" CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Apr 13 FROM: Rizzo SUBJECT: Please review the following new procedures: C-7.04 Drain Procedure - # 460612 E26Q Start Up Procedure - #460613 * Menh Barge Offloading Procedure - # 460614 ,1995 This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when vou have reviewed and understood the material. GROUP Day Staff ___ Taylor Witt PERSONS NEEDING TO REVIEW Miles ___ Bourne _j^,>Kel^ Young Michel ---Clebert ___ Haney Rizzo Supervisors x, Cook J. ^$Dugas SOS's X Breaux ^^-"Grant Beieler d^Bickham Z^ZTCook F. ^^"Cavalier Gravouilla^/pi Jackson vj Millender T^NVletrejean OS's 1'^2i Bishop ,/>^^Jourg ^T^^^Eltey Wolfe x C pKlHarrisoit ?)% Jack Day Oper. ___ Donatto ____ Grace / Il^Lonney ___ Davis ___ Johnson ____Simonson ____ Vavasseur Loaders ___ Armand ____ Doucet Instruments ___ Neyland ____ Shanklin 00 A 032029 CONryoFNTTAI Review & Initial SUBJECT: i CHLORINATED METHANE PRODUCTS COMMUNIQUE' DATE: FROM: jtj / 3 _______ ,1995 ______________ _____________ This form is used to insure the attached information is communicated to the appropriate plant personnel. NITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP Day Staff PERSONS NEEDING TO REVIEW Ulil^aylor ^^*M*w**____Bourne fov SSfey ___ Witt- rt-V^tiYounp Michel t- V Clebert Supervisors AyvCook J. /gj^TIugas ^TBreaux ^Beieler SOS's u ^iBickham &Xook F. ^'hMv ^^Ledoux Rizzo t^rCSvalier OS's (AsGrant \*K, Gravouilla HA Jackson Bishop /j^^I?ourg tey^ Millender ~*^fy-Metrejean Wolfe S&fttlHarrison 'U^ Jack Day Oper. ___ Donatto ____ Grace //'SJsLonney ^3? Davis ___ Johnson ____Simonson ____ Vavasseur Loaders ___ Armand ____ Doucet struments 1____________ i>eyiana snanKiin DO A 00?030 CONFIDENTIAL. e-nss 1 tfVI k-HUty l/fifo fjfA St* A-v _/ ^ >y^ -jo jb_ foj f fto<ft- Otrry 0 -ys'sr J VV&U /K-T'A-//'sLy su j-4*^0S#-rp^ cU*si t$-(-OT- r i4> Afa*e*-pdusu~~ jC ^ It tc- k<rrt^-J jz> 7%e- 7^-*- ^/(/ t4> , S4 l J> // A X. ^ ^ ^?e /y t A * cA A*'-*" t*->~\ - A k .<3kAS ^ /SI ^>VUL_ p\/<C C'f"^) A"1 4'^- -nr****- tryjj CsjtJlsL-dj't'fsi~ft-*-- &4-rn'snI'T. ^ fp/j Ls-hA ^ i*, /*v>Lcjs A> Al-tcr~i j>vo je> J. f* /-o-*e. Alp- yL^*A-- jz> tA-t^iA- "ft*---- ^ 7^ ir^rA //L4y^ ^^ A A'Av*-*-'' Do A 03P031 CONFTDFNTTAt. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE; j\f.n I 11 FROM; f)r>An ,1995. SUBJECT: Fv*e ry^cy % ^hle. Uf? ^ fowtf fa- 'JlLrt Pm u This form is used to insure the attached information is communicated to the appropriate plant personnel. "NITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE; Please initial and date when you have reviewed and understood the material. GROUP Day Staff Ab'Taylor ___ Witt PERSONS NEEDING TO REVIEW , Bourne Young //% Michel ^^tlebert WSy ^Ledoux ___ Rizzo Supervisors ^^?Cook J. ___ Dugas SOS's U ^^Breaux J^Beieler ^Bickham &= Cook F. MlCavalier rant Gravouilla^f Jackson vuk Millender TWMetrejean ^^jBishop Bourg ^( | tjdjfarrisnn ffi^.Iack />PLnnney Wolfe Davis Day Oper. A^Donatto Grace dfyxL Johnson ^^Simonson ^Tl/ Vavasseur \v Loaders ^ l^Armand Doucet V instruments ___ Neyland ____ Shanklin 1________________ DO A 03P032 confidfnttal CMP EMERGENCY DRILL Drill Date 4/2/95 B Actual Emergency Emergency Drill NOTE: The Safety Team must get Supervisor's approval to use an actual emergency to fulfill drill requirements. Record# _fl_ Safety Team Conducting Drill Safety Team Working on Drill Date B Team B Team Drill Topic POWER FAILURE ON L-44 Personnel Involved In Drill: List Names of People Responding to Drill Clarwnce Rirkhem. Richard Braamt. Dennis Wolfft. Emnrsnn Rishnn List Groups Participating in Drill Jamas Pnnlt Drill Critique (Give description of actions taken in response to the emergency and the deficiencies noted during the emergency.) DRILL SCENARIO_____________________________________________________________________________________ PARTIAL POWER FAILURE IN THE OLD PLANT AND BLOCK 43. L-44 DROPPED OFF LINE._________ EMERGENCY RESPONSE Since this incident happened at 11:30 PM all personnel ware accounted for in the control room. The spill alarm was not sounded nor was an announcement made. An assessment of the Incident was made and people responded by swapping to the offline pumps which needed to run. C-2of^htmtom^ pumps did not start and R-250 B was shut down. Acid had to be exported and procedure for exporting acid was followed. PSA-1760/1770 and theTHROX shutdown. PSA-1760 did not swap to E-1760 run step and was swapped to that step. PSA-1770 swapped properly. Plant security responded and asked if there was a release or a possibility of a release. They asked us what could they help us with. We sent them to block 43 to check It out. The sprinkler system on T-514 had tripped but not T-511. The sprinkler was reset and the area checked out. All communications with Block 43 were lost. The supervision and engineer was notified and came out. All alarms on scam. Pics Vax, TDC, PDP 11 were checked and cleared If possible. Supervision then dropped TR-1 and closed 52-T crosstie for 480 volt. All of our flows came back and we wera.4ble to stBrt the rest of our pumps and restart R-250 B, PSA-1760, and PSA-1770. Communications for Block 43 did not come back on and was started up ' the next morning. The THROX was started up. BBD3/2MM DO A 032033 CONFIDENTIAL CMP EMERGENCY DRILL Block 43 was checked by operators after Inblock area was taken care of. All alarms which was still on was rechecked. An alarm on Pics/Vax was then noticed for THROX first pass temperature-showing low. The temperature was too low to bum dry vents. A note was made of this. While making rounds on PSA-1760 the next day the oil temperature was found to be high. Upon Investigation It was found that the fan had tripped during the power failure. Reset It and everything was okay. bbo:i/2S/m DO A 03P034 OONFIDFNTTAl. 1 CMP EMERGENCY DRILL Tollow-Up Actions: Action Power did not contact us. We had to contact them. Communicate the need for th6m to contact us in emergency situations. ________ ___________________________________________________________-- Responsible (Name) Donnie/James Expected Completion Date: 4/21(95 Actual Completion Date: 4/4/95 Action Consider the fact that both P-204s and P-301 C&D are on the same feeder. Investigate separating these,-- and Initiate project to do so if necessary.______________________________________________________----------- Responsible (Name) Stephen Ledoux Expected Completion Date: 5/31/95 Actual Completion Date: Action Have T-511 sprinkler system checked and repaired as necessary, Responsible (Name) Action Donnie/James Expected Completion Date: 4/5/95 Actual Completion Date: 4/3/95 - Responsible (Name) Action _____________________ Expected Completion Date: __________ Actual Completion Date: ________ Responsible (Name) Action - Expected Completion Date: -- Actual Completion Date: _ Responsible (Name) ____________________ Expected Completion Date: __________ Actual Completion Date: Action --------------------------------------------- -------------------------------------------------------------------------------------------- --- Responsible (Name) Action ____________________ Expected Completion Date: __________ Actual Completion Date: _________________________ Responsible (Name) Expected Completion Date: Actual Completion Date: BBD:V2*/M A 033035 CONFIDENTTAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: FROM: l ) 10,1995. 0^,-bk SUBJECT: ___ La VC A^hcheJ a topy as, Ui^arcj SJell n,L/1 fpr j'ht ma* tn'te r.g Cc v\4 rador*, ^ 'aSS o c.ici-i' IDS). / lets?. r.V\tn/ lb O* UnrlrsibnJ -tb*)' L/C Are. nc i rej. \,\e. t-c,' Cn-f-cr C i "L'is ^ Ufl jA)na)r (J /^1P g rJl,,~-->) PP/I nn.. CC--tt-u-u-r--rac-nit/tCC/> J iI1' J"ft- >*. TTI j-1b,,,Jj. ,x ^, ^fAan-rrr-ti`- /((r.f(, ^ans>)n 'eMA'lcc1fj/CCjniiif.Xc/,j /Vf 1o Improve. Ccnhr^chr -o-iSakhi^iyL. fle^c M far4 by StUwe/hnj A>\!____ enLcur^y nj //>- j? /W? I This form is used to insure the attached information is communicated to the appropriate plant personnel. NITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP DayJitaff QiiL^aylor ___ Witt Supervisors ^^Cook J. PERSONS NEEDING TO REVIEW ___ ^liles ___ Bourne y (jjj^ltyoung y^^.Michel jQCclebert Dugas ^//%fianey /^^Cedoux ___ Rizzo ySOS's os*^ ^ \ Breaux /<^_Beieler -Jjt^jiickham y^^CookF. ^^Scavalier <?^Grant Bishop < LJ^tlarrison Gravouilla lu^ Jackson WvA Millender ^WsMetrejean Bourg ^rt^Tilfey *DlWwolfe Jack j^Lonney Davis DayOper. ^^Donatto Grace Johnson Simonson lf]/_ Vavasseur Loaders Armand l^2L Doucet rstruments 1_____ ___ Neyland ____ Shanklin o ^ RLCF I V13 D P404 Ij A j /< o 3 3031 390 I 0 : DONA7 TO SOURC r usii: P L (PAM) DONAT t 0 B D (BRI AN) 4/04/95 4/04/95 1 0 : 30 i 0 : 35 U 4 3 4 0 31 039 U 4 33 4 CM (U434C)31 XF'LAGM r r,ok NAME U433TPi 1.143345; 1 ij?LACSI)CPHR. G A TE0USHV 0 2 > tct BG.l on ' T rnAU ' II NANCE Oi'"! li.iCl DR 1 S ASSUCI AT ION (MCA) COMF ANTES L T ^ T E1.' B CMP I;P-,'./EC JUST HC CU. ' 3 "1F' I.. E M E N I AT 10 N 0 F A U F'* D A 'I IF D 8 A F E T Y F` L A N F 0 FI 1 "f nRCi.'-jj.; mi :;j(C !;' A IF LI: nFN'l b OF Till-' PLAN ARE- ! 1 SUPF: P V 'I S )R S ON r i L" EOT ) Vf SAFE 1 Y ML El ING S/CUMMUIN 1C AT JON. !i-::rr- Tr ' . u)/I3F FT 0 '.'ID INC SUPERVI SION. WITH A LIST OF THE ) F PC FT AMT I" O'! Nl S REO U I R !3 P TO or MADE FOR THE TOF'11: c BUT NAT l-T'3 - WR.I. 1 ' i: u p,r RJ P7 IN OLD ER ' ENCOURASF DISC USSION OF I'FiF TUPiX AS 1 HL F RL LATE I 0 THE CREW ' S WORK RAT HE ft N m N Ft A V i 1 - 1 H!: h F 13" A S PL. CUD TO 7 HI:. J IT FF. 1. OYFFS. pi: pop; of f o know the. fujles ;: L 0 1113, J r. 0 n i b H A V!)' U !3 L N I SSUL D TOA L L. C 0 N T R A 0 T 0 R b , THRUUG H 17-113 A 0 \ F. TRAINING, 1' I-!! " Y WILL. PE SHOWN HOP 10 USE THIS nF NU.-.L 7 iO FTC".' 0 III) FF OWN A NS OF: I' S TO OUL'b 11 ONS ABOUT SAFE' J 01-1 F1 !' F F 0 K 0 A N C, E'. T FI E R E' W 1. L. L. A L b 0 B 1:3 '1 L S 7 S. 0 NM ANY 0 F T FI E S'! iv- JF 0 TS FNCLUrni' TN 'li-IF MAH IJ A! * IMPROVE t.OMMUN'I CAT Ji"IN T OLLOLI UP ON UNSAFE CONDITIONS AND INCIDENTS. ;'!F "NSAFL. CON'D IT ION REF'OR TYING HAS DECREASED RECENTLY. 7 H! 3 MCA WILL ACKNOWLEDGE EACH UNSAFE CONDITION FtEPORT RECEIVED IN AN EF I CRT TO ENCUUI- AG E. INCREASED F ART I Cl'PAT I ON . THE V WILL ALSU SET LIP A CDMPUTEFJ 'TRACKING SYSTEM TO ENSURE COhPI.E'I TON OF" F'OLI. MW UP ACTIONS ASSIGNED TO MCA COMPANIES IN ANY ACCIDENT INVESTIGATION. (THEY WILL HAVE ACCESS TO THE DIVISION WIDE INSIDE'"'! DATABASE WHEN IT BECOMES AVAILABLE TO ACCOMPLISH THIS.) 4 . C 0 0 M U N.! C (-*. 7 E E X l:' L C 7 A T 10 N S T 0 E M F:' L. 0 T E E S . THEr HAVE CHOSEN THE ACRONYM REACT TO OUTLINE THESE EXPECTATIONS, THIS STANDS FOR: R - READ AND KNOW THE. SAFETY RULES FOR YOUR JOB E - EXPECT THE UNEXPECTED AND PLAN AHEAD A AUDIT FOR HAZARDS CONTINUOUSLY C - COMMUNICATE' ANT PROBLEMS OFt CONCERNS 7 - T FI I N l< S A F E T Y F I R S T A N D A I.. W A Y S DQ A 032037 CONFTDFNTTAL 7. LEADERSHIP SUPERINTENDENTS WILL MEET WITH SUPERVISORS FOR. ANY SAFETY INCIDENTS WHICH OCCUR IN THEIR AREA. THERE WILL BE ADDED FOLLOW UP ON THE WEEKLY SUPERINTENDENT PLANT SAFE IF AUDITS F OfM fir N/SLH'T''/3"l OF'S WILL BE AUllTINC IHRS Jr-! PRuGRFAb I OF) ; i a 7' vd tdent i fication a i1 d elimination. all osha'S will de. REV ILWL I) BY CONTRACTOR MANAGEMENT (SITE AND ABOVE) WITH h A '! ,\!' (i: N A N C C G C DN 8 T RIJ C7 I 0 N M A N A & F M E N I . P P. 0 G R L C & I V E DISCIPLINE WILL HE APPLIED TO THOSE PERSONS OBSERVED WHO V O I1' 0 ! C 0 M P I. Y UIT H & T A TEL F. F' Q UI R E M I" N "f B < S & L P , R E D B OOK , SALE WORK PERMIT, ETC.) COMPLETE A PRE - JOB HAZARD ASSESSMENT IN ADDITION TO REVIEWING THE SAFE WORK PERMIT WITH THE CREW, THE PEL r-UT RECEIVER WILL COMPLETE A PRE-JOB HAZARD ASSESSMENT WITH THE CREW TO IDENTIFY ANY JOB SPECIFIC HAZARDS. THIS CONSISTS Of- A FORM TO USE AS A PROMPT FOR THE CREW WHICH LEADS THEM THROUGH DISCUSSION OF POTENTIAL. HAZARDS IN THE A P I! A B 0 F P P I:! T 0 0 L S , l-l 0 U S E K E E I-' IN G , E L. E C T RIC A L. , LI FT IN G , AND OTHERS SUCH AS CLEARANCES, TWISTING MOTION, SHARP OBJECTS, AWKWARD BODY '-'OSITION, ETC. THE MOST SIGNIFICANT' CHANGE THAT THE PLANTS WILL SEE IS A FEW EXTRA MINUTES BEING DEVOTED TO COMPLETION OF THE HAZARD ASSESSMENT. THIS AVERAGES ON THE ORDER OF Z TO 6 MINUTES PER JOB BUT COULD BE LONGER LARGE JOBS OR THOSE WITH WHICH A LARGE NUMBER OF HAZARDS ARE r.son A7 ED - T!!.I.S TIME HOWEVER IS IN SIG NIF IC A N T IF I T R E S U L. IS IN iC:.-' IN WHICH NO ONE IS INJURED. DURING THE FT!.. OF PHASE OF THE iPi. f'MLH'l AT'I ON OF i HE PLAN, THERE WERE MANY INSTANCES OF HAZARDS IT !'N7 I!" " I; i"1 .UR IMG THE F'RE - JOB IA2ARD ASSESSMENT AND THEN 17 L Y FI.. J. A 1 PAT L D 0R ftT: 0DCLD . TUI- IS A ON'T KAC ! OR LED PROGRAM AND DOW IS NOT EXPECTED TO LEAD OP EM- On J.T. ONLY )"L ENCOURAGE. IT. THE MAINTENANCE & CONST RUC T ION !.1 `f*.i [ K i; i. T AL TJN L W f 1 iI 11L rif i j i \ 1 L G!- CL C T b.L LI Kc TEAM W I L. L, ITE F (JL i. 0WI N vs rogham vcccrlsg to ensure cunt castor compliance, your support ;.,V BE l;." Xi 'RFC".!' D TO 'THE S ONI P AG I 011S BY SIMPLY ALLOWING THEM 7 I-'F TIME 0 FTFEUKm rui: HAZARD ACSLCuMFNT and provii-e them wj. ih identified 0 G S / P. L'IT.,1 I!i . pR i.'Z I: Bll!-' L S ''E T C . H-ifiT HICHT BE I I)E NTT !' .1. ED THROUGH EL Ab ELSSMEN"' VROCEuS AS BEING NEEDED TO MORE SAFELY COM PEE TUP, NLA: HAS BEEN ?!: V11: WF D WITH AND SUPPORTED BY THE DIVISION f si YuuF.CC S * EC F ] NO TEAM AS WELL AS (HE MAINTENANCE STEERING TEAM, VO,,! Mi ' HAVE Rf- OF T VLD ADDITIONAL INFORMATI ON OP COMMUNICATION ro; 'CFJ-C ? EG THE PLAN FROM ONE A F TUFSE GROUPS. IF YOU HAVE ANY OWL'- T 1P: 'C OR WOULD . J IT ADD! T I DMA! INFORMATION, PLEASE FEEL ITtL U! CALI.. ON ME. THIS MESSAGE IS SIMPLY AN EFFORT TO COMMUNICATE TO YOU THE EFFORT S GOING UN TO IMPROVE CONTRACTOR SAFETY AND REQUIRE NO ACTION ON YOUR p A F'' . IT v y |.| i; l p YOU l-l n W L V E R 7 0 A M S W E R 0 U F S TI 0 N 5 T l-l A T M A Y C- 0 M E UP IN YOUR PLANT AS TITS PLAN IS BEING IMPLEMENTED. THANK YOU FOR YOUR SUF`F'0RT 0F C0N7 RACTOR SAT"ETY IMPR0VEMEN7 . PAM L. US3 E SAF E7 Y SUFER! NTENDENT FROM: 11SIE "PAM L.. USIF, SAFETY SUPERINTENDENT, (50-4)353-804?" TO DISTRIBUTION LIST: T S2--i I'4C J BMQ , 04340 31 CUBMQ , LK 7204Ml-: I BML| , U A 33 (4 3G1BMQ, U 43 D584 CID i 10 , U43 1 327 0 I DOS' , U45JOSiE!BMQ, DO A 032038 CONFIDENTIAL RtrrocEriIvVrL.Oo 9,4 04 U434031 3032 99 10 '0 lOLCICL : 1 " ! P L ( PA A , DOt-L'-rfO B b (BRIAN) 4/04/'? 5 4/04/95 1 6 : 53 1 6 37 U 4 3 4 0 3 i 039 IJ433481 ( U 4 3 4 0 3 1 XPLAOM r p n hi <aae: i.k-?34C?; -' U"3340i icsdcsmp gati~c:fj::m' o;2> I .J ITT !. :r t i\ I.", i.v i i' rn list the: he:mrer companies of ;1 5 L H AN C L L U PI F(.A I" F ( > !-1' uc a r ion (hca > w11o aii1 involve:d in : l i.ii\'"f hi7 :c op oi-' THi- <- AFKTV PLAN. 1 NO LOT'I AO ThE PRE-JOB A:.V-fC': A HE HI o . TOC C OOP '' ;.C TORS ARE: 1/ r r no GEi'iOO ITC PA7 ,rO,\Ai. PL ! K.i.'1 MAINTENANCE: i'.,r THI r-n j:ous r.Lssiv:;1: -1'0 f i 1 11. " j- ilU R I .i [ L, 1 i. Li'-1 " : i: i) .1 .. '! Pi, j'1. i o i! L J. A I-LI I P I , 'I'ENT . i 504 > 353-80'' c mo:, : 1P/0 . 11 :v:,0 X ; .l .'rv . -s1 -1 ZZ7 i? J Tii'C , . 4 Z<..'Z '>(;' II IQ , :v: i:;o , - S3Cr- , PI BMP , 1.274-'.; "C 1 Lr:0 . J . 1 >:/ i i LJRHO IJV-Vi ,:4Cv !. HMD i !. i -T ( U -1334 3 'i lift A Tj L C I.'1 DO A 032039 CONFTDFNTIAl CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial SUBJECT: fz r*\g rye n cM DATE: {\^>r i 1/ Q FROM: P)f) .1995 _________ __________________ __ Or) ) 1Lexk or) T" I $00 f\0 \J fP Q' W This form is used to insure the attached information is communicated to the appropriate plant personnel. NITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP Day Staff l/ ^l^'Vaylor ___ Witt PERSONS NEEDING TO REVIEW ^ ___ Miles ___ Bourne fck. jileCxl.x (j^'Young >1/#,Michel TVciebert ^ffiftaney ' Rizzo '^j^-Ledoux Supervisors _ ^ ftfQ Cook J. MB Dugas SOS's 1/ ----- Breaux /^^Beieler Bickham i^^Cook F. /^^"Gaxalier Grant Gravouilla ffijackson Tyfy Millender "^^YVMetrejean OS's ^ < Bishop p^tffflrrisnn'X)3 Bourg Jack Wolfe ''nJsConney QS) Davis DayOper. ^^Donatto Grace Johnson -^'Simonson ~TV Vavasseur Loaders ^^Armand jJ$Doucet 1 'nstruments 1____________ DO A 033040 OONFTDFNTTAl CMP EMERGENCY DRILL Drill Date ____3/21015___ Actual Emergency 3 Emergency Drill NOTE: The Safety Team must get Supervisor's approval to use an actual emergency to fulfill drill requirementa. Record # _Z_ Safety Team Conducting Drill Safety Team Working on Drill Date F Team A Team Drill Topic ___________ LEAK SIMULATED ON T-1500 AOV TO C-1510 fvalve boxed, difficult to operate! Personnel Involved in Drill: List Names of People Responding to Drill Fmrtriin C.. Brant B. Oiivnr J.. Ron M.. n.n M List Groups Participating in Drill Barry Young-control room obserrer, Steve Ledoux-outslde observer. All Dow and contract personnel participated In drill. Drill Critique (Give description of actions taken in response to the emergency and the deficiencies noted during the emergency.) BUILDING 4601 The head count from B-4601 was good with the exception of one day person not signed out. Their vehicle was not in the parking lot. Operations decided to assign a sweep team to search the block. Several people drove into the block parking lot during the spill. All said they did not see the lights. Some people were not signed In the book. Poor location of the books has been identified as contributing to the problems. BUILDING 4610 All persons were accounted for. Al Shanklin communicated with the control room within five minutes the status of the building.________ Concern was raised on whether or not the warehouse or the trailer was searched. CONTROL ROOM The control room did a great job In handling the spltl. A simulated call to gate 1 was made with the proper Information. An announcement was made after the spill alarm had stopped sounding so that everyone could hear the announcement clearly. The SOS's received prompt assistance from operations personnel. BBDaOSTM DO A 037041 CONFIOFNIT Al. CMP EMERGENCY DRILL Ron gathered a headcount and Wayne came In the control room and assisted with answering the phones during the drill. Loading personnel shutdown loading and cocooned In the control room. Darren assigned a sweep team to search for missing person.The sweep team Immediately reviewed the block diagram and developed a sweep route. This Is an excellent method to ave time. Sweep team members took air packs searched spill areas and outlying areas. O.J. and Brent checked wind directions and proceeded to examine the spill. They reviewed the piping and determined isolation would require a complete shutdown of C-15l0 They Immediately contacted the control room with their radio. The communication between the control room and the outside team was very good. They Immediately proceeded to the control room to assist as needed. Freddie and Darren reviewed the P&ID's and determined that R-1300 would have to be shutdown. They tripped R-1300 and brought down one R-250. Moments later they determined the other R-250 would have to come down. Reviewed Isolation and clearing of C-1510 and developed a plan of purging the leaking line with nitrogen and blowing the low points to T-1500. After drill, we discussed other possibilities. One recommendation was to bring down R-1300 slowly by utilizing Step (109). This would allow you to bring down hydrochlorination more slowly. This was a very challenging drill. The shift did an excellent lob of identifying the necessary steps to successfully complete the drill. BBD;V2WM DO A c ONptD 3^04P PWTTa/. CMP EMERGENCY DRILL F llow-Up Actions: Action Review the standard for emergency lights. The lights In our front parking lot are not easily noticed, Replace the existing parking lot lights with more noticeable type.-------------------------------------------------- Responsible (Name) Rodney Burris Expected Completion Date: 5/31/95 Actual Completion Date: __ Action Add a slon-ln board for all three office buildings In the block.------------------------------------------------------- Responsible (Name) Stephen Ledoux Expected Completion Date: 5/31/95 Actual Completion Date: _____ Action Relocate the sian-in book in the main office building and the control room. Ensure adequate signs---- are located to ensure visitors slon-in. Responsible (Name) Brian Donatto _ Expected Completion Date: _ 5/31/95 -- ------- ------ Actual Completion Date: ______ Action Install a reminder sheet next to the spill alarm to remind the boardman whatio anflouncain thfi-BVent of an emergency.----------------------------------------------------------------------------------------------------------------------- ----- Responsible (Name) Donnie/James Expected Completion Date: 6/30/95 Actual Completion Date: Action Add to the responsibilities of the coordinator of building 4610 the sweep the trailer and the warehouse. Responsible (Name) ----- Brian D.onattg -- Exofictfid completion Date: --S^I/gS-- completion Date: ----- Action Communicate with Power and Utilities that persons working in our block must follow OUf evacuation procedures.------------------------------------------------------------------------------------------- --------- ------ ----------------------- Responsible (Name) Steve Ledoux Expected Completion Date: H2B/95 Actual Completion Date: ----- Action ------------ , --, i -- Responsible (Name) Action Expected Completion Date: Actual Completion Date: - R sponsible (Name) Expected Completion Date: Actual Completion Date: SBD:1/2WM 00 A 03P043 confidential I l, CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Mon, Apr 10>1995 FROM: Rizzo SUBJECT: Microsoft Mail has heen installed nn the, control room mac To locate movs the niiwtn the apnlg. icon located in the upper left hand comer of the screen. Depress the mouse key an^roilpWnlQ- the microsoft mail item and then release the huitnn----------------------------------------------------------------------- _ Log on: typifyoij Jnst name, first name: (Rizzo. Cary)--------------------------------------------------------- ------- Password- t^p^Welcorn*" Once on change ymir password---------------------------------------- T ngnff - fin to the Mail option on thp Innlhar Scroll dnwn lo Plosc anrl sign nff_nr dcprf.SSJhe apple icon nn the keyhoard InrateH directly lefl of the space har and depress lhc....!lQ".. l^ey Rnth >hese fjinrtion will Ingnf-------------------------------------------------------------------------------- .------------------- --- This fonn is used to insure the attached information is communicated to the appropriate plant personnel. 'NITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW Day Staff X Taylor ___ I^liles ___ Witt Qwft\*y%une ___ Bourne /?/?', Michel y^ (jj(JClebert Supervisors (^fcook J. z^^Dunas X ^2^$flaney '^2^Ledoux ___ Rizzo SOS's X OS's x Breaux ^^Beieler -^'Rickham Cook F. <y~r/Cavalier ^4-^Grant V*A Gravouilla JacksafT prkMillender Bishop^^A^Bourg jfeLiJkey *0Wwolfe Metrejean c Dfi^Harrison Jack SOjLLonney Cfr^-Davis Day Oper. M^Ponatto fi-L Grace X Johnson Simonson Vavasseur Loaders X f^D^Armand (J$ Doucet instruments 1____________________ ___ Neyland ____ Shanklin DO A 032044 CONriDFNTTAI. *rA----------- I ( i --------- CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Mon, Apr 10,1995 FROM: Rizzo SUBJECT: Please review the attached sheet on the F.-455 mod rorte changes This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW Day Staff ___ Taylor ___ lyiiles ___ Witt fy^Youne ___ Bourne --- Michel S&fiey Clebert Supervisors X yKA Cook J. /^^Dugas ___ Haney Rizzo SOS's X L \i>iyBreaux ^Grant OS's ----- Bishop ___ Harrison Day Oper. ----- Donatto <^OBeieler i^Bickham wJ Gravouilla Jackson ----- Bourg ___ Jack ----- Ekey ___ Lonney ___ Grace ___ Johnson -^T'Cook F. /i^-Cavalier ^1 Millender ___ Metrejean Wolfe Q^rDavis ___ Simonson ___ Vavasseur Loaders ___ Armand ___. Doucet Ledoux Mstruments ___ Neyland ___ Shanklin 1____________ DO A 03?045 CONFIDENT! Al CHLORINATED METHANES MOD V _1^_1 DESCRIPTION OF CHANGE S) A System E-455 Equipment Number 500 Can AO(514) Added code to the AO(514) that will place the control valve on a fixed position output at AP(528) setpoint if DC(1213) comes true and the actual N2 temperature, Al(512) is less than the operator entered setpoint, AK(552). The controller will stay on fixed position control as long as Al(512) is less than the AK and a downward temperature for Al(512) isn't detected, indicated by DC(524) becomeing true. The purpose for these changes is an attempt to ensure that the temperature we read is more accurate. DK(640) Added a delay timer on the Call DKZERO code for DK(640). The DK will autozero approx. 1 hour after the required conditions become true. See the following code DC(516), DC(517), DC(518) OO A 032046 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' hi w& Initial DATE: FROM: _ u/- 5?- ,199 SUBJECT: This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP Staff PERSONS NEEDING TO REVIEW Tavlor Miles Bourne Kellev Ledoux Wm Supervisors Cleben ^v/(jjook, J. Dugas ^Michel Rizzo Sauls V SOS's s Trice VS oung Breaux /'tyb Beider Gravouilla ^/Vjackson Bickham Cavalier I^C. Cook. F. Metreican ^SSfer- ^-"'Drant OS's |l^C Armand 1 Harrison Bishop /y^^Bourg /) ~\ Jack u 3<r Looney Davis TAa/ Wolfe lf Doucct O^^Ekcy / Day Operators Donatto Grace Johnson Simonson Vavasscur Instruments Bums Nevland Shanklin Rev. 11/4/94 :jpw DOW CONFIDENTIAL DO A 037047 CONFIDENTIAL &-ao/ yz TAf/: Jaa^hJ C.</'**t*Z*o*> $ 76S/. y^ /S" /7^ . d. ^***2** /tr#-{*-*-; /b0\/(/^7^ 7 X**-" yi^L- L-C+T. < *-*-+*<-> * X 7*. A+is /^7 /U^2 & . "/$ 'JiCtftr r JtU^jf. r"fl O3?04fi CONFTDFNTTA! Training & Development Procedures Chlorinated Methanes CMP PROCEDURE C-204 DRAIN PROCEDURE PROCEDURE # PURPOSE SCOPE RELATED PROCEDURES DEFINITIONS To provide the operator with a document which will assit them in the draining of C-204. To list the necessary steps required to safely and properly drain C-204. NONE NONE SAFETY CONCERNS The automated drain valve will eliminate the risk of & EQUIPMENT exposure to sulfuric acid while draining C-204. ENVIRONMENTAL CONCERNS The closed system of draining C-204 will eliminate emissions of methyl chloride. SPECIAL CONCERNS Do not blow down the column for too long. If the column is blown down for too long. Ml can pressure up T-651. Revision # 3 Dow Confidential Revision Date-1/9/95 This procedure is valid for 24 hours from the date viewed, April 10, 1995 12:59 PM DO A 032049 CONFIDENTIAL Training & Development Procedures Chlorinated Methanes C-204 DRAIN PROCEDURE PROCEDURE Step Action 1 A reminder to drain C-204 is located on the inside round sheet 2 Go to group 107, slot 6 and open the control valve manually. Open the valve slowly. It will not be necessary to open the valve 100%. 3 Drain the column until either an increase in T-651 pressure is noted or a decrease in the Ml header pressure is noted. 4 Once complete, place the valve in manual and closed. The operation of this valve will remain in manual. SBL 4/95 C204DRN.DOC DO A 032050 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 11/4/94 :jpw DOW CONFIDENTIAL DO A 037051 C0N5IDFNTIAL TDC ALARM SYSTEM CHANGES The proper MOC ' s have been written and approved for the following: 1. tf-213 suction & discharge pressure alarms and,D-213 & S-213 level alarms have been deleted from the alarm groups. 2. K-1GG2A & E hi/low amps alarms and R-750 liquid feed flow alarm have been changed to deviation alarms. The MOC limits have Deen updated in the blue book. The amps alarms for P1A & E have also been added to the book (also deviation alarms). This will allow for the alarm on the off-line pump or compressor to remain enabled and be cleared simply be setting the setpoint value to zero The same holds true for the liquid feed - when the setpoint is at zero and the flow is at zero/ there is no active alarm 3. We will now be able to disable the hi/lew pressure and surge flow alarms for the air compressor which is not on-line. When these alarms are disabled/ leave a note in the log book. These alarms/ along with the startup flows on the R-250'S/ are the only alarms uzhich may be disabled without the necessity of a new MOC being written. Do A 03?05? CONF TOFNT T A!,.. CHLORINATED METHANE PRODUCTS COMMUNIQUE' v & Initial DATE: FROM: whiles- ,199 --J7 .--> fvz^i r/n/> !=7c- SUBJECT: /04 r & ^ C ^ 'f-e-cz- e fi *>1* This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONIS NEEDING TO REVIEW lor Stafl^/ *^1 Miles Bourne ^/llev Ledoux Witt (^Jffyfclebert Supervisors^- l/ Trice Coolc-J- ^^^Du&as fVt Young Michel Rizzo Sauls SOS's Breaux Sj^SGravouilla Beieler Bickham W^L-Cavalier A ^-^Cook. F. ^Kjackson ~TS^Y)vietrejean Millender ^""Grant ,. f}lf^ Armand OS's \/( pRj^HarTison t BishoD Jack Davis f to Doucct vS _Ekey Looney Tl\A/ Wolfe Day Operators Donano Grace Johnson Simonson Vavasscur Instruments Burris Nevland Shanklin Rev. lI/4/94:jpw DOW CO'TFIDENTIAL DO A 032053 CONFTDFNTTA! /4tj A (30^^ $2v- .cAelxJt ~f& PoHs>^'>i -Jb*-- PQP-ft h*'-' e- PSA lyX<-*~ / nd-'t**-/-- b *' / P$A- 17So M 3 C/ Crts\4-r^-bfO'j P<U - /7fc0 MIL rrQfo Aa _J*Z /OO pp M 2 \ i r*.-f-io, \6_ArJ77iZ 2?o r/ /oo M2 /V| 3 /^f ^ MoOd Conc<^'(-re*4'` c> -> m te fred-ic, ^ Co>AC^Aii.4~'\i Cc 'U-'-+trcd~ion 252> 3SO /OO /oo> /o& 2S n^ 6. ItOC/^t, 6clJU*K ls\ cyr-tA*.*- Ao P^ul'cAr ptSAA& fcl&ot*s P$A P'O(?U_S^ i. 0^-4- A? /l/[is C-AOu^ <> A ^ p^ AVv / ' A-P c Oi //]7vuO'X> -cL--t---- _v / //sto.* Z2^ -1 / <--- /oA-- C-t^jw-V - c* CHLORINATED METHANE PRODUCTS COMMUNIQUE' L w & Initial DATE: 3/3/>199 FROM: ______________ SUBJECT; c ^ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP Staff PERSONi. S^ NEE""DIN--G TO-- REVIEW lor ___Miles ______ Bourne ^ Kelley oux _____ Witt Supervisors ^^Clebert J- $ftJk'T>ueas /$'/?}.Michel _____ Rizzo ______ Sauls SO^s Trice |uBreaux Young Beieler C^\` Bickham Gravouilla ^^Jackson '^T'^V'^Metjejean Cavalier Millender Cook.F. ^--Grant a. ms.Armand. Harrison l^rfr Bishop Jack ^^Bourg Davi.s it^Looney T)W Wolfe !< Day (mb Donano [ft ^ Grace Opt^tors Johnson /S Simonson V Vavasseur Instruments _____ Bums ______ Neyland Ip Shanklin DOW CONFIDENTIAL O a 03?0SS CONFTDFNTTAL - TAftJtn- --$Uj-- OlXJC Q--itacP X-'^-M. /y^cX4*Za**~ *----"-- ^^JL/las ur*J--Z~ ,, ^JL^~ os~c--4- /g^tm i UD O-lJ^- UU Q"ui~ uJ~3. ^tOfi-JE. 4*0 <3----afi. X^Ct^ r. * ?>*-* A* ^4ut^- _ ^i^L. ._ t<->~<*^ 1 **' X ^ ^ ^ .................... _ . . - - -- i*J>o-*-dx-- _u* <*rf /^ ^ Ujfl pX#-* jlSUL^Xct^ V^J -yujJuJl 'ft c* 0 /tjlg ''DX-0 Vc> Ct C-L'XkAjX-ti&-n_^a JL^ - 2-) 'f^AjL- CL-^xtLci-<jtc-^. \_,*\JLuc) Q-A-tt^JLxd. -p^L, jP^lyOKA-jt Lo-t-fi-ft 4* p^j~ oJL-C_ (Lmlu) y\4s^&A*dluLA*&' cx-t-PL ^Xb-uo E^W. . ox*J^ A "t" ^Xsa^- /%<*-a~. DO A 03P056 CONFTDFNTTAL i13d PRE-JOB HAZARD ASSESSMENT - ... Review the following with the work crew and check the items which apply to the job f~] Cherokee r~|Gemco f~lHBT Permits V N N/A Required Reviewed w/crew All conditions met Other fine JE Merit |~~1nmc | |oilfield |__ jPetrin | jwestgatc PPE y H HtA Available Trained in use inspected / good condition Other Tools V N HtA Proper tools for the job Inspection prior to use Qualifications (ifappropriate) Other Emergency V K N/A Intercom location Safety shower / eyewash Evacuation route Other Access / Egress V N N/A Scaffold (Properly inspected ) Ladder Aerial lift Personnel basket (Inspected and approved Hoisting of tools Special provision Overhead work V N N/A Barricades Signs Hole cover Other Electrical V A N/A GFCI test Extension cord inspection On / near energized equipment Procedure number Voltage level Qualified Other Housekeeping N M/A Aisleways clear Trash containers Containers labeled Other Gaskets V N N/A Asbestos containing gaskets Properly disposed Other Attention jail room1 Please route this form to Chuck Giffin at huild 4109 ) DO A 03P057 CONFIDENTIAL. UK 1 Lifting yN N/A Manual lifting (Body position ) Proper rigging practices' Mechanical Condition of equipment Other Hazards V N N/A Proper tool and material placement Hot / cold surfaces or material Inadequate lighting Pall potential Pinch points Slip trip potential Tight clearances Awkward body position Overextension Sustained position Repetitive motion Twisting motions Shaip objects Other lead pd know the safety rules for yourjob Expect the unexpected and plan ahead Audit for hazards continuously Communicate any problems or concerns Think safety first always CHLORINATED METHANE PRODUCTS COMMUNIQUE' '* k, tv & Initial DATE: yAf/j^c ft 23__________*" & FROM: Aju SS6cl A&MST&QfiJG SUBJECT: 4 total rteefo C.ttARqf C^Lr>uc^LT/^. Mt.c fc^A/ A7%t' (?r?I SYSTEM- This foim is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR' Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP Sc tair PERSONS NEEDING TO REVIEW Miles Bourne Z2.ti,.,, ^ Veliev '^^'^Ledoux 1VAj\ 1 ---- ---/| -----1"-/O--* ""------------- "" "" _ _---- " Supervisors^ amttri} 4/4*--Cook. J. .^Sfc^Dueas /^//-Michel Rizzo ''Sadis SOS's 17 Triop jt>*P Breaux Young Aft Beieler <? & Bickham --Cavalier Cook. F. Grant OS's ^ VjYvGravouilla y Jackson \/fY\ Metreiean >tfa\ Millender -----------------! C, -------------------\ZyT--------- -------- [ ---------------------------------------- ~~7j f Jjfa Armand BishoD /^'JtSoute Davis / Doucct C j^SZ/flarrison Day ^ ^jia^oc tFr* Jack h P Grace ij-4Loonev ^DIa/ Wolfe ^tohtlsflw' / V&a&srflj Operators Instruments Rev. ll/4/94:jpw DOW CONFIDENTIAL DO A 03P058 CONFIDENTIAL Methanes MOC Communique' Date: To: From: Subject: 3/23/95 [CMP Personnel] Russell Armstrong [Total freon charge calculation on the GPI system] [Code has been added to the GPI system to calculate the total freon charge of the K-l 100 refrigeration system. The output tag name for the calculation is PGM FREONTOTAL, The total charge has been added to the data history system in Section 7 (K-l 100) Scheme 58 (Total R-22 Charge). The total charge has been added to the Display Graphics area of the GPI Operator Menu under Section 7(K-1100) Sheet 3(D-1150,D-l 140,E-l 130,D-l 120,D-l 110 & D-l 100). The total freon charge is calculated in LBS.] RPA 3/23/95 POW CONFIDENTIAL 1 DO A 03P059 CONFTDFNTTA! CHLORINATED METHANE PRODUCTS COMMUNIQUE' Ac Initial DATE: 3.^3,199 5 FROM:"fc-.w^ SUBJECT: A. nr*io Slavic. J ,fjkrx-to.P-n 0*n05 rF"A,i*(uuyvet'"_7A c*'*. *t-u t S^+eu^ fi*i AKC, *y-,i tM.6:PT-P0P*ri utps pt*y**~. hs Ip M^oo dA X\5 vsA t-Vj^ pwISM** \S tUfl_u \j*,i +s ly' KiSfi fc>vV-*v. IIs P icsu*.* i} Y'V uoitl ievoe_ A5 This form is used to insure the attached information is communicated to the appropriate plant personnel. b *cAl>P +& MS P5 c INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP Staff i/ PERSONS NEEDING TO REVIEW {X'^^Tavlor Miles Bourne Kelley Ledoux Witt Supervisors L. V*< Clebert sn<!' j\ Trice TJu^V Rrnniv Cook, J. ^^^TJugas _____ Michel _____ Rizzo ______ Sauls A4^ Young /Xf A Relplpr dJk. Rif-lrham /;--Cavalier Coolc F. Grant OS's Day Operators Xrrfiand HWson psL DWItto &&10D 'jjfck =p f )\X Grace Bo^tg _____ ff&ds ___ t&upci U&oev ^z= JoWson Widfe -- ____ Sii^son____ Vaydsseur _____ Jsksy Instruments X Burris _____ Ntyl^nd _____ Shaltkljn DO W CONFIDENTIAL DO A 032060 CONFIDENTIAL \ t CHLORINATED METHANE PRODUCTS COMMUNIQUE' GROUP Day Staff PERSONS NEEDING TO REVIEW ___ Taylor ___ Miles ___ Bourne Veliev ___ _ ^^ ^j^^Haney ^^/^L&doux Witt (Vy^ Young Michel Clebert Rizzo Supervisors X , ffifcook J. MCU Dugas SOS's ^ Breaux /S^?Beieler i^Bickham ^j/j^"Cook F. /^^Xavalier X ^^Grant waGravouilla ^/Jackson Jdj\lMillender T^fAMeterjean OS's Day Oper. ----- Armand ___ Bishop ___ Harrison ____ Jack ___ Donatto ____ Grace __ Bourg J^rLonney ___ Johnson Ekey CjQ. Davis 1--0 Doucet ___ Wolfe .I^^Simonson ____Vavasseur Instruments ___ Neyland ____ Shanklin D0 A 037061. COMF1DFM^1AL T r e 1; t L 0 i - 11 i : c _ r-r i ' * n i c re * i LI j s 1 : i c c r ; r .j i ' ! c r c f. t- e J ` C t ? f I. C 7 17" t; ' J i to 3 t ' n n t 11 n l on 3 v- r t ' - t i ; r . ' -1:: 7 7 ' ` " : ' j c h n - jL e f nr Tja573y I. - y * A "if.; Pi - i - e 3 C.P 7 t - ' ' ,, - tsr; p * 3 1 7 r\ a l - t C 1 -I ' _* r f' 7t t 7 ti 1 i c h * 1 l l a tr 0*. r mJ 71 r 1 o I S/ T r ' i f - .r n -> 3-) " h p tC'" nr -: ur=^ / rr e s j re s ind ,es ' f F; r 7 v i ''*> rpa 0 C ? - S A ry 4 It .7U 7 1 - t J to ) n co r r rot i-v" `j t n V > ' ^ IPTM 1^ ^ 3r: : r - V ;2 lo: r : * for Ht 5i 7n3l ' t ri c ^ p * t r: (> 7In t V'. ; = v e r, t 0sent t 0 tne r t r - \ *. y _ 1 37 - t i l l 9 1t V ^ 9 .ill 7 o V, 7 r r p r " A u r 0 i n 0 i c a t i 0 7 s . T h P 3 e inni c tt ions 1 1 0j c t Li 3 l ortt s j r :1 t r n sr.i 1 er r 3 C3 lc J l 3 t ' 0 a r e s s j r f r; r t - e tf t J -n)r an-' lotl^'in, , t 3 0 e . Tr^^itter 3iort c; 1.- 1 J 17. 7i c v. j s t-'--pit."'? 11 l *7 re-1 in'icit ions 3 re not t ; * e n cut ot se' v i ce it t.e S-7Ct i - ?. A ricdte s'Lect for the t tre i n lie 3t i sns -i L l ; p - ter 7f: :sur:c Ic ul ct ions o- noth t" c: -'it t^f s I rT i t 0 n; j 1 t r 7 i i c c t i w i l l 0 e l.- c t . 7 i: rot in cervices t k i r n f c t of t h e t v 0 r?-i iri er _ # Ti e 3 3 1 r ;} L * r' ju ar7 3_ :i jy t l tc -3 j / 2 ' / DO A 032062 CONFIDFNTTAl CHLORINATED METHANES MOD V _m_ DESCRIPTION OF CHANGE B Sytem R-1300 Equipment Number 100 Can WARN(106) Added DC(1414) to warn(106). DC(1414) detects if a high rate of change occurs in any of the three bed sections. At present, the rate of change time frame is set at a 5 minute interval. If the rate of change of any of the 3 bed sections exceeds the value set by AP(1641/1642/1643), the alarm will activate. (See Alarm(106) code) To determine the rate of change for the 3 bed section temperatures a stack consisting of 5 aco's was written for each section. The upper section uses ACO(601) - ACO(606) The middle section uses ACO(607) - ACO(612) The lower section uses ACO(613) * ACO(618) ACO'S were used in this code primarely because we don't have enough ac's left for system B. The way the stack works is that when the DC() timer for each section becomes true the ACO'S value advances up one. EXAMPLE: When ever the DC() timer becomes true, the value that was in the first aco goes to the 2nd ACO, the value in the 2nd goes to the 3rd and so on, to a maximum of 5 ACO'S. This is a continual loop. ACO(605) ACO(604) ACO(603) ACO(602) ACO(601) AC(1181) 450 1 450 1 450 1 450 1 450 1 450 1 440 1 450 450 450 450 450 440 437 450 1 450 1 450 1 450 1 440 1 437 1 435 1 450 450 450 440 437 435 433 450 1 450 1 440 1 437 1 435 1 433 1 431 1 450 440 437 435 433 431 430 DO A 032063 OONFTDFNTIAI CHLORINATED METHANES MOD V __IjlJ DESCRIPTION OF CHANGE s/ R1 B System R-1300 Equipment Number 100 Can A high rate of change may suggest toefast of an increase in M1/M2 recycle. ] Once detected, DM(107) will be used to clear the DC. There is no automatic action taken by this alarm. Warn(138) DC(1415) was added to this alarm. DC(1415) detects when Al(126/146) reach a maximum flow output as set by AP(1644). Once activated, the alarm will stay on as long as the Al/s are above the unlatch setpoint AC(982). i DO A 03P064 CONFTDFNTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 11/4/94 :jpw DOW CONFIDENTIAL DO A 032065 CONFIDENTIAL Toi'-CM^Perstm^^ FromflStevel;^ Subject: R-7S0 Blowdown Betz requests we only blowdown the boiler, R-750, once per week. We must blowdown the boiler eveiy Saturday morning. Ask if you have any question. The round sheets will be modified soon with the change. Thanks, r'?k A 03^066 CONFID FNTTAi. s ! HTTS Water Management Group SYSTEM REVIEW Customer: Dow Chemical Co. Address: Plaquemine, LA. System: CMP Boilers Tests pH Conductivity Sulfite Phosphate BFW Throx 10.7 400 Test Results E-480 10.1 160 47 15 34 11 Date: Oust. No. Reported To: March 17,1995 16449 D. Taylor,LeD ux B. Miles. Operations Control Limits BFW Throx 8.5-10 10-11.5 9-10.5 ", - 10-20 400- 800 20-40 10-20 20-40 10-20 BP50716 (Tank #920443) Inventory: 600 gallons GCP-187 (Tank #6221) 135 gallons Feedrate: 1.2 GPD OGPD Comments: 1. Boiler chemistry in the Throx Boiler is good today, control parameters are at or near target levels. 2. Inventory of BP 50716 is adequate. 3. We are planning to reduce the number of manual blowdowns performed on the steam generators. Be sure to make note of any changes in the blowdown schedule. We anticipate a reduction to 1 manual blowdown per week. Thank you, ue. IT'ul iw kueFI W, o.Ue 4d f'rv-J Vvm reutr* /?c 05*1 W c~J HUtt vu "ioc/.'-G/ -h> J 'k1* j- ' DO A 032067 CONFIDFNT.TAI. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Mar 16 FROM: SUBJECT; Review the following procedures. Chlorine load change R-1300 liquid injection after a system shutdown RJ .300 liquid injf.ctinn start up ,1995. This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. 'MPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP Day Staff ___ Taylor Witt PERSONS NEEDING TO REVIEW ___ Miles ___ Bourne ffi-Kelley bu Young Michel Clebert / ^^^Haney-^^iLedoux Rizzo Supervisors Z^LCook J. J^S-Duzas xr SOS's ^ Breaux ^^.Beieler -^MiBickham j^jfXook F. ^^H0Svalier X OS's tft"'Grant Gravouilla jJ\,Jackson ^^Millender'^L^^TWIeterjean 77 ___ Armand ^__Bishop ___ Bourg ___ Ekey ,___ Doucet ___ Harrison ____ Jack Day Oper. ___ Donatto ____ Grace ___ Lonney Davis ___ Wolfe ___ Johnson ____Simonson ____ Vavasseur Instruments ___ Neyland ____ Shanklin 00 A Cn^TDrN^ Review & Initial CHLORINATED METHANE PRODUCTS COMMUNIQUE' DATE: Wed, Mar 15,1995 FROM: Rizzo This form is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. 'MPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW Staff ___ Taylor , Miles ___ Bourne J[jAj4elley ^2^^taney >^^Ledoux ___ Witt jrK}Young ** Supervisors -^fOcook J. X SOS's l ^ Breaux I V* ^^Dugas Beieler 113 Michel na Trice Bickham fejcook F. na Clebert na Rizzo //^-Cavalier X OS's ^^^Grant 1 ; 'Gravouilla fj(Jackson ncvlMillender'(JfQv^Meterjea^ * \ i L- ( t , l^i.5 Armand Bishop Bourg Ekey iMz Doucet ___ Harrison ____ Jack Day Oper. ___ Donatto ____ Grace ___ Lonney Davis ___ Wolfe ___ Johnson ____Simonson ____ Vavasseur Instruments ___ Neyland ____ Shanklin 00 A 032069 CONFIDENT tai CHLORINA TED METHANES MOD V ItJ DESCRIPTION OF CHANGE 7f D System T-1830 Equipment Number 400 Can AO(403) AO(403) control valve is replacing the AOV to the docks, D0(450/460). DO(450) code was changed to DC(467). The code used to open DO(450) is now used as the enable code for AO(403). When DC(467) is "TRUE" and if the control valve is less than the high limit setpoint, AP(467) the control valve, AO(403), will ramp open at a rate set by AP(483). When DC(467) is "FALSE" and if the control valve, AO(403), is less than the low limit setpoint, AP(484) the valve will ramp closed at a rate set by AP(483). D0(450/460) Deleted all reference to D0(450/460) code. Also deleted the digital abort code for D0(450/460). (DA(480), (380), (470) & (370)) Warn 480 Changed DC(1148) code for Warn(480) from a DI/DO mismatch alarm for D0(450/460) and made it an AO/DI mismatch alarm . AO(403) / Dl(450). DK(162) Changed the Call DKZERO(DK(162) CODE. Took out reference to DO(450) and DO(460) and replaced with AO(403). Warn (466) High High level T-1830 There was a typo in this code which prevented the alarm from activating if the high pressure transmitter failure DC, DC(1006) for C-1550 was true. Replaced it with DC(1106), failure of T-1830 level transmitter Al(404). UPDATED THE ALARM GRAPHICS DO A 002070 CONFTDFNTIAl CHLORINATED METHANES MOD V __ DESCRIPTION OF CHANGE SI D System C-1540 Equipment Number ]300 Can REQ(324) This alarm will activate when the differential pressure, Al(336), for V-1540, gets greater than the high pressure setpoint, AP(1484). Once engaged the alarm will remain activated as long as the differential pressure is greater than the unlatch setpoint, AC (1443). f r r r t- c - t /,/> ~jf r ', N. .rr- u DO A 037071 CONFTDFNT JAI CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. ll/4/94:jpw DOW CONFIDENTIAL I To: CMP Personnel From: Steve Ledoux Subject: T-814 Operation Do not add nitrogen in T-814 any longer. If we maintain at least a 25% level of Ml in the tank, nitrogen is not necessary. The NPSH for the pumps will be maintained above the minimum by maintaining the level. If the level is below 25% do not run the mag drive pump for any reason. Thanks, D0 A 032073 C0NFTDFNTTA1. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 1 l/4/94:jpw DOW CONFIDENTIAL DO A 037074 conftdfnttal To: CMP Personnel j From: Steve Ledoux Subject: Zone pump modification P-51 IB and P-531 pumps in Zone 1 have been modified with rubber bushings. The rubber bushings replace silicon carbide. We should get a longer life with the rubber material, but the problem will still exist. Please operate these pumps whenever possible over P-511A in order for us to get some run time with the new materials. Ensure operating parameters such as discharge pressure are all normal during operation. Thanks, DO A 037075 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' 7 & Initial DATE: FROM: % ^ ) Q,199 S [ 0u^A3 ____________ SUBJECT: ( rfUQ TccA 1^ This fonn is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONS NEEDING TO REVIEW Staff ^ Tavlor Miles Aj Bourne ^ /^^^Uev -^^^Tedoux Wn- -r------ ---- f pi A Clebert Supervisors Cook. J. /^^Dneas Michel Rizzo SOS's Aj"ft Trice Breaux Young Beieler ^ Gravouilla $b\ Jackson Bickham /'^Tcavalier ^ Cook. F. Metreiean Millender |lj$ Witt _. _ Sauls Grant OS's f\$ Armand C -Harrison Day Donano Operators BishoD Jack Grace Boure Ct> Davis ' Loonev *V)\a/ Wolfe l Doucet Johnson W A Simonson |v)A Vavasseur C Ekev Instruments WlA Bums yjP Nevland PJ'A Shanklin Rev. ll/4/94:jpw DOW CONFIDENTIAL 0 A 037076 Millwright Tool Availability it ft In the past there ha^been several problems with millwrights having tools available to them for repairing pumps after normal working hours. These craftsmen work with Dow tools and are not allowed to bring their own tools into the division. The following procedure will be used when millwrights are called out after normal hours. Vinyl 2 1. Contact Maintenance Supervisor using callout list. 2. Millwright tool lockers will be unlocked by Vinyl 2 operator. (Inform millwright to call Vinyl 2 control room to have shop area and tool locker inspected for housekeeping when job complete. When inspection is satisfactory to operator, tool cabinets will be locked and millwright released.) 3. While millwright is pulling pump in field. Inventory Management person should be contacted by using callout list. They should be here by the time the pump is disassembled. 4. All pump parts for Vinyl 2 are ordered from LHC #3 warehouse. Methanes 1. Contact Maintenance Supervisor using callout list. 2. Millwright tool lockers will be unlocked by Vinyl 2 operator at the Vinyl 2 shop. (Inform millwright to call Vinyl 2 control room to have shop area and tool locker inspected for housekeeping when job complete. When inspection is satisfactory to operator, tool cabinets will be locked and millwright released.) 3. While millwright is pulling pump in field. Inventory Management person should be contacted by using callout list. They should be here by the time the pump is disassembled. 4. All pump parts for Methanes are ordered from Cellulose warehouse. CMP will give the control room phone number to the millwright for any assistance they may need. Vinyl 2 will unlock, inspect, and lock tool area. Any improvement to this procedure is welcomed. There is a phone list for callout numbers in respective control rooms. John Meeker 3/7/95 A 037077 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. ll/4/94:jpw DOW CONF. _ ENTIAL A 03?078 confidential TOPIC: SAFETY CHECKS DATE: 3/6/95 TO: ALL OPERATIONS PERSONNEL FROM: BRIAN DONATTO I continue to have problems with the weekly safety checks. Each Monday morning I am having to track down the sprinkler system check which is required by C-9. The safety checks are now accessed through the procedure system. The sprinkler system check is to be complete and placed in the folder on the safety bulletin board. The oil mist and miscellaneous checks are to be filed with the operator round sheets. On Mondays the emergency light check is to be complete and placed in the folder on the safety bylletin board. Safety checks printing out on the PDP-11 should be ignored and each shift needs to call up the safety checks for the week ends and print them out from the procedure system. I will continue to inform the shifts responsible for the monthly safety checks. You'll be informed of what is due for each month. You^elp is needed and will be greatly appreciated in getting this back on track. DO A 03?079 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Thu, Mar 2*1995 FROM: Rizzo SUBJECT: Please Review the following procedures Taking C200 / 201 bottoms line out of service # 460337, Freon Policy # 460558___________________________________________________ P&TD flow sheel addition and revision 460607,__________________________ R250 recharpe procedure # 460014----------------------------------------------------------Shot pond 500 to T510 # 460122 / Shot pond to C-520 #A6024?-----------Swapping out a nalco tank # 460529. Pumping 1^510 to outfall #.460121 Vaeation Policy # 460550________________________________________________ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP Staff PERSONS NEEDING TO REVIEW ___ Taylor ___ Miles ___ Bourne ____Kelley ___ Haney '^^Eedoux Supervisors X ___ Witt ook J. Young ^^Dugas m Michel na Trice na Clebert na Rizzo SOS's 0 Breaux Beieler dh Bickham /^`"'''Cook F. /^^"Cavalier X Grant Gravouilla kA Jackson Millender `^NVcMeterjean OS's X IJ^Armand |^^Bishop < C^rFIarrison <^3ack Bourg Lonney |^5~Eliey Davis tLo. Doucet Wolfe Day Oper. X Donatto Grace Instruments ___ Neyland ____ Shanklin Johnson jla Simonson na Vavassenr V DO A 032080 DONFTDFNTT AL CHLORINATED METHANE PRODUCTS COMMUNIQUE' ktzriew & Initial DATE: j? //,,199 FROM: ^ _______________ SUBJECT: P-ffi! A/> Lo^/u>^ L ^-i /- This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR* Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. _ GROUP Staff < PERSONS NEEDING TO REVIEW Tavlor satu^, Miles Bourne Mfl^Cellev TM Supervisors X (}^Qdbert Trice JU?0 Cook. J. ^ ^/VyYoung Dueas -Michel Lcdoux Rizzo Witt Sauls SOS', Breaux Beieler XN Gravouilla Jackson OS's f\jl^ Armand O^^&shop X ( T^/iuarnson 33 Jack (L Bickham Cavalier Metreiean fyi Millender Cook. F. ^--Grant Boure CLQ Davis //^ Doucet jl- A / Looney \jvJ Wolfe * Day Donatto Grace Johnson Simonson Vavasseur Operators Instruments Burris Nevland Shanklin Rev. 11/4/94:jpw DOW CONFIDENTIAL DO A 03P081 OONFTDFNTTAL P-t^n Aio> ^ SefyoU't ) APt/^09) j k*<? {?-- "i cJm &-c^ 5A vAj l/OnSX^:,^ /O A / sy cJr-cJU S' 7/-1) diA^-*-y /j isj ZgA/e*' I Qqs\cA\-/;`oa > (Lv<>4- ^U^>,v* .X c-- ''- 00 A 03208? 00NFIOFNTIAL Event Summary 1. P-1511 B shutdown due to D-1511 low level after R-1300 shutdown. 2. P-1511 A started up 45 minutes later - D-1511 level at 50%. Pump ran for 1 hour. 3. P-1511 A shutdown due to D-1511 low level. Pump was making a sqealing sound at time of shutdown. Pump more than likely wrecked at this time. 4. Restart attempt, pump locked upD-1511 level at 50%. CB=CAUSED BY P-1511 A WRECK - 1/28/95 ROOT CAUSE FAILURE ANALYSIS DO A 0 3 7 0 8 3 C O N FID EN TIAL 1. Determine proper D-1511 low level trip point for the P-1511's when the column is in the shutdown step. 2. Determine if additional instrumentation can be installed on Klause Union pumps to detect cavitation problems earlier before a wreck occurs Jim Haney Steve Folse CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: * />*_______ ____________ ,199 FROM: 5 ET>tuX SUBJECT: P-Jib* _________________ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONS NEEDING TO REVIEW Staf^ / Tavlor WUt /-.... -4 Supervisors Clebert !J Trice Miles Bourne Afl^^eilev "`7''^ Ledoux r Cook. J. X$^5$"Dugas Young Michel Rizzo Witt Sauls SOS's X OS'? / Breaux Beider " Gravouilla P/ Jackstir^ Armand (^^^^ishop c D^t! Harrison /O^Jack Bickham ^^Metreiean -/^-^burg C. Cavalier /~C-- Cook.F. ^^"Grant Millender Davis / Doucet jjf^Sk&T^ XZ^Loonev AjU/ Wolfe / IM\Oberat^r1s Donatto Grace Johnson Simonson Vavasseur ^nstr ur^n\s Burris Nevland Shanklin ( Rev. , ./94:jpw DCW CONFIDENTIAL 00 A 032084 conftdfnttal To: CMP Personnel From: Steve Ledoux Subject: P-470A Seal h P-470A was started today with a modified seal. The modification recirculates the same oil through the seal all the time. The cooler temperature should improve the life of each rebuild. The modification is on a trial basis for a couple of weeks or until we can evaluate its performance. Before operating this pump, the seal piping must be completely full of oil. Ensure the high point bleed is used to bleed all of the gases from the seal piping. If you have any questions on the pump let me know. If this seal works as expected, we will modify the other two pumps soon. Thanks, M7o IW oil DO A 03C005 CONFIDENT!At i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: Fri, Feb 241995 FROM: Rizzo SUBJECT: Please review the following new procedures * Adding oil to seal oil pots # 460605___ * Encapsulated Suit Procedure # 460606 This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW Staff ___ Taylor ___ Witt Supervisors .......... X , ^^JCook J. SOS's ^ RreaiiY ___ Miles (yo^Vounp . 1. /j/^TOupas Reieler ___ Bourne ____Kelley ___ Haney ^^Ledoux 113 Michel na Trice ($,Bickham ^--pCook F. Clebert na Rizzo /^"-Cavalier X Grant *Sr Gp^vouilla /^(Jackson mK Millender Meter jean OS's M^Armand YLfSishop X , i)f^Harrisnn ^^Jack Day Oper. ^^Dnnattn lluL Grace X. Instruments ___ Neyland ____ Shanklin Bourg "^key /Ji2 Doucet Lonney l/C-r*~T)avis T)W Wolfe Johnson Simonson 'W Vavassemr DO A 032086 CONFIDENTIAL i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: 2-February,1995__________________________ FROM: Rizzo -7 SUBJECT: The ranges fnr the following variable; were changed for AOt?14) controller. The.transmitter---------- AU5I4). one of the transmitters used for control hv AOf514^ was ranged for 100 while all of the.. below listed variables associated with this control, were ranged fnr 200. This prevented the---------- controller from lining up properly. ------ Am2m ACH235T ACn233). AQ556T ACn270Y AC*1271Y ACf558). AC(5.59h AKf5521 AK(554). APQ233), THF. OLD RANCH WAS 200 / THF NF.W RANCH IS 100 - ~ This fonn is used to insure the attached information is communicated to the appropriate plant personnel. TNITLATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP Staff Supervisors X Taylor Witt PERSONS NEEDING TO REVIEW ___ Miles Bourne Jyu<4i'y 1 Young /^^Dugas m Michel na Trice ___ Haney ^^LLedoux na Clebert na Rizz Breaux /5A Beieler dQ* Bickham ^Cook F. /^-Cavalier Grant -j&V Gravouilla /f^Jackson Millender ^SKjVleterjean OS's Armand ___ Bishop Day Oper. Harrison ___ Jack Donatto Grace Instruments ___ Neyland Shanklin __ Bourg __ Ekey ___ Lonney C^-pavis ____ Doucet ___ Wolfe .Johnson Simonson Vavasseur DO CONF A ^087 TFNTTA|. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: 2-February FROM: Rizzo ,1995 SUBJECT: Please review the following revised procedures *Quartine Tanks #460306. *0-1750 pump down spec # 460781. *K 1100 start up after a long shutdown # 460097. .*T-814 fire #460182. *Line opening initialing #460303. *Cvclohexane off procedure #460183, *Fire in the distillation area # 460079. . *Spill in the distillation area 460080 This form is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR.: Place a check mark by the group(s) needing to review. -iMPLOYE E: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW Staff ___ Taylor Miles Bourne ___ Witt Young Supervisors X( Cook J. /<W$T>ugas 113 Michel SOS's X Breaux /^^Beieler Bickham ^'^Grant _ Gp/vouilla^^Jackson Kelley Haney -gLgJjedoux na Trice na Clebert na Rizzo Cdok F. 2^-CavaIier Millender fT^NVleterjean___ OS's 1^. Armand C^^Bishop ^>spJ^Bourg ___ Ekey Zlz>Doucet x jlM Harrison2- Jack 'JtZ_Lonney ____ Davis !\)VJ Wolfe Day Oper. X 113 Dnnattn na Hracp 113 -Inhnsnn Simonson ~)V Vavasseur Instruments ___ Neyland ____ Shanklin I A 033088 ^ONFlOFNTTAj' CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. ll/4/94:jpw DOW CONFIDENTIAL \T L r r O - Ja /2I / , 01 r ^ r i r cr T r e t 0 ll C * i n i (i > : y se tr i r en ao L ? G n 3.n i t e iTiD er 31 ur CO r*. ^T e r oC i? C ai i ^ au t 0 r- *=. ti C 2 u y s t t p ci nt A r` / f, i C ) y sr Tt t r c c nt r g ll 1 ^ i + * V .* ) - y se T t i it C 0 nt rc n i g * ^ ( ) y , t: 1 : dr 1 Gr t S 7r n i t r 0 J 0- 5 fc_ ut 11 V a L v = r' <T C r _ s ut n e r rs ui t - C ' nc w a n Z1 C c t c C' " G e r 3 t j r t? i- 3 tc - '-4S=> V "T `-C \'^'-v SYZTv ' Djj^s w> r e : 3 ie tc the , --- ; j v pnt c0n oe ns e r 5 y; t3!1 T \(57j) Z'V the Liquid nii ro = ?n controller 40(514) .nil =ss^ ir ~-uZ5 ore sour-: a n J control the liquid nitronen outlet ?. ) c t i t s setrcift -^(St;?). Once the d? d:c v-3 Ive A ? ( 5 ' 4) is eat*"r Than t C (? 5 5 ) *r, tf13 l i o u i o nitr o:ei controller wilt r to control T^e nr o cess outlet tercerature -1(514) at its (1 ?1 ) ; *lf occii) will iff. ueiiat* ly enable constantly i s ,, i r n tiro sen outlet t^e^sture '*1(^17). * l r ?: ) ' 0 ' - j ( : z 4 will i n rr, ed i s t e l y enable constantly recces v * n t outlet t ? r o ' r a t u r e - 1(514). (-..) T J * 11 , : i t u i 11 ''el-'1 will enable ana < r : 4 ) Aill initially to- control th3 re roc esc ore -cool the excnnnocr control The linuio vent outlet cne T ^ e be oe r t r f', 4 v1 ,r' > r c S T : ,, , -:,, > ; nc a I t j r, ( ' ( Cl JT n ascitic^ t c / L 1 ( 5 1' ') i o- t n case to-3 i i u i : nitres * 0 r 5: seconds. which will n outlet T c n g \ i: 1/ 17 /; 4= 2 1 ( DO A 037090 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: 2-February*1995 FROM: Rizzo SUBJECT: Please review the attached sheet crmreming the MOD V upload of System A. The upload concerns the revisions of P-1250A____________ __________ _ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP Staff Taylor PERSONS NEEDING TO REVIEW Miles ___ Bourne ^^^elley laney `^^'Xedoux ___ Witt Young Supervisors X UK^Cook J. z^^Dueas 113 Michel na Trice ' Clebert ___ Rizzo SOS's X OS's L hdx Breaux jMk Beieler Bickham Cook F. ^^pavalier ^-Grant Gravouilla Jackson ffiLMillender Meter jean Armand ___ Bishop __ _ Bourg i^p-EkSy i-ftfDoucet ___ Harrison ____ Jack Lonney w^-Davis ___ Wolfe Day Oper. ___ Donatto ____ Grace ___ Johnson ___ Simonson ____ Vavasseur Instruments ___ Neyland ____ Shanklin DO A 037091 OONFTOFNTTAl CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE Qf A System P-1250's Equipment Number 600 Can WARN(630) This alarm was used for P-1250 A, DI/DO mismatch, Hi - low amps. It was revised and is now used to alarm on Hi-Hi amps, Low low amps, Hi-Hi Differential temperature for both P-1250 pumps. P-1250 A/B - DO(601/611) This pump has been revised. Bump code logic , DC(633/1331) and trip logic have been added to the logic for this pump. When the condition for the pump to run becomes true the logic will cause the pump to energize for 1 second and then re-energize after a specified time frame. The P-1250's will no longer shut down on low discharge pressure (ALM(633)) Also trip logic has been added, DC(1352/1357). The operator has to option of enabling the trip logic by setting DK(240/241) true. When set true, if the conditions for the trip flag become true indicated by DC(1353) becoming true the pump will trip. The trips for the pump is as follows. (SEE WARN(630)) P-1250A P-1250B 1) Hi-Hi amps/power 2) Hi-Hi Temperature Diff. 3) Lo-Lo Amp/power - DC(1354) DC(1355) DC(1356) DC(1359) DC(1361) DC (1362) DO A 03709? CONFIDENTIAL CHLORINATED METHANES MOD V DESCRIPTION OF CHANGE A System P-1250's Equipment Number 600 Can ALARM(612) This alarm was revised so that the off line pump will energize when this alarm activates. The alarm activates if a high virgin Ml flow to R-1300 AC(1727) is detected along with low pump discharge pressure. ALARM(631) This alarm was revised. The alarm was used for P-1250 B, DI/DO mismatch, Hi/Lo amps. P-1250A logic for the same items have been added to this alarm. Also the items from ALM(667) were combined with this alarm. This alarm now activates for both P-1250's on Hi/Lo power, Hi shroud temp., Hi differential Temperature between suction and discharge temperature and DI/DO mismatch. This alarm is now a 1st level alarm that will activate if there is a problem with the amps. If the amps continue to increase or decrease Alarm(612) will activate and if the DK's are set the pump will trip. ALARM(667) This alarm was deleted. The items that were in this alarm were combined with alarm 631 DO A 03?093 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: 2-February>1995 FROM: Rizzo SUBJECT: Please review the following revised procedures* T-inetest.doc - #460444_____________________ ni8l71iq.doc-#460153___________________ * El 813su.doc - # 460148____________________ * K11 OOshortsn.rior #460106________________ * MK1100ri.doc #460291___________________ * K11 00emersd.doc # 460099________________ * Modvpump.doc # 460206__________________ This form is used to insure the attached infonnation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understood the material. GROUP PERSONS NEEDING TO REVIEW Staff ___ Taylor ___ Miles ___ Witt r^jl Young ___ Bourne ___ Kelley C^^Haney ^^Xedoux ' Supervisors y^Lcook J. yft/^Dugas -x -f m Michel SOS's V. Breaux A6 BeiejEr QJjl Bickham X 4'**--Grant Gr^vouilla $)( Jackson na Trice na Clebert GR Rizzo P-' Cook F. -A^Ccavalier Millender /iKHvieterjean OS's Armand Ci^Z^ishop /^^Bourg i$pE)iey /&> Doucet X c Harrison Jack / lV/ Lnnnev Davis Wolfe Day Oper. ___ Donatto ____ Grace ___ Johnson ___ Simonson ____ Vavasseur Instruments ___ Neyland ____ Shanklin C>0 fa 035*094 ^ONFTOFNTTAI.. CHLORINATED METHANE PRODUCTS COMMUNIQUE' kesiew & Initial H,DATE: feU, , / FROM: >rt\r\ Di^eCTnO if,199 SUBJECT: 1^ ^ i-f Drill This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP Staff PERSONS NEEDING TO REVIEW Taylor Miles Bourne ^^^|4fellev i^J^--iedoux Witt Supervisors ,/ SOS's --''Clebert Trice Breaux Gravouilla Cook, J. /^^Dugas Michel Young Beiele/ %^. Bickham :?t/^~CavSier Jar^son oS^Metrejean Millender Rizzo Sauls Cook. F. ^ "Grant , OS's ^ Armand c Ijt^WJiarrison . Jx^Bishop Jack Bourg (2 0- Davis Looney ^\YW Wolfe / Doucct ' key Day Donatto ir). Grace ^*ulson Simonson "TV Vavasseur Operators Instruments Burris Nevland Shanklin Rev.ll/4/94:jpw DO A 03P095 CONFIDFNTTAI DOW CONFIDENTIAL CMP EMERGENCY DRILL Drill Date 12/20/94 Actual Emergency H Emergency Drill NOTE: The Safety Team must get Supervisor's approval to use an actual emergency to fulfill drill requirements. Record# Safety Team Conducting Drill Safety Team Working on Drill Date E Team A Team Drill Topic _____________________ SPILL ON H2S04 TANK CAR AT H2S04 UNLOADING RACK---------------------------- Personnel Involved in Drill: List Names of People Responding to Drill Freddie Cook, Dale Gravoullla, John Ekey, Donald Harrison. Randy Loonev. Loading Personnel List Groups Participating in Drill Shift Supervisor-James Cook, Observer-Fritz Simonson and Judl Witt. Participants: All DOW and all contract personnel. Drill Critique (Give description of actions taken in response to the emergency and the deficiencies noted during the emergency.) Drill Scenario: Personnel going to tank car loed rack discovered e leak on the head seam of a H2SQ4 tank car approximately 1' from the bottom of the car. Emergency response: The drill announcement was made. Outside personnel responded to scene of spill. The main track was already flagged and the area was Immediately roped off. It was discovered that H2S04 had reached zone 2. Made certain that T-510 was lined up. The tank car was already hooked up and offloading. Plant security responded end wanted to put a water fog on the spill. This was not allowed due to reaction potential. Head counts were taken at the evacuation points. It was discovered that some Cherokee people were missing. Located them quickly. Positive Aspects of Response: 11 Main track already flagged, tank car already offloading. 2) Emergency plan was pulled and sign In books checked. 3) Area quickly barricaded. 4) Zone 2 already going to T-510. Areas for Improvement: 1) Still having problems with control room operators designating someone to take charge of emergency activities. 2) The drill announcement was lacking. 31 There was poor communication between Inside and outside personnel. 4) One person went right through spill area Instead of taking safe route. 5) Cherokee personnel went to T-804s and were watching what was going on instead of going to evacuation point to be accounted for. 6) There was misunderstanding as to how to con* * the division Emergency Response Team and determine product experts. 7) ___ Cgnsider a limestone containment area at H2S04 unload rack. 00 A 033096 CONFIDFNTIAL CMP EMERGENCY DRILL Consider a limestone containment area at H2SQ4 unload rack.__________________________ Follow up: 1) Determine encapsulated suit break through time. Determine acid suit break through time. 2) Determine who Is In charge of Division Emergency Response Teem. 3) Determine product expert. 4) Educate back-up personnel for permit writer on permit writers responsibilities during an emergency. Get with craft supervisor to make sure procedures for signing In/out of block Is understood by all contractors and that they fully understand the importance of responding properly to any emergency alarm. follow Up Response: 1) The break through time for H2S04 on the Level A encapsulated suit Is greater than 480 minutes. No permlation was detected at this point. 2) The division Emergency Response Team Is headed up through plant security. They will initiate actions to get the appropriate personnel out. FollowJJp Actions: Action Item 1 & 2 of follow up. Responsible (Name) Expected BrianDonatto Completion Date: 2/28/95 Action Item 3 of follow up_______________ Responsible (Name) Julie Clebert Expected Completion Date: 2/28/95 Action Item 4 of follow up_______________ Responsible (Name) Adam Michel Expected Completion Date: 2/28/95 Actual Completion Date: Actual Completion Date: Actual Completion Date: BBOaOttM 00 A 032097 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' view A Initial DATE: 15-Feb ,1995 from: Gary Rizzo______'______ _________ SUBJECT: The following check sheets have been input into the procedure system. They can be located by choosing the 'CHECKSHEET* button on the main screen. Then choosing one of the options Aiipack check sheet, Chain Operated Valves, Hazard Signs & Utiliti Station, Quarterly Lab Hood CMP Emergency Drill, Lights & Emergency Exits, Fire Extinguishers, Housekeeping, Guidelines CMP Jack Inspection & Monthy Safety Shower and Eye Wash.___________________ ___________ This form is used to msure the attached mtormation is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review EMPLOYEE: Please initial and date when you have reviewed and understand the material GROUP PERSONS NEEDING TO REVIEW Staff -Taylor Miles Witt -Young Supervisors Clcbcrt, J. ook ,J. ugas Kelley Michel -fccdoux Trice -Rizzo SOS's X OS's X )L>$ Breaux Beieler /t(^, Bickham Cook, F. avalier JLGravouilla Jackson Metrejean Millender "Grant Armand (Vffir BishopO- Bourg Davis -fed Doucet oMharrison Q.HS Jack Looney DV/ Wolfe Day Donatto Grace Johnson Simonson Vavasseur Operators Instruments Shanklin Wayne Rev. 2/15/95:jpw DOW CONFIDENTIAL DO A 033098 OONFTDFNTTAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 2/15/95 :jpw DOW CONFIDENTIAL DO a 03^099 confidential CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 2/15/9S:jpw DOW CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' i^ev. 2/i5/95;jpw DO A 032101 CONFIDENTIAL DOW CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' ! ktYidw & Initial DATE: feLruL^r*/ / ^ ,199 i-fi FROM: br\0-v\ SUBJECT: List- oft Z ItLHyarJj, tvi-}In J^feiv harnesse . This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONS NEEDING TO REVIEW Staff Tavlor Supervisors < ^ ^Clebert Miles Bourne Dugas Kelley * Michel -faedoux Rizzo Witt Sauls ; (X Trice vX'/Young SOS's Breaux Beieler ^V> Gravouilla f}p\ .Jackson OS's Armand L^^BishoD ^ c r&tl Harrison D ^ Jack Day fiftyDonatio Grace (L Bickham yj^-Xavalier /TC, Cook, F. ^ Grant "ZD^frletreiean *3$^LMillender A Boura Davis 1 Loonev T^\a/ Wolfe / fch Doucet / Johnson Simonson / Vavasseur Operators Instruments y Burris Neyland Shanklin 1 Rev. ll/4/94:jpw DO A 03?10? CONFXDFNTIAI. DOW CONFIDENTIAL v USE OF 2 LANYARDS WITH SAFETY HARNESS The warning sheet with the instructions for safety harnesses have a statement that says, "NEVER ATTACH MORE THAN ONE SNAP HOOK TO A D-RING". the safety department was contacted about this. This statement does not hold true for systems with locking type snap hooks which are required by DOW. This statement remains in the instructions because this company makes several different types of equipment and the same instruction sheets goes into each one. Also OSHA have not outlawed non-locking snap hooks. DOW requires locking type snap hooks which greatly reduces any potential for roll-out. Using two snap hooks ofthis type on a D-Ring is okay. Attached is a copy of the warning sent with safety harnesses. DO A 037103 CONFIDENTIAL RTC INSTRUCTION #569 EFFECTIVE: 5/1/66 PAGE 13 OF 14 - Never attempt to make any repairs or adjustments to RTC equipment. All problems or concerns must be reported to RTC Customer Service. - Never punch or cut extra holes in a harness or belt. If the size is incorrect, check with your supervisor or contact RTC for the correct size. - No addition or substitution of any part of a RTC system is permitted without the written approval of an RTC Officer. -Do not use this equipment in violation of any applicable company, state or federal standard or requirement. - After impact loading* harnesses and belts must be removed from service, destroyed and replaced to meet U.S. OSHA requirements. -Never use or attach a snap hook to incompatible hardware such that it may be possible for it to disengage (roll-out) from being twisted. - Never attach more than one snap hook to a D-ring. - Never rely on the sound of a snap hook closing on a D-ring, check it visually for proper attachment. -Anyone who has a history of back or neck problems which could be aggravated or complicated by using RTC equipment should not do so. especially a body belt Prior to use or operation of any RTC system, each potential user should be medically certified to be free from spinabifida (congenital), spondylolisthesis and other spinal, cervical or muscular history. -All users must be in good mental and physical health and not under the influence of drugs or alcohol. - Never use belts, harnesses, lanyards, webbing, snap hooks or other fall protection equipment for any other use except personal fall protection as detailed in RTC instructions. TO ACHIEVE THE MAXIMUM LEVEL OF SAFETY POSSIBLE WITH THIS SYSTEM, ALL INSTRUCTIONS MUST BE FOLLOWED CAREFULLY AND FULLY. YOU MUST PLAN THE USE OF SAFETY EQUIPMENT BEFORE THE JOB BEGINS THEN REGULARLY INSPECT AND MAINTAIN THE SYSTEM. f1v DO A 03?104 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 1'.. ^4:jpv, DO A 002105 CONFIDFNTIAt DC:7 CONFIDENTIAL TOPIC: Potable water January 27,1995 As of January 27, we will start running the potable water for chlorine residual. Just grab a sample of the drinking water from any faucet or water cooler and check for chlorine using the same test as the one for the cooling tower. This sample will log in automatically every morning at 06:00 am and should print out with the normal rounds. Please enter in your results as this is a requirement The spec range is .4 to 4.0 ppm. If this is a problem the time can be change to match that of the cooling tower. The reason for this sample is due to the fact that we have a close loop system and if the system is not cycled enough the chlorine residuals will be depleted. If the results are lower than the minimum spec the system will need to be cycled up. This is accomplished by blowing down the system until the chlorine levels are within the required range. Again this is a requirement and the data will be checked should we have a audit Thanks, Terry Vavasseur DO A 03?106 CONFTDFNTTAl. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Review & Initial DATE: felorvCA r'y: 2.-S_ FROM: P)r\^n SUBJECT : PIlAj. I/aIiz n\, ' Wg/y flkr-J- This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR; Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONS NEEDING TO REVIEW Staff rybjt Tavlor P'J Miles Bourne /v1 Kelley Ledoux Wiu yh lSupervisors -3 ' </ ^ Clebert Trice Cook.J. HW Young Dugas y^/Z/'klichel Rizzo Sauls SOS's y C^reaux Bcieler Gravouilla ./^Jackson Bickham /'^-''Cavalier P<A/\uiV>'Metreiean Millender ^C- Cook. F. Grant /], OS's ^ ^^ftamand c L^f^T5anison BishoD / V^^Bourg f)3> Jack (jj^ Looney Q^--Davis S)V\f Wolfe / ^Doucet fIr "'T^/Day onatto Grace Johnson Simonson Vavasseur Operators / Instruments y Bums Nevland Shanklin Rev. 11/4/94:jpw 1^0 A 037107 OONFTOR'MTTAI DOW CONFIDENTIAL n m BRIAN DONATTC t SAFETY COORDINATOR H ELDS. 4601 Safety Coordinaton/Representative* Bulletin Boardi Plug Valves with Actuators Safety Alert Recently, a valve manufacturer made notification that there is a safety issue with plug valves that use the cover/bonnet bolts to attach manual or power actuator brackets to the valve (see Figure 1). Personnel, while attempting to remove the actuator, could mistakenly loosen the valve cover/bonnet bolts, while the valve is in service. If the valve cover/bonnet bolts are loosened while the valve is pressurized, massive leakage will result that could also result in personal injury or property damage. Plants should ensure this issue is reviewed with all personnel and that this type of hazard is part of training programs. __ Actuator Bracket ---------- r ^Cover/Bonnet Botta^ ^^ Cover/Bonnet Manual Actuator PflW AdlMtflt Figure 1: Old Style Cover Mounted Bracket It is suggested that plants audit for these valves in hazardous service and determine if corrective action is needed. Relatively simple solutions to this are available through the I/E Department (contact Ike Eichelberger at 8799 for information). DO A 032108 CONFIDENTIAL LAD Safety Communications Committee cm 01/31/95 SF95-01 Remove Date: 02/28/95 *TrMeiw(i At Tim Dow Clwmlcal Company OvpSpHA STAR WORK AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY PP m i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. l/23/95:jpw DOW CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' A jw& Initial DATE:/ FROM: j/^,0,199 S' 0U AS /CoVX-* SUBJECT: 7~- /230 ___________ __________________________ This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check marie by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONS NEEDING TO REVIEW Stair Taylor Miles Bourne ^Kelley __Ledoux Witt * ^jf /Clebert Supervisors ZK'C Cook.J. x^^Dueas Michel Rizzo Sauls SOS's X OS's A Trice /juJL^Breaux L y Young Beieler ;>A\ Gravouilla -AX' I30*45011 ' ^ j-n Armand c T)&JitemsoD Bishop Jack Bickham 4V^_Gavalier --Cook. F. ""^Orant Metreiean Tv^l Millender Bourg /jLlJavis f *CD Doucet /i yjt --- -------- Looney OWwolfe / Day Donatto Grace Johnson Simonson Vavasseur Operators Instruments Burris Neyland Shanklin Rev. 1 l/4/94:jpw DO A 032110 OONFIDFNTTAI V CONFIDENTIAL VJe desk TO #/*) csercriifj T~jt3o Oricer/tfeee- QAf SurJbd'f AjlfrtfTS. r/ff 81 /ss jySTcm us Td /$ //Zi)/t/?/v/nm to 0 . Do A 03?]] C0NF^tia,' CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 11/4/94:jpw DOW CONFIDENT S VCfrfiO f/WflC/eS AefT 0*J 77t& -fpC* er/fdZ& /aJ& 2>-f f^CL Fcoui -rfrtAJSFfiTTirf, ftp 2>-/330 TC A-/3*o fteu) rf/fFS^/rrsf f/fcSF fft f /SfeAl FC AfeFTznP /frf& /T A/Oti) LOOKS l/kf Y7fe U> scfe/vF dF CCFT #><-<-/* Ttff Food TO &'f tJt/CKrS FWtf* ae ttff df /fe^e e#Mt> THE CO*n&0u Sttfemr /ffCK 7~* Yfltr- oFJ F/AJ4L fF tHod. 77/e fjjjg FJ/Ss/f/O A/UAlSe/tS /fF AW COffFC T. OOft/Ml. TFer FCOO 71 Z>~* At f/fF0F/**Ar&i y 3 ~ y stf ^ss/z-fC- f#a A/pb)y FFi> t^e /*/F/ fey urr'*/fr TA'$ sack 4 //rr/r /t/e/Lf /a/ rfe fa T^A-if. Oo ^Ohjp tD^ii3 CHLORINATED METHANE PRODUCTS COMMUNIQUE' view & Initial DATE: 18-Jan from: Adam Michel ,1995 SUBJECT: Review the following procedure in the event that we need the FIRE WATER header 1, Open the block limit valve at the Northwest roadway 1. Open the Jumper coming out of the ground at the north roadway? 3. Open 6" jumper on the east side of the cooling tower 4. Refer to P&ID for valve location ____________ ~P~ /.?Zo This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial and date when you have reviewed and understand the material GROUP St X Supervisi f ot < 'Vi ay A' *) *jy "7 REVIEW X All IVillwS Bourne ILfcUey" oung ,3. ^/^Dugas flrffl Michel Lcdoux -T-fiee X SOS's X OS's X Breaux /TSBeieler Bickham f~^~ Cook, F. Cavalier Gravouilla . QlD\Jackson Armand Harrison | AUOvletrejear jggftsJvlillender Bourg mLooney iM ^^^Grant Doucet Day Donatto Grace Johnson Simonson Vavasseur Operators -Rizzo Instruments Shanklin Wayne Rev. l/18/95:jpw DO A 03?114 CONFTDFNTTAl DOW CONFIDENTIAL $ ) * 7 a K DO A 03?115 dfnttai C0NF1 CHLORINATED METHANE PRODUCTS COMMUNIQUE* Rev. l/16/95:jpw DOW CONFIDENTIAL i CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 1/13/95 :jpw DOW CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 1/13/95 :jpw DOW CONFIDENTIAL Jan 13, 1995 To: Plant Personnel re: Annual Procedure Review It is once again time to begin our annual procedure review process. Only this year we are going to do it a little different from last year. This year we are not going to have to review and update the IPT modules and resource material. They will be updated when changes are warranted by the Management of Change process. The process that we will use this year for annual review is similar to last years. Plant personnel have been assigned specific procedures that they are responsible for reviewing and if warranted, initiating the MOC process (This includes Area Engineers and Production Supervisor). The difference is how we will review the procedure and document the change. The Master Procedure List Book that contains a list of all the documents that we presently have in our system has been revised to include columns for personnel assignments, review dates, MOC required and initial. A Lab Master book will be kept in the lab and a Loading Master Book will be kept on die Load Rack. It is very important Uiat Uiese books do not become misplaced since diey are our only source of documentation for revisions. The actual process in reviewing a procedure will be as follows: When a task Uiat is being performed requires a procedure to be used, die operator will pull die procedure and review it for accuracy just as it is done now. If, after reviewing die procedure you note dial diere are no changes required, locate die procedure in die Master Procedure Book and fill in die space provided for die Date Reviewed and Reviewed By. In diis way, as we use procedures diroughout the year they will automatically be reviewed and documented. If a procedure needs to be changed, die person reviewing the procedure will follow the same process as stated above and also place a check mark in die place provided for MOC Required. Hie reviewer will then be responsible for implementing die MOC process. Meaning that die changes should be noted on the procedure and an MOC form filled out widi die reviewer signed off as the Originator. The MOC and the attached procedure are dien forwarded to the Shift Supervisor or Area Engineer for review and update and Uien to die production supervisor for final approval. Area Engineer or Shift Supervisor will dien be responsible, as diey are now, for getting die procedure to die Training Supervisor so diat it can be updated in die system. We need to have all the procedures reviewed by the end of the 3rd quarter. It is the responsibility of each operator to ensure that their assigned procedures are reviewed and documented. Please contact me or your shift supervisor should you have any questions concerning this process. Thank You Gary Rizzo DO A 032119 CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' keview & Initial DATE: FROM: 5///2 ____________ >199 . ~ SUBJECT: This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR- Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP PERSONS NEEDING TO REVIEW Staff Taylor ^*5$^ Miles Bourne ^y^Keilev *5^-----Ledoux / 52T/A-V r PfLsClebeit JVj)C,, Cook, J. .'l'1 ^Michel Rizzo "7 sosy y Trice (Breaux Gravouilla \Af\ Young Pj/^Beitlu <^)/Jackson Bickham A^2-Cavalier ^7')YY\Metreiean Millender Cook.F. _ Witt Sauls ^ Grant OS's X lyCUAnnand (Jj^BishoD/Davis l/ ( k^LHanison ^"2> Jack -V aZAoonev UlA/ Wolfe /fe Doucet [ / ____ Day Operators Donatto Grace Johnson Simonson Vavasseur Instruments Burris Heyland Shanklin ( DO A 03?IPO CONFTDFNTTAL DOW CONFIDENTIAL Communique From: Jim Haney Subject: D-l Feed Flow Controller Change The flow indication input for the D-l feed controller, FRC-28710, has been changed. The controller now uses the D-l330 to D-l320 flow indication as its input for control instead of the D-l inlet. The D-l inlet flow indication(FT-28710) is now located in Group 158 on the TDC. The D-l flow controller is still located in Group 122, but now the D-1330 to D-1320 flow is displayed in the slot. This change was made in order to stabilize the flow controller since the D-1330 to D-1320 flow is cleaner than the D-l feed flow (flowmeter less likely to plug). 1/12/^ AO A OONFTDFNTTA!,. CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 11/4/94:jpw r'OW CONFIDENTIAL ; * e t: U o., v; list ' v - a * >. ' - '1 ; * ~ i c * ' wrich will , e nc r, :ra`. into n ' t us In a o J a no ar y tto It'.. - l e o > e loon over tot list. "if distillation 1 r ` 3 chetule: for T u s o a y s i. \_ 1 1 o vf rv, t a n t: f -i l y Z 0 r control s C t" e wilt row t- O C 3 rr S C is ajl? f 3"; 2 r alyi or c C'i t r c L i f t fr. e ;t yz fails 3 U t SO* t w 3 * d: t -f c t i o n TOO _ * r , 1 7 , ; vf rr*f- O-' -4 3 r s l y z = r control 5t'"r? will new r:- con* * i s a 3 l a t ani H TOO if a l yi or c 0't r cl i f the analyze*- fails .toe to s of * sr ? 0`i t?ct isn. a. C* Of tL t l.err: I- ? ` tr ea c o u; kt If trtiress is ^nrs lr t rsy r, tsp rre> 1' ao at t 11 t7 h5* on t* r-occu-l'' ' 3 . ', .; i 2 ' 7 ) for S will now Of uses 3S an indicat i fferrntial te-r.eratjre 3 "tween tt> 3 '.= o.jr-x alar- and 'S:<1?17> for on e a t. o nt w i.'- . r alar- *1 ` * ' * C l* ?- -T\* ** ill re retotnsi-le for izroim 'v (ill jMch will a1 j p ,- ** 1 " r: otto. * s f r o^ 3 o in' tj :'-ir.?5 to T-2 5.-C. w. in e C- 1 >_ ".3 s s f r s c t i " r - ' ( - 4 ~ ) will row o e rarest to a newly entetes y d l u i i " at . 3 -nj K',t rations * T 5 y i r - tc C*1 ono* tt'n ratio. The rano is i r co r; or at c ^ t n * C1 : tv m t ~ = function n y nerjtcrs for C " 1 ^ -- C. a. / Or l o y t i rr W 3 S 3 - c ' to ' ' ( i r r l - T-l'Tj :u*: cut `.' ' for ruroosas 3 l l 0 W i no t :,e line t -J 'rd r ;f*or the ~u"r n a s s h J t town. d) m C . ) - ' - rises t liXi- w '. . ri er t * t '-1 . era:!1 o* t l r- L * 1 * : ~~ .ill V1,, o = c j z f i s ;. Ir- unless t "> a t f v = l _l V, ,, *X v`> - l v - l s - t r :, i - t w : n n not level ccntrcllinn to 41 _, w S - ;. l v l c n " t r " l l- z to v ' (I: A 5 -'ill o ot ec or e L , 'I l ' ( - - 1 : " l > V 1 c s r t r 0 I S t O C i rs t . 1/1./ - 00 A confiofntJ(3 CHLORINATED METHANE PRODUCTS COMMUNIQUE* > Rev. l/6/95:jpw DOW CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' kwiew & Initial SUBJECT: DATE:_ "Ja^ , FROM: __ Soul*-- ^ T fDP- l I This form is used to insure the attached information is communicated to the appropriate plant personnel. INITIATOR; Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. ,199 -S' GROUP Staff PERSONS NEEDING TO REVIEW Tavlor Miles Bourne f$\ .Kdlev Ledoux ~*Wm * " r----(-- Supervisors ^tebert ---- .... ^ Sf Michel Rizzo "Sauls SOS's OS's Trice vl Ml Young Breaux Beieler Bickham ^^Zoavalier F. ^'"'""Grant Gravouilla /--7Jackson >T) Armand df^7^ttshop Metreiean Py \ Millender Boure C]lL Davis //h> ^Hlttamson /O^ Jack ilP Looney DlO Wolfe Doucet At _z \V ]_ Crikey \ Day Operators X ^i^Donatto t S Grace Jobnson ^7 Simonson Vavasseur Instruments Burris Nevland Shanklin Rev. 11/4/94 :jpw DO A 03?1?5 donftdfnttai DOW CONFIDENTIAL OPERATIONS COMMUNIQUE' Leak Repair Sealants Update K. KELLEY 1/4/95 During CMP's August 1994 reactive chemical audit, it was noted that Chip's existing PDP-11 list of tested sealants is constantly in need of updates. The group decided that the best way to ensure all of the latest testing data is available for leak repairs is to refer to the LACSDC Vax "Safety" Menu. The safety menu is continuously updated as new tests are performed, thus eliminating the need for CMP to constantly update the PDP-11 list. The current 'Tested Sealants" list existing on PDP-11 text screen #6 and is 7 pages long. In the near future, the text in this sheet will be replaced with the paragraph below. This will allow operations and engineers to know the proper place to refer to in case leak repair is needed. CMP Leak Repair Tested Sealants: In order to ensure the most up to date version of the division's reactive chemical tests are referred to when installing leak clamps, refer to the division's list. It can be accessed from the LACSDC Vax cluster by accessing the "Safety Menu". Type "SAFETY" at the Vax prompt and enter the correct menu option for "LAD Reactive Chemicals Program". The option for "Leak Repair Sealant Compatibility" should be chosen. Contact shift supervisor or area engineer for assistance in accessing the data base. Kevin K. 00 A 03?1p& CONFIDENTIAL CHLORINATED METHANE PRODUCTS COMMUNIQUE' Acweft' < Initial DAm fROM: S j<f. & /lei ,199 :SUBJECT ms tip* BcJy Con hr! This form is usseed to insure the attached information is commmuunni<icated to the appropriate plant personnel. INITIATOR: Place a check mark by the group(s) needing to review. EMPLOYEE: Please initial once review is complete. GROUP StafT PERSONS NEEDING TO REVIEW Tavlor ^^ldiles Bourne ev Ledoux Witt Supervisors if Clebert Cook,J. Dugas d/?/- Michel Rizzo Sauls SOS's OS's Day Trice 1I/A Young 1 Breaux Beieler pt Bickham ^^^"Cavaiier y^S^JQook, F. ** Grant > OX Gravouilla iCj Jackson - j|jv|^Arinand f^^Bishop ' Metrejean ^p^-Millender /foy Bourc Davis /&> Doucet P\|\, \ / j^t+narrison 0^ Jack kJ A Loonev *\) ^ Wolfe J}lfl^Dona.vio Grace Johnson Simonson Vavasseur ^ Operators Instruments Burris Neyland ^ Shanklin Rev. ll/4/94:jpw DO A 037X77 CONFIDENTIAL DOW CONFIDENTIAL 1995 Hog Body Contest All CMP (Chlorinated Methanes Porkers) are invited to enter the 1995 Hog Body Contest. This is the third annual weight loss competition. Last year's contestants lost a whopping four pounds on the average. As you can see, every one has a decent shot at victory in our group of overachievers. As was done in past competitions, the contestants will be divided into 2 groups. The "piglet bodies" and the "fat-old-sow bodies". The group will be split in two according to weight. In the event of an odd number of people, the person on the bubble will be competing with the "fat-old-sows". Weigh in should be completed by January 13, 1995. The competition will last 4 months, with final weigh outs done between May 1-8,1995. As always, weigh in's and out's should be witnessed by a fellow competitor, according to the rules in the "Rules" section below. Penalty for conspiracy to cheat is life ineligibility for further competition, and a mandatory 6 month SlimFast diet. Moneys will be divided equally between the two least Hoggy bodies (largest % loss of start weight) at the end of the competition. Good Luck, and - from a fellow competitor - eat lots of crawfish and drink a lot this spring! Rules: Open to CMP employees and support personnel with residence at Methanes. Weigh in must be conducted without shoes, anything in pockets or any extras (i.e. jackets, hats, ankle weights, etc.) At weigh out, participants must wear pants and shirt, but shoes and other extras are acceptable. Competitors are encouraged to bring snacks for their opponents. Loss of a limb, limbs, or life disqualifies a participant. Entry fee refunded in full 0-- $19.95 procciting fee). Entry fee will be $20. At weigh out, one dollar per pound gained will be paid as a penalty. There is a stop loss of $9 in penalty payments. Entry fee due by January 31,1995 or the heaviest competitor sits on you. All weights will rounded to the nearest pound (199.49 = 199 and 19930 = 200). No exceptions. Kevin will be official record keeper. A weigh in log will be posted by the scales. DO A 032178 CONFTDFNTIAI CHLORINATED METHANE PRODUCTS COMMUNIQUE' Rev. 11/4/94 :jpw DOW CONFIDENTIAL OPERATIONS COMMUNIQUE' E-455 Start Up Procedure Update K. KELLEY 1/4/95 The E-455 start up procedure has been modified. The revisions deal with the cooldown of the system during start up. The revised procedure is attached. Gary will have the system updated in the next few days. See me or your supervisor with questions. AO A 03?]30 CONFIDFNTIAI Training & Development Procedures i Chlorinated Methanes CMP PROCEDURE E-455 START UP PROCEDURE fE455SU.DOC) PROCEDURE # 460489 PURPOSE SCOPE RELATED PROCEDURES To ensure the safe start up of the DV-455 vent recovery system. This procedure covers the line up of equipment and routine valving associated with a normal start up of the E-455 vent recovery system. N2TRUCK.DOC -Liquid N2 tank truck offload procedure E455SD.DOC - E^55 system shutdown DEFINITIONS Air Liquide- Liquid nitrogen tank vendor. ( SAFETY CONCERNS & EQUIPMENT ENVIRONMENTAL CONCERNS Frostbite: Line openings on any liquid nitrogen system are very hazardous because of the threat of frostbite. Additional safety items required for a liquid nitrogen line opening are: long sleeves, heavy gloves, face shield. The system must be started up properly to ensure the vent recovery system will operate correctly. This system is required in order to control methanol emissions to the atmosphere. SPECIAL CONCERNS None. 0J DO A 03?1 CONFIDFNTT ( Revision # 3. Dow Confidential Revision Date-1/3/95 This procedure is valid for 24 hours from the date viewed, 1/4/95 08:48 AM Training & Development Procedures Chlorinated Methanes E-455 START UP PROCEDURE tE455SU.DOO 4 Cool down the liquid N2 line to E-455 as per following page. 5 All bleed valves are closed and blinded or plugged Checklist complete: _______________ Date/Time: Approved by: -- (supervisor or boardman) Date/Time: KJK 2/94 rev.1/95 DO A 00?132 OONFIDFNTIAI E455SU.DOC Training & Development Procedures Chlorinated Methanes E-455 START UP PROCEDURE (E455SILDOQ PROCEDURE E-455 Vent System Start-Up Step 1 2 3 4 5 6 Action Move E-455 sequence 52 to Step 520. Ensure all red tags are cleared and the system is ready for start up. T-455, liquid nitrogen tank should have an adequate level in it for start up. All control valves except the liquid N2 C/V should be in auto, all instruments should be in normal mode. Terminate to Step 521. The OS should begin lining up the system as per the outside OS checklist. System cooldown. Ensure the liquid N2 b/v at T-455 is closed. Open the liquid N2 C/V in manual to 100%. The OS should then open the manual B/V at T-455 1/4 to 1/2 turn. A steady, heavy vent should be coming out of the PRV near E-455 on top of DV-455. Watch E-455 outlet temperature. When it becomes less than 0 C, the OS will open the manual B/V one full turn . Complete the line cooldown by maintaining flow until the E-455 outlet temperature is less than -40 C. Place the N2 control valve in automatic. Open the manual B/V at the liquid nitrogen tank all the way. Complete the E-455 Start Up Check Sheet & Mod V Check Sheet Review the AK's and AP's through the Dynamic Data Display (GPI option 18). (NOTE: The check sheets only need to be filled out if we are starting up after being down for a long duration) Terminate step 521 to step 522. Once the MOD enters step 522, ensure that all controllers are enabled for normal operation. AO(515) and A0(504) should control DV-455 pressure, while AO(514) works to control the temperatures around E-455 based on the pressure in DV-455 KJK 2/94 rev.1/95 DO A 03?l33 CONFTDFNTTAl E455SUXOC