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CHEMICALS ;/ ' ^*0 (j // INTEROFFICE / LAKE CHARLES TO: DISTRIBUTION FROM: MICHAEL P. DOBRASKO fAfO DATE: FEBRUARY 7, 1989 SUBJECT: SPILLS AND RELEASES, 1988 Attached for your review is a summary of spills and releases which occurred at the Lake Charles Complex during 1988 (includes previously unpublished data from the 4th quarter). A number of graphical representations of the data are included and are discussed below. Figure 1 presents the total number and reportable number of spills/releases for the entire Complex by month in 1988 and compares the monthly values to the average monthly values of 1987. There were 144 total incidents for an average of 12/month in 1988 as compared to 124 and 10/month, respectively in 1987. This amounts to an increase of 16% in the total number of incidents from 1987 to 1988. However, on the positive side, only 45 of these incidents were reportable to a regulatory agency^ or 4/month, as compared to 58 and 5/month in 1987: This represents a 72% decrease in the number of reportable incidents from 1987 to 1988 Figure 2 illustrates the releases by month from the Chlor/Alkali and Derivatives areas. No graphs are shown for the Shipping, Silicas, and Complex areas as they are responsible for very few of the total incidents. The pie charts shown in Figure 3 illustrate the percentage of total releases attributable to each section of the Complex. A better accounting of area of responsibility for an incident was made in 1988 resulting in statistics being obtained for Shipping, Silicas, and complex in addition to Chlor/Alkali and Derivatives. Figure 4 shows a comparison of total and reportable incidents since 1983. This figure again illustrates the increase in total incidents but decrease in reportable incidents that occurred this year. Figure 5 illustrates the 1988 incidents by Shift, shift l represents Graveyards, Shift 2, Days, and Shift 3, Evenings. The distribution remains similar to that observed for 1987 with the majority of the total incidents occurring during Shift 2. A significant increase of incidents occurring during Shift 3 is noted (42 in 1988 vs. 25 in 1987). Figure 6 illustrates 1988 total and reportable incidents by day of the week. As compared to last year, a shift occurred to Thursday SL 85737 (from Tuesday) as being the day for the majority of the total and reportable incidents in 1988. Figure 7 compares the breakdown of incidents by cause between 1987 and 1988. The relative magnitudes did not change appreciably. The major changes appear to be a 7% increase due to People Errors and Other Problems and a 75 decrease due to Mechanical Problems. Another measure of spills and releases is the total poundage of chemicals released to the environment. In 1987, a total of I, 047,567 pounds of chemicals were released. This included a on time spill of 806,766 pounds of brine. Excluding the brine, 240,801 pounds of material were losf. in contrast, only 45,856 pounds of chemicals were lost to the environment in 1988 as a result of spills or releases. This represents an 80% decrease' compared to the 1987 loss excluding the brine. This would suggest that the magnitude of any particular incident is much less than that previously observed. For 1988, a goal was set to decrease Reportable incidents This goal was achieved. By diligent attention to our work, ther is no reason why a further decrease of 15% in Reportable incidents cannot be achieved in 1989. Distribution: T. G. Brown S. L. White H. C. Hank W. J. Peard J. E. Meadows cc: R. J. Samelson (G.O.) W. G. Wallace M. P. Dobrasko R. L. Holliday Shift Superintendents Area Supervisors File #1111.4.03 #1103.3.07 #1109.6 J. E. Wyche R. P. Byars M. W. Wood C. R. Parnell J. M. Porter A. P. Plauche J. C. LaFleur 085738 SL DATE MATERIAL/AMOUNT 01/04/88 CHLORINE G Mon 6.5 tbs. SHIFT 2 REPORTED TO 01/10/88 CHLORINE Sun 8.3 lbs. SHIFT 1 G 01/10/88 CHLORINE Sun 6.7 lbs. SHIFT 2 G 01/10/88 HaOK L Sun 292 lbs. SHIFT 1 01/11/68 CIHC G Mon 30.2 lbs. SHIFT 2 01/14/88 HCl L Thu 'T 2 77 lbs. Co t-* SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ Hg CELL DESCRIPTION CIRCUIT SHUTDOWN DUE TO COMP. ACCIDENTLY SHUTDOWN AT LIQUE. C(2 GAS BACKFLOWED THRU Hg CELL HEADERS TO NEUTRALIZING TOWERS. CHLORINE SURGE NOT COMPLETELY NEUTRALIZED. CORRECTIVE MEASURES SCAFFOLD WAS BUILT OVER COMPRESSOR TO PROTECT TRIP MECHANISM DURING MAIN TENANCE WORK. IN THE FUTURE, SUCH A STRUCTURE WILL BE BUILT AHEAD OF TIME IF NEEDED. CA/ ELECT. A CHLORINE COMP. PRESS. CONTROL IMPULSE LINE FROZE Die TO COLD WEATHER. COMP. HAD TO BE TRIPPED; HIGH PRESSURE OH DISCHARGE CAUSED WATER SEAL ON COOLER TO BLOW RELEASING GAS. LINES WERE INSULATED TO PREVENT FREEZING IN THE FUTURE. CA/ ELECT. A CHLORINE COMP. CONTROL FAILED DUE TO FROZEN IHPULSE LINE WHILE PUTTING CKT. 16 ONLINE. ULTIMATE RESULT WAS HEAVY C12 LOAD TO NEUTRALIZER ALLOWING CI2 TO BLOW THRU 10" LIQ. OVERFLOW SEAL LINE LINES WERE INSULATED TO PREVENT FREEZING IN THE FUTURE. CA/ CAUSTIC C COLD WEATHER CAUSED DRAIN LIME TO FREEZE WITH CAUSTIC. TWO VALVES LEAKED BY CAUSING ABOUT 50 GAL. OF ET-50 CAUSTIC TO DRAIN TO THE GROUND. REPLACED LEAKING VALVES, INSULATED AIR MANIFOLD TO KELP PREVENT FREEZING, RAH DRAIN LINE BACK TO CONTAINED PUMP PAD AREA. B/ PER/TRI SUSPECTED PREMATURE RUPTURE DICS FAILURE ON MIDDLE DH FEED TANK AT PER/TRI. ANTIFREEZING OF STACKS WILL BE PUT OH FREEZE PRECAUTION LIST. A PRESSURE TRANSMITTER WITH ALARM HAS BEEN INSTALLED ON ALL DH FEED TANKS. B/ WTU FLANGE LEAK OF WEAK ACID IN PIPE RACK BEFORE THE ISOLATION DROP POINT JUST NORTH OF DERIVATIVES SWITCHGEAR ROOM PRIOR TO COLUMBIA-SOUTHERN ROAD. A QAT IS LOOKING AT NEW MATERIALS AND IMPROVING OPERATING PROCEDURES TO STOP LEAKS ON THIS LINE. SPILLS AMD RELEASES AT LAKE CHARLES DATE HATERIAL/AMOUNT 01/14/66 EDC G Thu 196 lbs. SHIFT 2 REPORTED TO PLANT B/ WTU AREA DESCRIPTION A SLUG OF ORGANICS IMS FED TO #2 CSS CAUSING RUPTURE DISC TO BLOW FOR ABOUT 1 HIN. NO UNUSUAL INCIDENTS IN THE OHC UNITS APPEAR TO BE PRECURSORS. CORRECTIVE MEASURES DISCUSSIONS ARE BEING HELD WITH VCM-1I AND TE-II OH THIS HATTER. RESULTS AND PLANS UILL BE WRITTEN AND PRESENTED TO THE COMMITTEE WHEN COMPLETED. 01/15/86 PER/ TCE L Fri 17 lbs./ 49 lbs. SHIFT 2 DEQ/NRC PER/ TCE 17lbs./ 49 lbs. B/ UTU RUPTURE DISC ON *2 WASTE RECOVERY KETTLE BLEU DUE TO VALVE(S) LEAKING BY. LIQUID DRAINED OUT THE STACK FOR ABOUT 5 MINUTES. SHUTDOWN SYSTEM ALARMS WERE CHANGED SO THAT AH ALARM WOULD SOUND IF HIGH PRESSURE EXISTS EVEN IF THE SHUTDOWN SYSTEM HAS TRIPPED. 01/26/66 NaOH L Tue 3200 lbs SHIFT 3 DEQ/NRC NaOH 3200 lbs. | SH/ SHIPPING A 6350 lbs. OF 50X CAUSTIC SPILLED TO GROUND DUE TO OVERFILLING A T/C DURING LOADING. LOADER UAS READYING ANOTHER T/C AND FORGOT ABOUT THE ONE HE UAS LOADIHG UNTIL IT OVERFLOWED. FAILED TO FOLLOW SOP. EMPLOYEE UAS COUNSELLED. 01/27/66 CHLORINE Ued 10 lbs. SHIFT 3 G SARA/NRC CHLORINE 10 lbs. COMPLEX WEAK ACID LINE RUPTURED AT 90 ELBOW UHEN ACID pH CONTROL VALVE SLAMMED SHUT SHOCKING THE LINE. ACID RELEASED TO 116 SEWER CAUSED RELEASE OF CHLORINE. A PLAN TO REPLACE THE PRESENT FIBERCAST LINE WITH DERACANE OR TEFLON-LINED STEEL PIPE HAS BEEN INITIATED BY FLOYD FONTENOT, SS. 01/30/88 NaOH L Sat 715 lbs. SHIFT 1 SILICAS A CIRCULATING HOSE ON #3 CCD RUPTURED CAUSING A SPILL OF 400-500 GAL. LIQUID BLEND OF CAUSTIC AND SOOIUH SILICATE. HOSES HAVE BEEN ELIMINATED AND EXTERNAL PORTIONS HARDPIPED. HOSES ONLY OH IN SIDE OF TANK. 01/30/66 NaOH L Sat 72 lbs. SHIFT 3 SILICAS RUPTURED RECIRCULATING HOSE ON #3 CCD (AGAIN). HOSES HAVE BEEN ELIMINATED AND EXTERNAL PORTIONS HARDPIPED. HOSES ONLY OH IN SIDE OF TANK. SL 085740 SL 085741 DATE HATERIAL/AMOUNT 01/30/88 NaOH l Sat 150 lbs. SHIFT 2 02/01/88 NaOH L Hon 245 lbs. SHIFT 3 REPORTED TO 02/03/88 CiHC L Ued 10 lbs. SHIFT 1 DEQ/NRC CIHC 10 lbs. 02/06/68 HCl L Sat 702 lbs. SHIFT 1 02/12/88 NaOH L Fri 408 lbs. SHIFT 3 02/17/88 CHLORINE Ued 7.9 tbs. SHIFT 2 G SPI AND RELEASES AT LAKE CHARLES PLANT AREA CA/ ELECT C DESCRIPTION RINE LINE RUPTUREO SPILLING 50,000 GAL. BRINE. IMPROPER PUMP SHUTDOWN CAUSED HEADER TO BREAK. CORRECTIVE MEASURES OPERATOR WAS GIVEN A VERBAL WARNING IN A COUNSELING SESSION AND WAS TOLD TO USE PROPER SOP'S. CA/ "C" CAUSTIC BLEED VALVE ON BOIL OUT PUMP WAS LEFT OPEN. WHEN A TRANSFER WAS HADE FROM THE 2ND EFFECT TO THE BOIL OUT STG. TK. MATERIAL LEAKED OUT OF THE OPEH VALVE ONTO GROUND. PUMP PAD OVERFLOWED. REEMPHASIZED NEED TO CLOSELY CHECK DRAINS IN PIPING BEING PUT INTO SERVICE ON BOI LOUTS. UNPLUGGED PUMP PAD DRAIN. LOOKING AT A BETTER WAY OF KEEPING pH PROBE UPRIGHT IN DITCH. 0/ VCM-II #1 VC DOPP KETTLE WAS BEING EMPTIED INTO A TAR BUGGY. A LEAK OCCURRED AT THE HAMMER UNION CONNECTION ON THE LOADING LINE INTO THE TAR BUGGY. SPILL RAN OFF CONTAINMENT ONTO THE GROUND. PROCEDURE WAS REWRITTEN TO PRESSURE CHECK CONNECTION PRIOR TO PUTTING BOTTOMS IN THE LINE. B/ UTU A TEFLON BACKING REMAINING UNNOTICED IN VENT LINE AFTER REPAIRS TO WEAK ACID STG TK. CAUSED TANK TO OVERPRESSURE WHEN PUT INTO SERVICE, MOVE OFF FOUNDATION, AND SHEAR PIPING. PRESSURE RELIEF HAS BEEN INSTALLED ON TOP OF TANK. VENT SYSTEM HAS BEEN SEPARATED FROM OTHER COS TANKS. IMPLE MENTED PROCEDURE TO PUT TABS ON ALL TEFLON BLINDS. SHIPPING/ A CAUSTIC WAS DUMPED INTO SUMP FROM DAMAGED CARS. HIGH LEVEL ALARM AND PUMP AUTO SWITCH DID HOT WORK. SUMP OVER FLOWED BEFORE OPERATOR NOTICED AND COULD TURN PUMP ON MANUALLY. OPERATOR WAS COUNSELED. HIGH LEVEL ALARM &HD PUMP AUTO SWITCH WERE REPLACED. CA/ HG CELL DURING SWITCHING OF NEUTRALIZER CIRCULATION PUMPS, DIVERSION SYSTEM TRIPPED SEWING TAILGAS TO POWER HOUSE STACK. FAULTY PUMP SWITCH OH ONE OF THE PUMPS CAUSED PUMP TO WORK WRONG. AMP METERS HAVE BEEN INSTALLED FOR THE CIRCULATION PUMPS TO GIVE A BETTER IN DICATION OF PUMP OPERATION WHEN SWITCHING IS REQUIRED. SL 085742 DATE HATERIAL/AHOUNT 02/19/88 NaOH L Fri 318.5 lbs. SHIFT 2 REPORTED TO 02/20/86 EDC L Sat 305 lbs. SHIFT 3 02/23/68 HETHYLCHLOROFORK Tue 21.7 lbs. SHIFT 2 L 02/25/88 CIHC L Thu 358 tbs. SHIFT 3 02/26/88 CIHC L Fri 110 tbs. SHIFT 2 DEQ/HRC CIHC 110 lbs. 03/03/88 CIHC G Thu 27.6 lbs. SHIFT 2 SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA RIPPING/ DOCKS DESCRIPTION A DRAIN VALVE AT C DOCK CAUSTIC SUMP WAS LEFT OPEN AFTER LAST CLEARING OF CAUSTIC LINES. WHEN CAUSTIC TANK WAS LINED UP, SUMP FILLED AND OVERFLOWED INTO THE RIVER. CORRECTIVE MEASURES TANKERMAH WAS COUNSELED AND TOLD TO FOLLOW SOP'S. B/ WTU WET EDC WAS BEING UNLOADED INTO #1 VC TK A LEAK WAS LATER NOTICED FROM THE 3" SUCTION NOZZLE ON THE TANK. ALL EDC WAS CONTAINED BY THE DIKE AROUND THE TANK. TANK WILL BE INSPECTED INTERNALLY AND REPAIRED. NOZZLE WILL BE MOVED FROM BOTTOM TO SIDE OF TANK. 8/ TE-IJ AFTER FILLING DRUMS WITH PRODUCT USING A HOSE, THE HOSE WAS LAID DOWN. PRODUCT LEFT IN THE HOSE DRAINED ONTO THE PAD. (NOT CONSIDERED A RECORDABLE SPILL UNDER PRESENT GUIDELINES. GUIDELINES ARE UNDER REVIEW BY THE SPILL CONTROL COMMITTEE.) 6/ VCH-lt SHALL BLEED VALVE ON SIDE ARM COOLER WAS LEFT PARTIALLY OPEN AND NOT CHECKED WHEN COOLER WAS PUT BACK INTO SERVICE. EDC REACTOR LIQUOR SPILLED OUT OF VALVE ONTO PAD. OPERATORS COUNSELED. PROCEDURES ARE BEING CHANGED TO REQUIRE LEAK CHECKING OF EQUIPMENT BEFORE RETURNING IT TO SERVICE. B/ WTU INCINERATOR FEED LEAKED TO THE GROUND FROM A DRAIN VALVE ON THE CPC LIQUID LINE THAT HAD BEEN LEFT OPEN. DRAIN HAD BEEN HOOIFIED ALLOWING SPILL TO BE TO THE GROUND RATHER THAN THE PAD. OPERATOR COUNSELED TO INSPECT FOR OPEN VALVES CAREFULLY PRIOR TO STARTUP. FITTINGS WERE REMOVED TO DIRECT POSSIBLE SPILLS TO A CONTAINED AREA. B/ EDC TRI STILL OVERHEAD WAS FED TO THE HOT TCE STRIPPER. WHEN IT ENTERED THE HOT COLUMN, IT VAPORIZED AND OVERPRESSURED THE COLUMN, BLOWING A RUPTURE DISC. PRESSURE TRANSMITTER WAS READING LOU. THE TRAHSHITTER WAS PUT ON THE PROOFTEST PROGRAM. SL 085743 DATE MATERIAL/AMOUNT 3/11/08 CHLORINE G Fri 5 Lbs. SHIFT 1 03/24/88 CHLORINE Thu 6 lbs. SHIFT 2 G 03/28/88 HCl G Mon 62 lbs. SHIFT 2 04/05/88 NaOH L Tue 440 Lbs. SHIFT 3 04/07/88 NaOH L Thu 254 lbs. SHIFT 2 04/16/68 CHLORINE Sat 9 lbs. SHIFT 3 G REPORTED TO DEQ/LSP CHLORINE 6 lbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA * SHIPPING/ A DESCRIPTION LIQUID CHLORINE LOADING LINE VALVE PACKING BLEU OUT. OCCURRED AT TANK 21 VALVE ON THE CHLORINE PATIO. RESULTED IN A FIRST AID CASE. CORRECTIVE MEASURES CHANGING TO ANOTHER TYPE OF CHLORINE Vn^EVITH BETTER PERFORMANCE RECORD. B/ EDC UHILE HEATING UP #3 RX, VENT WENT TO SCRUBBER INSTEAD OF INCINERATOR HEADER. CHLORINE UAS RELEASED FROM SCRUBBER FOR ABOUT 2 MINUTES UNTIL VENT UAS SUITCHED TO INCINERATOR HEADER. CHANGED PROCEDURES TO PUT VENTS TO INCINERATORS BEFORE CHLORINE ADDITION. B/ PER/TRI #5 WEST PRIMARY CONDENSER BOTTOM HEAD GASKET BLEW OUT WHILE ATTEMPTING TO TIGHTEN A LEAK AT THE SAKE LOCATION. POLICY CHANGED SO THAT BOLTS UILL NOT BE ADJUSTED UNLESS THE PROCESS SIDE OF GRAPHITE EXCHANGERS HAVE BEEN DEPRESSURIZED. CA/ CAUSTIC A CA/ CAUSTIC C DRAIN LINE VALVE LEFT OPEN ON FEED LINE TO WEST CONCENTRATOR FEED PUMP. SPILL UAS TO A CURBBED PAD. PAD DRAIN UAS PARTIALLY PLUGGED CAUSING CAUSTIC TO OVERFLOW PAD. PAD DRAIN UAS CLEANED AND THE DRAIN LINE AT THIS POINT UAS REMOVED TO ELIMINATE THE POSSIBILITY OF A LEAK. UEST CELL LIQUOR TANK HEEL UAS BEING PUMPED OUT. HOSE OH PUMP DISCHARGE TORE AT THE SUMP PUMPING CELL LIQUOR TO THE GROUND. SOP HAS BEEN CHANGED TO REQUIRE MAN UATCH WHENEVER TANKS ARE BEING DRAINED OR CLEARED IN THIS WAY. 'SHIPPING/ A CHLORINE LEAK FROM THE SNIFF BLOWDOWN VALVE BEING OPEN AW LOOSE HAMMER UNION (HAND TIGHT) DURING CLEARING OF EMPTY TANK CARS AT CHLORINE LOADING RACK. COUNSELLED CHLORINE TEST RACK OPERATORS ABOUT TIGHTENING ALL FITTINGS WHEN HOSES ARE DISCONNECTED. AND RELEASES AT LAKE CHARLES DATE MATERIAL/AMOUNT 0*18/88 CIHC L Hon 5 lbs. SHIFT 3 '04/18/88 EDC L Mon 100 lbs. 7 SHIFT 3 ,04/16/88 HaOH L Mon 600 lbs. SHIFT 3 REPORTED TO PLANT AREA SHIPPING/ DOCKS Shipping/ docks * SHIPPING/ DOCKS DESCRIPTION FORWARD GAGE HATCH ON STARBOARD SIDE OF CSCC 200 WAS FOUND LEAKING PRIOR TO UN LOADING BARGE. HATCH WAS NOT COMPLETELY SEALED OFF (RUST?). MATERIAL WAS BRAZILIAN EDC BLEND FEEDSTOCK. CORRECTIVE MEASURES SOP CHANGED TO LIMIT MAXIMUM LOAD ON Barges usd for storage in the plant. EDC LEAKED THROUGH A CLOSED VALVE ON VENT LINE ON PPG 212. LEVEL IN BARGE WAS UP IN EXPANSION TRUNK. LEAK STOPPED WHEN VENT PIPE WAS RAISED UP. SOP CHANGED TO LIMIT MAXIMUM LOAD ON BARGES USED FOR STORAGE IN THE PLANT. PPG 209 WAS BEING LOADED WITH ET-50 CAUSTIC. LOADER WAS DISTRACTED BY ANOTHER PERSON ANO BARGE OVERFLOWED ABOUT 50 GALLONS. COUNSELLED OPERATOR TO IGNORE ANYONE WHENEVER A BARGE OR ANY PIECE OF EQUIP MENT IS ABOUT TO BE LOADED. POLITELY TELL THEM YOU WILL BE GLAD TO TALK LATER. U/21/8B OIL L Thu 2 lbs. SHIFT 2 USCG OIL 2 lbs. SHIPPING/ DOCKS LEAK OF HYDRAULIC FLUID FROM A MIS THREADED PIPE UNION ON A BARGE. (HO REPORT WILL BE 1SSUE0 AS THIS HAS NOT A SPILL OR ABNORMAL LEAK.) 04/26/88 CIHC L Tue 12 lbs. SHIFT 1 DEQ/NRC PER/TCE/UNSYH 2/3/1 lbs. B/ WTU PIN HOLE LEAK ON #2 TETRA TANK PUMP SUCTION LINE. ABOUT 1 GALLON RELEASED. THE LINE WAS REPLACED. SOUTH TERMINAL MATERIAL WILL NOT BE PUT INTO THESE TANKS AGAIN. 05/01/88 ETHYL CHLORIDE Sun 75 lbs. SHIFT 3 G DEQ ETHYL CHLORIDE 75 lbs. B/ EDC (EC/HCl) THE SOUTH EC REACTOR COOLER DEVELOPED A TUBE LEAK fHAT ALLOWED EC TO LEAK INTO THE COOLING TOWER WATER. LEAK WAS FOUND BY OBSERVING LOW COOLING TOWER WATER A COOLING TOWER WATER pH METER AND ALARM WILL BE INSTALLED TO DETECT LEAKS EARLY. SL 085744 SL 085745 DATE MATERIAL/AMOUNT 05/04/88 CHLORINE G Wed 8.8 lbs. SHIFT 2 05/06/88 CLHC L Fri 34 tbs. SHIFT 1 05/06/88 NaOH L Fri 113 tbs. SHIFT 3 05/07/88 HaOH L Sat 335 Lbs. SHIFT 2 05/09/88 DIESEL FUEL Hon 3 lbs. SHIFT 2 05/09/88 CHLORINE Hon 338 lbs. SHIFT 2 G REPORTED TO USCG DIESEL FUEL 3 lbs. NRC/DEQ/SP/LEPC CHLORINE 338 lbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ POWER DESCRIPTION PINHOLE LEAK IN GASEOUS CHLORINE LINE FROM C CHLORINE TO SABINE TREATMENT. CORRECTIVE MEASURES THIS LINE HAS BEEN SCHEDULED TO BE REPLACED. B/ VC-II CA/ ELECT C CA/ CAUSTIC A SHIPPING/ DOCKS CA/ Hg CELL PRESSURE GAUGE DOWNSTREAM OF EDC SIDEARM COOLER BLEW OFF SPRAYING EDC REACTOR LIQUOR. THE CAUSE HAS INTERNAL CORROSION ON GAUGE THREADS. SPILL HAS CONTAINED ON ON CONCRETE PAD. MAINTENANCE WAS AGAIN INFORMED OF THE NEED TO USE STAINLESS STEEL FITTINGS IN THIS AREA RATHER THAN CARBON STEEL. WILL TRY TO ARRIVE AT A VISUAL METHOD OF REMINDING PEOPLE OF THIS. A 3/8" HOLE IN A 1 1/2" CELL LIQUOR LINE HAS FOUND WHEN OPERATORS TRIED TO PUT THE LINE IN SERVICE. LINE HAS BLOCKED IN AGAIN, BUT VALVE HAS NOT COMPLETELY CLOSED ALLOWING LINE TO LEAK SLOHLY. THIS SECTICHI OF CELL LIQUOR LINE HAS BEEN REPLACED. A REVIEW OF THE SOP FOR ENVIRONMENTAL RESPONSIBILITIES OF A SPILL WAS HADE WITH THE "C" CHLORINE OPERATORS. WHILE TRANSFERING CELL LIQUOR TO AREA, FLARGE GASKET FAILED ALLOWING CELL LIQUOR TO SPILL TO GROUNO. LESS THAN 3 lbs. LEAKED BY DIKE VALVE INTO 003 OUTFALL. THE GASKET WAS CHANGED. THE CONTAINMENT SYSTEM KEPT SERIOUS ENVIRONMENTAL INSULT FROM OCCURRING. DIESEL FUEL LEAKED AT A SCREWED CONNECTION IN FUEL LINE ON BARGE USL 491 BETWEEN FUEL TANK AND ENGINE. REPLACED PIPING/TUBING WITH FLEX FUEL LINE. TAIL GAS WAS DIVERTED FROM Hg CELL NEUTRALIZING TOWER TO POWERHOUSE STACK. HYPO CIRCULATING PUMP TRIPPED THREE TIMES CAUSING DIVERSION. A BACKUP SYSTEM FOR PREVENTING EXCURSIONS TO THE POWERHOUSE STACK HAS BEEN ENGINEERED. PIPING AND VALVING WILL TIE DIVERSION SYSTEM INTO ONE OF PLT. A`S NEUTRALIZING TOWERS. DATE MATERIAL/AMOUNT 05/12/88 CHLORINE G Thu 6.4 tbs. SHIFT 2 REPORTED TO 05/13/88 CIHC L Fri 62.5 tbs SHIFT 3 DEQ/NRC CIHC 62.5 lbs. 05/14/88 MaOH L fat 50 tbs. SHIFT 3 05/17/88 CHLORINE Tue 5 lbs. SHIFT 1 G 05/17/88 CHLORINE Tue 1 lb. SHIFT 3 G 05/18/88 MERCURY tied 3 tbs. SHIFT 1 L DEQ/NRC MERCURY 3 lbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA SHIPPING/ DOCKS DESCRIPTION LEAK FROM A 3/8" HOLE IN SHIPPING BARGE BLOUDOUN LINE AT NORTHUEST CORNER OF K306. MATERIAL IN LIKE UAS VENT OFF OF A RETURNED CHLORINE BARGE. CORRECTIVE MEASURES LINE UAS REPAIRED. IT IS DUE TO BE PAINTED IN 1988. B/ UTU BOTTOMS PLANT DH FEED TANK PIPING MANIFOLD UAS BEING PUT BACK INTO SERVICE. A BLIND FLANGE ON THE MANIFOLD UAS LEFT HAND-TIGHT RESULTING IN A SPILL. PROCEEDURES TO PRESSURE CHECK EQUIPMENT PRIOR TO RETURNING IT TO SERVICE ARE BEING INITIATED. SHIPPING/ DOCKS 1 A FLANGE GASKET ON E-50 CAUSTIC BLOCK VALVE GOING TO C DOCK STARTED LEAKING. LINE UAS PROBABLY LEFT LIQUID FULL AND LIQUID EXPANDED CAUSING LEAK. WILL CONTINUE TO DRAIN SOME MATERIAL FROM LINE AFTER LOADING. CA/ ELECT C CHLORINE BLEU THROUGH THE ACID TOUER SEAL POTS DURING A SHUTDOWN OF CIRCUITS 14,13,11, AND THE WEST CHLORINE COMPRESSOR. THE UET DEMISTER BLOCK LVE VALVE UAS NOT OPENED AS IT SHOULD. LEAD OPERATOR INVOLVED UAS COUNSELLED. SOP UAS REVISED AND REVIEWED WITH EACH LEAD OPERATOR. CA/ ELECT c OPERATOR SLOWED DOUN WEST CHLORINE COMPRESSOR TOO FAST. AS A RESULT, THE ACID TOWERS OVERPRESSUREZED AND CHLORINE BLEW THROUGH THE WATER SEALS. SOP UAS REVISED TO COVER "SUEETENING UP" OF THE CHLORINE SYSTEM. THIS WILL BE DONE ONLY WHEN THE CHLORINE COMPRESSOR IS DOUN OR AT A SLOU ROLL. REVISIONS HAVE BEEN REVIEWED UITH OPERATORS. CA/ Hg CELL LEAK DUE TO A BLOWN GASKET ON THE BOTTOM FLAHGE Of CELL 15 MERCURY INLET VALVE. ALTHOUGH A FLANGE GUARD UAS PRESENT, SPLATTERING AS MERCURY HIT THE FLOOR CAUSED SOME TO CONTACT GROUND. ROOT CAUSE ANALYSIS TO IDENTIFY CAUSE OF LEAKS. FLANGE GUARDS ARE BEING INSTALLED TO PREVENT SPRAY OF LEAKS. TEST PROGRAM TO IDENTIFY A BETTER GASKET MATERIAL. DATE HATERJAL/AMOUNT 05/24/88 HCl L Toe 53 lbs. SHIFT 2 REPORTED TO 05/29/88 CIHC L Sin 1033 lbs. SHIFT 3 06/01/88 TRICHLOR Wed 216 lbs. SHIFT 2 06/01/88 HCl L Wed 100 lbs. SHIFT 2 DEO/NRC CIHC 334 lbs. 06/05/88 HCl G Sun 29 lbs. SHIFT 1 06/08/88 CHLORINE Wed 5 lbs. SHIFT 3 G 06/09/86 PERCHLOR Thu 93 lbs. CU1CT 3 DEO/NRC PERCHLOR 93 lbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ ELECT C DESCRIPTION PROCESS SUMP LINE WAS PLUGGED. DURING ATTEMPT TO CLEAR THE PLUG USING SUMP PUMP, SOLIDS DISSOLVING SYSTEM EFFLUENT BACKED UP THE LINE AND STARTED DRAINING TO THE GROUND. CORRECTIVE MEASURES AREA AROUND PROCESS SUMP PUMPS HAS BEEN PADDED. INCIDENT WAS REVIEWED IN ORDER TO BE MORE AWARE OF WHAT CAN HAPPEN ON NON-ROUTINE PROCEEDURES. B/ UTU #2 VC TANK WAS BEING FILLED WITH CONTENTS OF H TETRA TANK. #2 VC TANK BEGAN LEAKING FROM THE INLET LINE TO THE TANK AT THE TANK ITSELF. TANK WAS INSPECTED AND REPAIRED. ST-1 MATERIAL WILL NOT BE PUT INTO THESE TANKS IN THE FUTURE. 8/ PER/TRI TRI SHIPPING TANK OVERFLOWED. DISCREPANCIES IN LEVEL INDICATORS RESULTED IN THE OVERFLOW SITUATION. AN ENGINEERING WORK ORDER HAS BEEN WRITTEN TO RESOLVE LEVEL INDICATION PROBLEMS. CA/ C ELECROLYZ PLUGGED CHLORINATED CONDENSATE LINES ON CIRCUIT 14 WERE BEING WASHED OUT WITH WATER. WHEN SALT PLUG BROKE, CHLORINATED CONDENSATE/ACID SOLN. SPILLED TO PAD WITH SOHE TO SURFACE DRAINAGE. A WORK ORDER HAS BEEN WRITTEN TO CURB THIS AREA. B/ EDC RUPTURE DISC ON VC-I INCINERATOR HEADER BLEW. DISC MAY HAVE BEEN FAULTY OR DETERIORATED AS PRESSURE WAS BELOW RUPTURE POINT. HAVE A GROUP LOOKING AT PREMATURE GRAPHITE RD FAILURES. CA/ POWER CHLORINE ADDITION AT RIVERSIDE PUMP HOUSE WAS ON MANUAL CONTROL AND WATER ON AUTO CONTROL. LOST WATER. WATER AND CHLORINE SUPPLY WILL BE OPERATED MANUALLY. B/ PER/TRI DURING TRANSFER OF PER/HQMHE MIXTURE TO STABILIZE A TANK, A LEAK OCCUREO FROM A CRACKED GASKET IN THE 1" LINE USED TO STABILIZE PER 232. LOOKING AT FLANGES THAT ARE HOT OVER CONCRETE PADS. MAKING PLANS TO ELIMINATE FLANGES AND INSTALL PADS TO COPE WITH THIS PROBLEM. SL 085748 DATE HATERIAL/AMOUNT 06/09/88 CHLORINE G Thu 8 lbs. SHIFT 3 REPORTED TO 06/09/88 NaOH L Thu 375 lbs. SHIFT 3 06/14/88 CIHC G Tue 49.3 lbs. SHIFT 2 06/14/88 NaOH L Tue 30,(WO tbs. SHIFT 2 OEO/NRC PERCHLOR 11 Lbs. 06/15/88 HCI L Wed 57.8 tbs. SHIFT 1 06/18/88 CHLORINE Sat 4 lbs. SHIFT 1 G 06/18/88 CIHC L Sat 54 tbs. SHIFT 3 DEQ/NRC CIHC 54 tbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ Hg CELL DESCRIPTION LOAD SHED INITIATED BY A CIRCUIT START UP AT A CHLORINE CAUSED A SUDDEN DROP IN CIRCUIT LOAD. Hg CELL COMPRESSOR COULD NOT SLOU DOUN FAST ENOUGH CAUSING BACK PRESS. RESULTING IN BLOWN SEALS. CORRECTIVE MEASURES WORK ORDER WAS WRITTEN TO INSTALL NEW FASTER RESPONSE INSTRUMENTATION ON THE Hg CELL COMPRESSOR SYSTEM. ALSO CHANGES WERE HADE IN THE LOAD SHED PRIORITY SEQUENCE. SILICAS MECHANICAL SEAL FAILED ON THE NORTH CAUSTIC FEED PUMP. CAUSTIC FLOWED TO PUMP PAD AND PROCESS DITCH. REPLACED PUMP SEAL. B/ PER/TRI HI DH STILL RUPTURE DISC BLEU. LOU DH FEED TANK LEVEL ALLOWED LIGHT ORGANICS AND/OR HIGH MOISTURE TO BE FED TO STILL CREATING PRESSURE PROBLEMS. COUNSELLED OPERATORS TO MONITOR LEVELS MORE OFTEN. ALSO WROTE AN ENGINEERING WORK ORDER TO FIND A RELIABLE WAY TO MONITOR OH FEED TANK LEVELS. CA/ PELS FAILURE OF A 1.5" GASKET AT A THERMOWELL CONNECTION ON SIDE OF EAST CONCENTRATOR RESULTED IN SPILLING MOLTEN CAUSTIC TO CONCRETE PAD. CAUSTIC SOLIDIFIED AS IT FELL. ALL GASKETS ON THIS SYSTEM HAVE BEEN CHANGED TO Ni GASKETS. AN RES WAS WRITTEN TO INSTALL A REMOTE LEVEL INDICATION ON THE CONCENTRATOR VESSEL. B/ uru EXTERNAL CORROSION CAUSED FAILURE OF BOLTS HOLDING A PRESSURE GAUGE BLOCK VALVE IN THE WEAK ACID FILTER DISCHARGE LINE. CORRODED BOLTS WERE REPLACED. B / EDC DURING START-UP OF #3 EDC PLANT, VENTS WERE GOING TO SCRUBBER. VENT ANALYZER SHOWED C2H4 EXCESS WHEN IN FACT REACTOR WAS OH C12 EXCESS. SOP'S REVISED TO CHECK CHLORINE OUTSIDE WITH ORTHO-TOLUDINE IF VENTS ARE NOT BEING SENT TO THE INCINERATOR. B/ WTU A HOLE IN INCINERATOR FEED LINE AT A WELD DOWNSTREAM OF THE LIQUID FEED FCV CAUSED A LEAK. LINE HAS BEEN REPLACED. SL 085749 DATE HATER1AL/AHOUNT 06/28/88 DCE/HCl L Toe 1133 lbs./60 Lbs. SHIFT 2 REPORTED TO 06/28/88 CHLORINE Tue 3.6 lbs. SHIFT 2 G 06/29/88 CHLORINE Wed 2.3 lbs. SHIFT 2 G 07/03/68 SULFUR CHLORIDE Sun 15.5 lbs. SHIFT 3 G 07/05/88 CHLORINE Tue 8 lbs. SHIFT 1 G 07/06/88 HCl G Wed 10.6 lbs SHIFT 2 SPILLS AM) RELEASES AT LAKE CHARLES PLANT AREA B/ TE-II DESCRIPTION HOLE IN SUCTION LINE OF COMPRESSOR OF LOU PRESSURE HCl SYSTEM CAUSED LIQUID TO SPILL TO PAD. FLASHER ACCUMULATOR LEVEL WENT HIGH OVERFLOWING LIQUID INTO HCl SYSTEM. CORRECTIVE HEASURES PIPE WAS CHANGED OUT. INSPECTIONS ARE BEING HADE TO TRY TO DETECT SPOTS OF EXTERNAL CORROSION. 8/ WTU DURING PROCESS OF FLOATING CPC CHLORINE VAPORIZER, MANUAL BLOCK VALVE CAME OFFSEAT SUDDENLY PUTTING TOO MUCH STEAM TO VAPORIZER. SRV LIFTED FOR 2 SECONDS. START-UP PROCEEDURES WERE REVISED AND VALVES REPAIRED AND REPLACED. CA/ Hg CELL CORROSION LEAK IN TAIL GAS HEADER TO NEUTRALIZER TOWER AT Hg CELL. EXTERNAL CORROSION ON THE BOTTOM SIDE OF THE LINE AT A PIPE SUPPORT CAUSED A LEAK IN THE LINE. WORK ORDER WAS INITIATED TO REPLACE THE TAIL GAS HEADER. SOP IS IN PLACE TO INSPECT THE LINE TO PREVENT FUTURE EXTERNAL CORROSION FROM OCCURRING. CA/ LIQUIFACTION PIPE RUPTURE DUE TO INTERNAL EROSION AT AN ELBOW AT THE S2CI2 DISCHARGE PIPING SUBCOOLER. PIPE WAS CARBON STEEL ANO WAS PLANNED ON BEING CHANGED TO MONEL. PIPING HAS BEEN CHANGED TO MONEL. THIS PIPING WAS BEING FABRICATED WHEN THIS INCIDENT OCCURRED. B/ WTU A TUBE LEAK DEVELOPED ON THE CPC CHLORINE VAPORIZER ALLOWING CHLORINE TO ENTER THE STEAM SIDE AMO BE EMITTED THROUGH THE STEAM TRAP OUTLETS. VAPORIZER WAS REPLACED WITH A SPARE. THE STEAM TRAPS WERE ALSO REPLACED. THE DAMAGED VAPORIZER WILL BE INSPECTED TO SEE IF ANY SPECIFIC CAUSE FOR FAILURE CAN BE DETERMINED. B/ EC/HCl A CORROSION LEAK OCCURRED ON THE HCl FEED LINE ORIFICE LEG JUST DOWNSTREAM OF THE ORIFICE TAP BLOCK VALVE AT EC/ HCl. SEVERELY CORRODED PIPING, VALVES, AND TUBING IN THE UNIT WILL BE REPLACED. BADLY CORRODED PIPING WILL BE BLASTED AND PAINTED. SL 085750 DATE MATERIAL/AMOUNT 07/09/88 PERCHLOR G Sat 0.3 lbs. SHIFT 2 REPORTED TO 07/10/88 CHLORINE Sun 125 Lbs. SHIFT 1 G LSP/DEQ/NRC CHLORINE 125 lbs. 07/10/88 PERCHLOR G Sun 11.2 lbs. SHIFT 1 DEQ/NRC PERCHLOR 11.2 lbs. 07/10/88 HCI G Sui 192 lbs. SHIFT 1 LSP/DEO/NRC HCI 192 tbs. 07/10/88 HCI G Sun 70 lbs. SHIFT 3 07/10/88 VDC G Sut 764 lbs. FT 1 SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA B/ PER/TRI DESCRIPTION *2 PER STILL HAD BEEN N2 PURGED THROUGH THE REFLUX DRUM. THE VENT VALVE WAS NOT OPENED WHEN THE N2-FILLED STILL WAS STARTED UP RESULTING IN PRESSURE AND A LEAK AT A PREVIOUS PATCH JOB. CORRECTIVE MEASURES OPERATORS WERE COUNSELLED REGARDING THE GENERAL NEED TO MAINTAIN ADHERANCE TO ALL SOP'S. CA/ C ELECTRO PLANT POWER FAILURE CAUSED CHLORINE COMPRESSORS TO SURGE RELEASING CL2 AT ACID TOWER PRESSURE SEALS. POWER SURGE TRIPPED OFF NEUTRALIZER BLOWER WITH C12 ESCAPING THRU DILUTION AIR STACKS LEVEL III STUDY HAY BE PERFORMED AND WILL ADDRESS RECOMMENDED CHANGES TO THE NEUTRALIZER PROTECTION SYSTEM. 8/ PER/TRI PLANT POWER FAILURE CAUSED LOSS OF PUMP CONTROL, INSTRUMENTS, ETC. EMERG. SHUT DOWN OF REACTOR PROBABLY CONTRIBUTED TO INCREASED HEADER PRESSURE RESULTING IN BURSTING LOWER RO ON *2 DH STILL. INVESTIGATING REROUTING OF RD VENT FROM BOTTOM OF STILL TO SOMEWHERE ELSE. B/ TE-II PLANT POWER FAILURE SHUT DOWN UNIT. #4 OHC REACTOR WAS SHUT DOWN. REACTOR VENT MLS VALVE TO SCRUBBER WAS OPENED AND PRESSURE SURGE BLEW RD ON VENT LINE. SUSPECT LIQUIDS IN LINE CONTRIBUTED. INSPECT SCRUBBER DRAIN LINE FOR ANY PLUGGIHG/RESTRICTION AT NEXT OHC RX OUTAGE. MODIFY SHUTDOWN SYSTEM TO AUTO MATICALLY OPEN THE MLS VALVE AT SHUTDOWN. B/ EC/HC1 WHEN VC-11 PUT HCI INTO HCI HEADER, IT PUSHED N2 INTO EC REACTOR CAUSING A PRESSURE INCREASE. THE SYSTEM BACKUP PRESSURE CONTROL VALVE OPENED TO THE SCRUBBER 8LOWING SCRUBBER WATER SEAL. HOOIFY AUTOMATIC WATER SUPPLY TO EC SCRUBBER SUCH THAT IT RESPONDS PROMPTLY TO ANY EMERGENCY RELEASE OF NCI. REVISE SOP REGARDING LINING UP OF THE EC SYSTEM VENT WHILE REACTOR IS RUNNING. B/ EDC PLANT POWER FAILURE. VDC REACTOR STEAM VALVE FAILED TO SEAT OFF COMPLETELY ALLOWING REACTOR TO OVERPRESSURIZE AND SLOW RUPTURE DISC. CHECK VDC REACTOR STEAM FCV AND REPAIR/ REPLACE. CAMPAIGN FOR AUXILLARY OPERATOR TO ADD ADDITIONAL PAIR OF HANDS DURING EMERGENCY SITUATIONS. SPILLS AND RELEASES AT LAKE CHARLES DATE HATERIAL/AMOUNT 07/13/88 CIHC L Wed 12 lbs. SHIFT 2 REPORTED TO DEQ/HRC PER/PEHTA/HCBD 5.6/1.5/3.2 lbs PLANT AREA B/ PER/TRI DESCRIPTION EAST HEAVIES STILL REBOILER WAS BEING REMOVED FOR CLEANING. REBOILER WAS SUSPENDED OVER CATCH PAN. PAH NEARED FULL. REBOILER WAS TILTED TO SLOW DRAINING AND SPILLED CIHC TO GROUND. CORRECTIVE MEASURES CONCRETE CURBING TO BE INSTALLED AROUND HS REBOILER REMOVAL AREA. SIZE OF CATCH PAH TO BE INCREASED. SOP FOR REBOILER SHUTDOWN TO BE REWRITTEN TO IHCLUED A 4 HOUR BAKEOUT PRIOR TO REMOVAL. 07/13/88 CIHC L Wed 153.7 lbs. SHIFT 2 6/ PER/TRI #4 PER/TRI REACTOR WAS BEING PREPARED FOR STARTUP. ORGANICS WERE BEING FED TO VAPORIZER. A BLEED ON THE WEST FLOAT CHAMBER WAS LEFT OPEN AND LIQUID CAME OUT WHEN LEVEL REACHED THIS BLEED. LEAD OPERATOR AND REACTOR OPERATOR WILL BE COUNSELLED REGARDING THIS INCIDENT. LEAK CHECKING OF OUT-OF-SERVICE EQUIPMENT WILL BE IMPLEMENTED. 07/14/88 OIL L Thu 45 lbs. SHIFT 1 8/ EC/HCl A LUBE OIL TUBING BROKE LOOSE ALLOWING OIL TO SPILL TO THE GROUND (PAD7). OCCFURRED AT THE INSTRUMENT AIR COMPRESSOR BUILDING AT EC/HCl. REPLACE OIL LINE AND INSPECT OTHER OIL SYSTEMS FOR POSSIBLE PROBLEHS. 07/14/88 NaOH L Thu 680 lbs. SHIFT 1 CA/ ELECTRO C 1/2 INCH CELL LIQUOR VENT LINE WAS LEFT OPEN AFTER REPAIRS TO THE LINE. HIGH POINT VENTS HAD BEEN CHECKED. THIS ONE WAS MISSED. DEVELOPED AN SOP TO WATER FLUSH AND PRESSURE CHECK THE LINE BEFORE STARTING UP WITH CELL LIQUOR. 07/14/88 MERCURY Thu 3 lbs. SHIFT 1 L DEO/NRC MERCURY 3 lbs. CA/ Hg CELL LEAK DEVELOPED ON THE TOP FLANGE OF CELL 34 MERCURY INLET VALVE SPILLING HERCURY TO FLOOR. SPLATTERING OR SPRAYING FROM GASKET FAILURE CAUSED SOME MERCURY TO SPILL OUTSIDE OF CURBED AREA. FLANGE GUARDS HAVE BEEN INSTALLED ON FLANGES HEAR OUTSIDE OF BUILDING. CURBING WILL BE EXTENDED TO CONTAIN POTENTIAL SPILLS. 07/15^8 ETHYL CHLORIDE Fri 1185 lbs. SHIFT 3 L DEO/NRC ETHYL CHLORIDE 1185 tbs. SH/ SHIPPING B SHIPPING WAS LOADING AN EC T/C AND THE LEVEL INDICATOR OH THE T/C WAS DEFECTIVE. THE CAR WAS OVERFILLED MU) EC VENTED INTO THE EC/VC STACK. GAGE ROD WAS REPLACED. ROD HAD A BURR ON IT IJHICH COULD HAVE CAUSED IT TO HANG UP. ROOS WILL BE INSPECTED ON ALL CARS. SL 085751 SL 085752 DATE MATERIAL/AMOUNT 07/16/88 CIHC L Sat 209.7 Lbs. SHIFT 2 REPORTS) TO 07/18/88 HCt/CtHC/CuCL2 G Hon 1912/4/448 SHIFT 3 DEQ/NRC HCI/CIHC/CUCI2 1912/4/448 07/21/88 CHLORINE Thu 4.2 lbs. SHIFT 2 G 07/21/88 HCl L Thu IS.8 tbs. SHIFT 3 07/21/88 HCl L Thu 36 lbs. SHIFT 3 07/26/88 NaOH L Tue 56 lbs. SHIFT 1 07/27/88 TR1CHL0R G Ued 1552 lbs. SHIFT 2 DEQ/NRC TRICHLOR 1552 lbs. 07/28/88 HCl L Thu 135 lbs. SHIFT 2 SPILLS AMO RELEASES AT LAKE CHARLES PLANT AREA B/ VC-II DESCRIPTION FLASHER VENT LINE FILLED WITH LIQUID AND BACKED UP INTO CHLORAL TREATMENT PHASE SEPARATOR VENT LINE. LIQUID CORRODED A HOLE IN THE PIPE CAUSING A SPILL TO THE PROCESS PAD. CORRECTIVE MEASURES CARBON STEEL LINE THAT CAUSED THE PROBLEM WILL BE REPLACED WITH TEFLONLINED PIPE. B/ TE-1I RUPTURE DISC ON #4 OHC REACTOR FAILED PREMATURELY. IT HAD BEEN INSTALLED IN CORRECTLY AW) RUPTURED AT 38 PSIG RATHER THAN THE RATED 60 PSIG. REVIEWED AND REEMPHASIZED PROPER INSTALLATION PROCEDURE WITH MAINTENANCE PERSONNEL. CA/ POWER CHLORINE LEAKED FROM A PINHOLE LEAK IN THE FLANGE OF AH ELBOW IN THE CHLORINE LINE TO SABINE CLARIFICATION. LINE HAS BEEN FRABRICATED AND WAS REPLACED DURING THE WEEK OF AUG. 22. 8/ WTU WEAK ACID FILTER INLET SIGHT GLASS GASKET FAILED DUE TO THE LOOSENING OF THE FLANGE BOLTS. CONTAINMENT PAD FOR THIS SYSTEM WILL BE ENLARGED. ALSO PERIODIC TIGHTENING OF FLANGES FOR THIS SYSTEM WILL BEGIN. B/ PER/TRI WEAK ACID LINE FROM PER/TRI TO PLANT A DEVELOPED A FLANGE LEAK. THE WEAK ACID OAT IS LOOKING INTO PROBLEMS WITH THE WEAK ACID DISTRIBUTION SYSTEM, LEAKS BEING ONE OF THE PROBLEMS. CA/ ELECTRO C CELL LIQUOR LINE TO ACCELATORS DEVELOPED A LEAK. LINE WAS REPLACED AMO WILL BE ONE OF THE INSPECTED LINES FOR ENVIRONMENTAL SURVEILLANCE. 8/ PER/TRI RUPTURE DISC ON TRI TOPPING STILL BURST. REFLUX DRUM LEVEL TRANSMITTER WAS FOUND TO HAVE A PINHOLE IN DIAPHRAH. SUSPECT THIS CONDITION ALLOWED A HIGHER LEVEL TO OCCUR THAN WAS INDICATED. ASKED FOR INSTALLATION OF A PRESSURE TRANSMITTER FOR THE TOPPING STILL. WILL BEGIN DAILY CROSSCHECKING OF SIGHTGLASS/ FIELD LEVEL INDICATORS VS LEVEL TRANSHITTER/BOARD INDICATORS. B/ PER/TRI FLANGE LEAK ON WEAK ACID HEADER ON EAST SIDE OF THE PLANT B SWITCHGEAR ROOM. THE WEAK ACID QAT IS INVESTIGATING PROBLEMS WITH THE WEAK ACID DISTRIBUTION SYSTEM. ALSO REVIEWING PIPING SPECS TO SEE IF ACID HEADERS SHOULD BE SPECIFIED AS FRP. SL 085753 DATE HATERIAL/AMOUNT 08/02/88 HCl G Tue 153.6 lbs. SHIFT 1 REPORTED TO OEQ/LSP HCl 153.6 lbs. 08/06/88 HaOH L Sat 120 lbs. SHIFT 2 08/08/88 HETHTLCHLOROFORH Hon 165 lbs. SHIFT 1 L 08/09/88 PIVALOVL CHLORIDE Tue 17.4 lbs. SHIFT 2 L 08/10/88 KOH L Wed 644.6 lbs. SHIFT 2 08/11/88 CHLORINE G Thu 13.2 lbs. SHIFT 2 NRC CHLORINE 13.2 lbs. SPILLS AMD RELEASES AT LAKE CHARLES PLANT AREA B/ TE-II DESCRIPTION A TUBE LEAK DEVELOPED IN A WELD IH THE NORTH PASS OF THE TE-II CRACKING FURNACE. WELD FAILURE WAS THE CAUSE. CORRECTIVE MEASURES REPLACE FAILED WELD AND ASSOCIATED PIPE. INSPECT AND X-RAY HEW INSTALLATION. IN SPECT OTHER WELDS IN FURNACE FOR SIGNS OF CRACKING. INVESTIGATE CAUSE OF WELD FAILURE (INSPECTION DEPT.}. SH/ DOCKS AN 8-IN. HC-50 CAUSTIC HOSE DEVELOPED A SPRAT LEAK WHILE LOADING A SHIP. HOSE WAS OLD AND WORN. HOSE WAS REPLACED. HOSES ARE INSPECTED PRIOR TO EACH USE. THIS HOSE PRESSURE TESTED OK IN MARCH, 1988. B/ TE-II MC REWORK PUMP SEAL FLUSH TUBING FAILED. MC SPREAD TO PAD AND SURROUNDING SHELL. WRONG MATERIAL USED FOR SEAL FLUSH LINE AND VALVES LEAKED BT. TUBING WAS REPLACED WITH MATERIAL COMPATIBLE TO THE SERVICE. MAINTENANCE ALERTED TO IHPORTANCE OF USING CORRECT MATERIALS AND OPERATORS TO CHECKING JOBS BEFORE ACCEPTING THEM. B/ WTU CPC REFLUX SPLITTER BROKE SPILLING CONTENTS ONTO THE PROCESS PAD. REFLUX SPLITTER WAS HADE OF GLASS. CAUSE OF FAILURE IS UNKNOWN. THE GLASS SPLITTER WILL BE ELIMINATED ALTOGETHER AND FOR THE TIME BEING REPLACED WITH A CONTROL VALVE SYSTEM. B/ PER/TRI TANK SUPPORTS ON BETZ 20K TANK GAVE WAT DUE TO CORROSION. TANK CONNECTIONS BROKE AWAT FROH THE TANK AS IT FELL TO THE GROUND. OBTAIN FEEDBACK FROM BETZ REGARDING THEIR INSPECTION RESPONSIBILITIES. B/ EDC HODICON SHUTDOWN STSTEH FOR *1 EDC REACTOR TRIPPED CAUSING LIQUID CHLORINE PRESSURE TO INCREASE. AS A RESULT, CHLORINE VAPORIZER SRV LIFTED BR1EFLT. CHECK MOOICOM SYSTEM TO SEE WHY IT TRIPPED #1 EDC REACTOR AND REPAIR AS NEEDED. INSTALL AN EMERGENCY SHUTOFF VALVE AT LIQUIFACT ION CONTROL ROOM ON LIQUID LINE COMING TO EDC. DATE HATER1AL/AHOUNT OS/11/86 CHLORINE G Thu 6.9 lbs. SHIFT 2 REPORTED TO 06/11/68 PERCHLOfi L Thu 26.7 lbs. SHIFT 2 DEQ/NRC PERCHLOR 26.7 lbs. 08/13/86 CIHC L Sat 110 lbs. SHIFT 2 08/23/86 CHLORINE Tue 2 lbs. SHIFT 2 G 08/27/86 HCl G Sat 946 lbs. SHIFT 2 08/29/68 HCl G Hon 57.8 lbs. SHIFT 2 DEQ HCl 948 Lbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT B/ WTU AREA DESCRIPTION CPC CHLORINE VAPORIZER WAS FLOATING ON THE LINE. AS A RESULT OF EDC SHUTTING DOWN (SEE ABOVE) CHLORINE HEADER OVER PRESSURIZED AND CAUSED THE CPC CHLORINE VAPORIZER SRV TO LIFT. CORRECTIVE MEASURES THE CPC CHLORINE VAPORIZER WAS REMOVED FROM SERVICE AND SENT TO SRV SHOP FOR OVERHAUL AND REINSTALLATION. ALSO SEE CORRECTIVE ACTION FOR EDC RELEASE ABOVE. B/ PER/TRI PERCHLOR LEAKED OUT OF DECOLOR]ZER AFTER SRV'S HAD BEEN REMOVED FOR INSPECTION. SUSPECT DECOLORIZER WAS FULL OF PERCHLOR. INCIDENT WILL BE REVIEWED WITH THE OPERATORS. THE DECOLORIZER WILL BE OPENED TO DETERMINE IF THERE WERE ANT MECHANICAL CONDITIONS THAT WOULD HAVE CONTRIBUTED TO THIS EVENT. B/ UTLI DH BOTTOMS SAMPLE POINT PIPING BLEW OUT AS M2 DH STILL WAS BEING SHUT DOWN. SPILL WAS CONTAINED OH THE PROCESS PAD. THE LINE WILL BE REPLACED WITH 3/4 INCH STAINLESS STEEL BY 06-26-88. CA/ Hy CELL CHLORINE WAS RELEASED AT THE ATMOSPHERIC VENT VALVE DUE TO INSUFFICIENT VACUUM ON INLET TO NEUTRALIZER. OPERATORS DIO NOT OBSERVE RISE IN PRESSURE AND ACT TO LOWER IT. ALARM WAS RESET TO 2.75 INCHES WATER VACUUM. A NEW ATMOSPHERIC VENT VALVE ACTUATOR WILL BE INSTALLED. B/ EDC END OF COMPRESSOR HEAD ON #3 HCl COMPRESSOR WAS KNOCKED OFF. BOLTS SHEARED OFF WHICH WERE HOLDING PISTON SEGMENT. INVESTIGATE AND CORRECT PROBLEMS CAUSING COMPRESSOR HEAD TO OVERHEAT. REPAIR OR INSTALL HIGH TEMPERATURE ALARM AT DISCHARGE OF EACH COMPRESSOR. B/ WTU WASTE STORAGE TANKS PRESSURIZED. WHEN TRIPPED TO THE SCRUBBER THE HIGH FLOW OVERLOADED THE SCRUBBER AND BLEU THE SEAL POTS ON THE BOTTOMS TANKS. OPERATORS WERE INSTRUCTED TO BE MORE OBSERVANT WHEN READING A GAUGE. PRESSURE WILL BE BLED DOWN MORE SLOWLY IN THE FUTURE, PERHAPS USING A HOSE. tn X? tS L S S O SL 085755 DATE MATERIAL/AMOUNT 08/31/66 METHVLCHLOROFORM Wed 140 lbs. SHIFT 2 REPORTED TO L 09/01/68 CHLORINE Thu 5.6 lbs. SHIFT 3 G 09/02/66 HCl G Fri 76.6 lbs. SHIFT 1 09/04/68 CtHC L Sun 1117 lbs. SHIFT 2 LSP(SARA) HCL 76.6 lbs. DEO/NRC CIHC 1117 lbs. 09/06/66 ETHYL CHLORIDE G Thu 262 tbs. SHIFT 1 DEQ/NRC ETHYL CHLORIDE 262 lbs. 09/09/68 HCl L Fri 57.7 lbs. SHIFT 2 SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA SH/ SHIPPING S DESCRIPTION SHIPPING ATTEMPTED TO LOAD A T/T UITH 1600 GAL. TE 366 WHEN COMPARTMENT WOULD HOLD ONLY 1500 GAL. OF THE 136 GAL. SPILLED 10-12 GAL. SPLASHED ONTO THE ROADWAY OUT OF CONTAINMENT. CORRECTIVE MEASURES LOADER COUNSELED. FAILED TO FOLLOW SOP TO CHECK TANK COMPARTMENT CAPACITY WITH DRIVER'S OUTAGE TABLE. CA/ Hg CELL A LEAK DEVELOPED IN THE HYPO RECIRCULA TION LINE TO THE NEUTRALIZER. THIS LESSENED THE FLOW OF CAUSTIC TO THE TOWER ALLOWING CHLORINE TO BREAK THROUGH. THIS LINE WAS REPLACED UITH NEW TITANIUM PIPE. B/ EDC A 1/2 INCH NICKEL NIPPLE BLEW OFF THE #1 EDC REACTOR VENT LINE DOWNSTREAM OF THE VENT CONDENSER. NIPPLE WAS CORRODED FROM THE INSIDE. INSPECT OTHER NOZZLES ON THIS LINE TO TRY TO DETECT ANY OTHER INTERNAL CORROSION ON NIPPLES IN SAME SERVICE AND REPLACE. B/ UTU A 1 INCH NIPPLE ON THE PRESSURE TRANS MITTER ON THE CLASSIFIER AQUEOUS TRANS FER LINE TO WTU SETTLERS CORROOED SPRAYING CLASSIFIER AQUEOUS PHASE MATERIAL ONTO THE GROUND. STEEL NIPPLE UAS REPLACED UITH KYNAR. STAINLESS TUBING WILL BE REPLACED WITH KYNAR PIPE. B/ EDC ETHYL CHLORIDE WELL WATER CONDENSER DEW LOPED A PINHOLE LEAK AT THE WELD WHERE THE CONOENSATE DRAIN LINE IS WELDED TO THE CONDENSER SHELL. WILL HAVE INDUSTRIAL ENGINEERING CHECK THICKNESS READINGS ON BOTH THE COOLING TOWER WATER AW) WELL WATER CONDENSER SHELLS. FINDINGS WILL BE CORRECTED AS NECESSARY. B/ UTU LEVEL CONTROLLER FAILURE OH THE ACID TANK IN SODIUM FORMATE COUPLED WITH A LEAKING JOINT ON THE SEAL POT CAUSED THE TANK TO OVERFLOW TO GROUND AS IT WAS FILLING. IP (NO CORRECTIVE ACTION PLAN ATTACHED TO REPORT.) SL 085756 DATE HATERIAL/AMOUNT 09/09/88 OIL L Fri 24(7) lbs. SHIFT 2 REPORTED TO 09/13/88 HCl l Tue 333 lbs. SHIFT 2 09/15/88 CHLORINE Thu 5 lbs. SHIFT 3 G 09/15/88 NaOH L Thu 634 lbs. SHIFT 2 09/20/68 BUTYLENE OXIDE Tue 172 lbs. SHIFT 3 L 09/20/88 NaOH L Tue 48.2 lbs. SHIFT 2 SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ LIQUIFACTION DESCRIPTION A 55 GALLON DRUM OF OIL LOCATED AT THE PORTABLE 250# COMPRESSOR UAS PUNCTURED AND ABOUT 2/3 OF ITS CONTENTS LEAKED OUT. SUSPECT PUNCTURE UAS DUE TO CONTRACTOR EQUIPMENT. B/ VC-11 LEAK OCCURRED IN PRIMARY SCRUBBER EFFLUENT LINE FROM VC-11 INCINERATOR. APPARENT CAUSE UAS LINE EXPANSION THAT PUT THE FLANGED JOINT IN A STRAIN. LINE BROKE AT A FLANGE. CORRECTIVE MEASURES DRUM STORAGE UAS MOVED TO A MORE SECURE AREA. A PERMANENT INSTALLATION UILL BE COMPLETED BY NOV. 30, 1988, ANO THE PORTABLE COMPRESSOR UILL BE REMOVED. FLANGES THAT WERE IN A BIND UERE REMOVED ANO THE SECTION OF PIPE UAS FABRICATED AND REPAIRED AND HADE A LITTLE SHORTER IN LENGTH. INSPECTION OF THE PIPE RACK UILL CONTINUE ON A REGULAR BASIS 8/ EDC SILICAS B/ TE-1I UHILE HEATING #3 EDC REACTOR FOR START UP Hg CELL CUT IN/OUT CELLS CAUSING AN UPSET IN CHLORINE PURITY. CHLORINE BROKE THROUGH REACTOR TO SCRUBBER ANO SOME ESCAPED THE SCRUBBER. A OAT UILL BE COMMISSIONED BY K. EZELLE TO DEAL UITH THE CONDITIONS UHICH CAN CAUSE A RELEASE OF THIS TYPE. PAINTER UAS PAINTING #3 CCD TANK. AS HE UAS MOVING MANL1FT, HANLIFT BUMPED A 3 INCH VALVE ON SIDE OF TANK NEAR THE BOTTOM AND BROKE IT OFF. A PLUG UAS INSERTED INTO THE BROKEN PIPE. A SPOOL PIECE AND BLIND UERE BOLTED OVER THE PLUG FOR A PERMANENT SEAL. UHILE PUMPING BLM INTO A PRODUCT TANK, A DRAIN VALVE ON THE TRANSFER LINE UAS LEFT OPEN AND SPILLED MATERIAL TO A PAD. SURVEY LINES THROUGHOUT THE UNIT AND IN STALL PLUGS ON DRAINS AW) BLEEDS. COUNSEL THE RESPONSIBLE OPERATOR STRESSING THE NEED OF BEING MORE CAREFUL UHEH BEGINNING TO PUMP STAB. CA/ ELECTRO C TUO 4 INCH FLANGES BROKE OFF OF THE CELL LIQUOR HEADER UPSTREAM OF CIRCUIT 13 SOUTH CELL LIQUOR TANK. RELEASE UAS CAUSED BY DETERIORATION OF EPOXY PIPING ANO EVENTUAL FAILURE. A SECTION OF THIS HEADER UAS REPLACED AND A WORK ORDER UAS URITTEM TO CHANGE THE REMAINDER OF THE HEADER. SL 085757 DATE MATERIAL/AMOUNT REPORTED TO 09/23/88 SULFUR CHLORIDE G Fri 70 lbs. SHIFT 3 09/26/88 CIHC L Hon 5119 lbs. SHIFT 2 DEQ/MtC CIHC 5119 lbs. 10/03/88 METHYLCHLOROFORM L Hon 162 lbs. SHIFT 3 10/06/88 HCl L Thu 10 lbs. SHIFT 2 10/07/88 HCl L Fri 46 lbs. SHIFT 2 10/09/88 SULFUR CHLORIDE Sun 60 lbs. SHIFT 1 L SPILLS AMD RELEASES AT LAKE CHARLES PLANT AREA CA/ LIQUIFACTIOM DESCRIPTION THE SULFUR CHLORIDE AFTER COOLER FEED LINE DEVELOPED A HOLE AT THE FEED VALVE. CORRECTIVE MEASURES SECTIONS OF SULFUR CHLORIDE WHICH ARE EXPOSED TO HOT HONOCHLORIDE ARE BEING CHANGED TO MONEL. B/ VC-II ORGANICS FROH A HEAVIES STILL WATER FLUSH BACKED INTO THE HOLE WHERE A NEW SUMP WAS INSTALLED THROUGH A CRACK IM THE SEWER LINE NEXT TO THE NEW SUHP. THE LEAKING SEWER LINE WILL BE UNCOVERED TO A GOOD SECTION AND A DERAKANE SPOOL INSTALLED TO REPLACE THE LEAKING SECTION. DISCUSSION WILL BE MADE WITH FIELD ENGINEERS RE WORKING NEAR PIPE. B/ TE-1I THE SPEC-12 TANK SAMPLE POINT WAS LEFT OPEN AFTER PUTTING THE TANK BACK INTO SERVICE. AS THE TANK WAS FILLED, PRODUCT SPILLED OUT OF THE SAMPLE POINT ONTO THE PAD. POLICY OF INSTALLING PLUGS IN DRAIN VALVES WILL CONTINUE TO BE PURSUED UNTIL COMPLETED. RESPONSIBLE PARTY COULD NOT BE ASCERTAINED. B/ EC/HCl CA/ C ELECTROL. A WARPED KYMAR FLANGE BROKE THE SEAL BETWEEN FLANGES CAUSING A WEAK ACID LEAK TO THE GROUND. CIRCUIT 11 CHLORINATED CONDENSATE STRIPPER OUTLET WAS PLUGGED WITH SALT. WHEN CLEARING THE PLUG, A MIXTURE OF CONDENSATE, BRINE, AND HCl SPILLED TO THE GROUND. VISUAL INSPECTION OF FLANGES FOR LEAKS WILL CONTINUE TO BE HADE DURING ROUNDS. OTHER KYNAR FLANGES WITH POTENTIAL TO DEFORM WILL BE CHECKED AND REPAIRED AS NECESSARY. A WORK ORDER WAS WRITTEN TO CURB AREA TO DIRECT FLOW TO PROCESS SUHP RATHER THAN SURFACE DRAINAGE. CA/ LIQUIFACTION IN PROCESS OF CLEARING A LINE OF S2C12, MATERIAL LEAKED FROH A FLANGE WHEN THE PIPING SHIFTED AS THE FLANGE WAS BROKEN MATERIAL WENT TO A DITCH. PE (NO ACTION PLAN FILED.) SL 085758 DATE HATER1AL/AMOUNT 10/17/88 CHLORINE G Hon 23.7 lbs. SHIFT 3 REPORTED TO NRC CHLORINE 23.7 tbs. 10/20/88 CHLORINE G Thu 66.6 lbs. SHIFT 2 10/21/88 PERCHLOR Fri 975 lbs. SHIFT 3 L OEQ/NRC CHLORINE 66.6 lbs. 10/31/88 EDC/HCl/VC G Hon 131/4/62 lbs. SHIFT 3 DEQ/NRC VC 42.5 lbs. 11/03/88 EDC L Thu 30 tbs. SHIFT 2 11/09/88 CHLORINE Wed 2.5 tbs. SHIFT 1 G SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA B/ VC-11 DESCRIPTION COMPUTER PROBLEMS TRIPPED THE LP-EDC REACTOR. THE CHLORINE PCV ON THE SURGE ORUH DID NOT IMMEDIATELY CLOSE ALL THE WAY CAUSING THE SRV TO RELIEVE. CORRECTIVE MEASURES DISCUSSION WILL BE HELD WITH THE COMPUTER GROUP TO SEE IF THERE IS A WAY TO DISABLE THE CHLORINE FLOW SYSTEM AND NOT INTERFERE WITH THE REST OF THE PLC SYSTEM. CA/ POWERHOUSE C A 1/4 INCH HOLE DEVELOPED IN THE CHLORINE SUPPLY LINE TO THE SABINE WATER CLARIFICATION UNIT. THE HOLE WAS CAUSED BY EXTERNAL CORROSION. THE CHLORINE SUPPLY LINE WAS REPLACED. PROPER PIPE SUPPORTS WERE USED. 8/ PER/TRI THE PER 208 SHIPPING TANK OVERFLOWED DURING FILLING. VISUAL ALARMS ON THE CONTROL PANEL FAILED TO WORK PROPERLY. SPILL WAS CONTAINED ON THE PAD. FILLING OF THE 208 SHIPPING TANK WILL NOT EXCEED 260 FEET TOP OFF. WEEKLY ALARM CHECKLIST WILL BE CHANGED TO IN CLUDE A LOU LEVEL ALARM CHECK STARTING 10-29-88. 8/ TE-tl A REPAIR DEVICE ON THE TE-II QUENCH TOWER FLOAT CHAMBER DEVELOPED A LEAK. THE REPAIR DEVICE SEAL FAILED. LEAKING BLOCK VALVES WERE REPLACED AS WERE THE 90`S ON THE FLOAT CHAMBER. THE FLOAT CHAMBER SECTIONS WERE REPLACED WITH INCONEL LINED PIECES TO TRY TO PREVENT INTERNAL CORROSION. SHIPPING/ DOCKS CORROSION LEAK FROM 1/2 INCH VALVE ON GAUGE AT "A" DOCK. A VALVE AIN) TJJE GAUGE WERE REPLACED IN THE LINE. SHIPPING/ DOCKS PINHOLE CORROSION LEAK IN BARGE LOADING LINE LOCATED ABOVE CAUSTIC DEPARTMENT. ABOUT A 3 FT. SECTION OF PIPE WAS REPLACED. NEW LOADING LINES WILL BE IN SERVICE BY 12-21-88. SL 085759 DATE HATERIAL/AHOUNT 11/10/88 NATURAL GAS G Thu 416 tbs. SHIFT 3 REPORTED TO 11/11/88 PERCHLOR Fri 16 lbs. SHIFT 3 L DEQ/HRC PERCHLOR 16 lbs. 11/12/88 EDC/HCI/C2H4 G Sat 5.5/13.8/8.3 lbs. SHIFT 2 11/17/88 GROUHDUATER Thu 2485 tbs. SHIFT 2 L DEG/NRC F024 2485 Lbs. 11/18/88 CPC/DCPC L Fri 22.5/27.5 lbs. SHIFT 2 11/21/88 THERHALAHE Hon 210 lbs. SHIFT 3 L 11/21/88 HETHYLCHLOROFORH Hon 55 lbs. SHIFT 2 L SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ POUER B/ PER/TRI DESCRIPTION CUT BACK IN POUER LOAD DUE TO Hg CELL REDUCING DEHAMD RESULTED IN INCREASED NATURAL GAS PRESSURE IN CONOCO HEADER AND 1NTERHITTANT LIFTING OF THE SRV. CORRECTIVE MEASURES NO CHANGES PLANNED. SRV RELIEVED AS DESIGNED. UHILE PRESSURE CHECKING A*1 INCH STABILIZING LINE, A LEAK DEVELOPED IN THE LINE. ABOUT 1-2 GALLONS OF PERCHLOR LEAKED TO THE GROUND. ENTIRE LINE TO BE REPLACED BY 12-15-68. AFTER INSTALLATION OF A SEPTIC TANK, THE ENTIRE SHELLED AREA BENEATH THIS PIPE RACK WILL BE CONCRETED IN AN EFFORT TO PREVENT LEAKS TO THE SOIL. B/ EDC VENT LINE TO *2 EDC SCRUBBER BLEU A HOLE IN IT WHEN VENTS UERE TRIPPED TO CONTROL SYSTEM PRESSURE. LEAKING HEADER UAS REPLACED UITH A NEU ONE. a/ wtu A HOLE DEVELOPED IN THE SIDE OF THE AIR EJECTOR CAN AT #3 DEEP UELL AT SO. TERM. WHEN UELL PRESSURIZED, UATER UAS FORCED OUT OF THE UELL CASING RATHER THAN THE DISCHARGE PIPE. (ONLY 0.2# CtHC) PERFORH PERIODIC INSPECTION OF AIR EJECTOR CAN UHENEVER PUMP IS PULLED. PERFORH RANDOM THICKNESS READINGS ON CAN TO TRACK CORROSION. B/ UTU BLEED ON CPC INCINERATOR FEED PUMP BLEU OFF DUE TO CORRODED THREADS. RELEASE UAS TO THE PAD. BLEEDS OH INCINERATOR FEED PUMP BOUL AND REACTOR FEED PUMP BOUL HAVE BEEN REPLACED UITH STAINLESS STEEL. B/ TE N OPERATORS UERE CLEARING #4 OHC REACTOR PIPING TO THERHALAHE STORAGE TANK. TANK OVERFILLED. OPERATOR UAS HATCHING SIGHT GLASS BUT COULD NOT BLOCK IT OFF BEFORE SPILL OCCURRED. OPERATOR COUNSELLED TO FOLLOU THE LEVEL CLOSER WHEN FILLING THE TANK. SOP WILL BE REVISED TO RESTRICT FILLING STORAGE TANK INTO THE TOP SECTION OF THE SIGHTGLASS. SHIPPING/ DOCKS LEAKING VALVE BONNET GASKET ON LINE BETWEEN TR1-ETHANE TANK AND HEH DOCK UAS DUE TO TEMPERATURE FLUCTUATIONS CAUSING PRESSURE TO BUILD UP IN LINE. VALVE UAS REPLACED 11-22-86. SPILLS AND RELEASES AT LAKE CHARLES DATE HATER1AL/AHOUNT 11/22/68 NaOH L Tue 300 lbs. SHIFT 2 REPORTED TO PLANT AREA SHIPPING/ DOCKS DESCRIPTION WHILE FILLING ET-50 CAUSTIC LINE FOR BARGE LOADING, CAUSTIC OVERFLOWED THE **C" DOCK SUMP BECAUSE OF A DRAIN VALVE BEING LEFT OPEN. CORRECTIVE MEASURES A WORK ORDER HAS BEEN WRITTEN TO REPLACE THE DRAIN LINE VALVES WITH BUTTERFLY TYPE VALVES. 11/29/88 C1HC L Tue 30 lbs. SHIFT 3 DEO/NRC TCE/UNSYM/etc. 20.1/2.4/2.4 lb B/ WTU WHILE UNLOADING A TANK TRUCK OF TCE, AN OPERATOR OPENED THE UNLOADING SCREEN WITHOUT FIRST CLOSING THE BLOCK VALVE ON THE TRUCK SIDE OF THE SCREEN. ABOUT 3 GALLONS SPILLED TO THE GROUND. INCIDENT WAS REVIEWED WITH THE OPERATOR ON 11-30-88 WITH EMPHASES ON PREVENTING THIS TYPE OF ERROR IN THE FUTURE. 11/30/88 CIHC/HCL G Wed 54.7/8.9 lbs. SHIFT 2 DEO/NRC PERCHLOR 34.7 lbs B/ PER/TRI A LEAK DEVELOPED IN THE BOTTOM CONE OF THE *3 PER/TRI REACTOR CYCLONE. THE LEAK WAS CAUSED BY INTERNAL CORROSION/EROSION THE CYCLONE WILL BE REMOVED AND REPLACED. THE FAILED CYCLONE WILL BE AUTOPSIED. UNIT IS IN THE PROCESS OF A MATERIAL AND DESIGN CHANGE ON THE CYCLONE CERAMIC INSERTS TO IMPROVE PERFORMANCE. 12/02/88 NaOH L Fri 600 Lbs. SHIFT 2 SHIPPING/ A EXPANSION BELLOWS ON PUMP SUCTION LINE BETWEEN HG 1 CAUSTIC TANK AND TRUCK LOADING PUMP RUPTURED. CAUSTIC WENT TO SEWER AND GROUND. PUMP PAD WAS IN BAD CONDITION. A WORK ORDER HAS BEEN WRITTEN TO REPAIR THE PAD. 12/03/88 CHLORINE Sat BOO lbs. SHIFT 2 G DEQ/HRC/LASP CHLORINE 800 lbs. CA/ C ELECTROLY. A POWERHOUSE STEAM UPSET RESULTED IN THE CHLORINE COMPRESSORS TO QUIT PUMPING. WITH CHLORINE GOING TO THE NEUTRALIZER, PRIMARY CAUSTIC FLOW DROPPED CAUSING CHLORINE TO EXIT THE STACK. PROOF TESTING WILL BE FOLLOWEO. CHANGES TO THE WINTERIZATION SYSTEM OK RAT ION WILL BE HADE. THE NEUTRALIZER INTERNALS WILL BE INSPECTED ANNUALLY. 12/08/68 CHLORINE Thu 20 lbs. SHIFT 2 G HRC CHLORINE 20 lbs. CA/ C ELECTROLY. AN INSTRUMENT MAN WAS WORKING OH THE CHLORINE COMPRESSOR SUCTION PRESSURE CONTROLLER. AS A RESULT CONTROLLER WOULD HOT RESPOND, SYSTEM PRESSURE GA INCREASED, AIR) CHLORINE BLEW SEALS. THE INSTRUMENT MECHANICS WILL FOLLOW THE TAGGING PROCEDURES FOR INSTALLING INSTRUMENT CLEARANCE TAGS ON SHUTDOWNS AT "C" CHLORINE. SL 085760 T94.S80 "IS DATE MATERIAL/AMOUNT 12/10/SB CHLORINE G Sat 6.3 lbs. SHIFT 2 REPORTED TO 12/13/S8 C1HC G Tue 152.2 lbs. SHIFT 3 12/16/B8 PERCHLOR Fri 3.4 lbs. SHIFT 2 L DEQ/HRC PERCHLOR 3.4 lbs. 12/20/88 CHLORINE Tue 3 tbs. SHIFT 2 G 12/21/88 HCl G Wed 311 lbs. SHIFT 1 DEQ/LASP HCl 311 tbs. 12/22/86 HC1/CIHC G Thu 13.1 tbs./51.5 lbs SHIFT 2 SPILLS AND RELEASES AT LAKE CHARLES PLANT AREA CA/ Hg CELL DESCRIPTION A CORROSION HOLE DEVELOPED ON ELBOW WHERE TAIL GAS HEADER AMD SHIPPING BLOWDOWN LINE TIE TOGETHER JUST BEFORE THE Hg CELL NEUTRALIZER. CORRECTIVE MEASURES THIS LINE WAS REPLACED WITH A LINED STEEL PIPE. B/ UTU DUE TO A FAILED TEMPERATURE PROBE, ORGANICS WERE SENT TO THE CSS FEED TANKS BY VDCM. CONTENTS OF FEED TANKS WERE HOT ORGANICS CAUSED TANK TO OVERPRESSUR IZE AND RUPTURE DISC BLEU. EXISTING TEMPERATURE INDICATOR AND ALARM WERE REPAIRED ON 12-14-88. SOP WILL BE CHANGED TO INSURE ORGANICS GO TO THE LIFT STATION HEADER IN THE FUTURE INSTEAD OF THE CSS. B/ PER/TRI PER 208 TRANSFER LINE WAS BEING DRAINED BY SPREADING FLANGES. MECHANIC DID HOT NOTICE SPRAY OF PERCHLOR OVERSHOOTING DIKE HALL AS HE ADJUSTED BOLTS TO DRAIN THE LINE. AN ENVIRONMENTAL TRAINING SCHOOL WAS HELD ON 01-17-89 FOR INSTRUMENT PEOPLE, MECHANICS, SUING CREWS, AND NORMAL P/T MAINTENANCE CREW. CA/ Hg CELL CHLORINATED BRINE OVERFLOWED FROM THE DEPLETED BRINE TANKS DUE TO A PUMP NOT OPERATING PROPERLY. PUMP WAS OVERHAULED AND CLEARANCES RESET TO CORRECT CAPACITY PROBLEMS. INSTALLED A DEVIATION FROM SET POINT ALARM TO GIVE EARLIER WARNING ON TANK LEVEL. B/ TE-ll #4 OHC RX TRIPPED. WHILE OPENING THE VENT VALVE TO THE OHC SCRUBBER, THE 10 INCH RUPTURE DISC BLEW. DRAINING LIQUID FROM PIPING UPSTREAM OF THIS VALVE WAS INSUFFICIENT IN THIS CASE. ENTIRE CONDENSING TRAIN WAS THOROUGHLY FLUSHED. PULLED HEAD ON SECONDARY AND RD ON TERTIARY TO VERIFY GOOO FLOW WAS POSSIBLE. WILL CHECK SCRUBBER LINE FOR LIQUID 2X PER SHIFT AT STARTIN'. B/ PER/TRI TWO INCH RUPTURE DISC ON THE N. DH FEEO TANK HAS RELIEVING. HOST LIKELY PRE MATURE FAILURE OF DISC. DISC SET TO BLOW AT 15 PSIG; VENT HEADER AT ONLY 4 PSIG WHEN DISC BLEW. RUPTURE DISCS WILL BE REPLACED ANYTIME TANK IS TAKEN OUT OF SERVICE AND OPENED FOR CLEANING/INSPECTION WITH A FREQUENCY FOR DISC REPLACEMENT OF AT LEAST ONCE EVERY 12 MONTHS. SL 085762 DATE HATE RIAL/MOUNT 12/23/68 CIHC/ WATER L Fri 27.3/11923 lbs. SHIFT 2 REPORTED TO DEQ/HRC F024 11950 lbs. SPILLS AND RELEASES AT LAKE CHARLES PLANT B/ WTU AREA DESCRIPTION SUCTION HEADER OF UTU FEED PUHP WAS PLUGGING. MECHANICS ROLLED SPOOL FROM THE PUHP SUCTION CAUSING A PLUG TO BREAK LOOSE. SLUDGE/WATER SPRAYED FROM SUCTION LINE TO GROUND. CORRECTIVE MEASURES CHECK SUSPECTED BLOCK VALVE FOR RELIABLE OPERATION. REPLACE IF NECESSARY. STRESS UITH LEAD OPERATORS IMPORTANCE OF TAKING EXTRA EFFORT TO DOUBLE BLOCK WHEN CONVENIENT. NUMBER OF RELEASES ? I G 'J R i LAKE CHARLES COMPLEX LAKE CHARLES COMPLEX SL 085763 NUMBER OF RELEASES NUMBER OF RELEASES CHLOR/ALKAU DERIVATIVES 1MB WLEASCS SL 085764 NUMBER OF RELEASES aua2 LAKE CHARLES COMPLEX TOTAL PLEASES, 1967 LAKE CHARLES COMPLEX TOTAL FCLEASES 1968 SL 085765 NUMBER OF RELEASES LAKE CHARLES COMPLEX LAKE CHARLES COMPLEX SL 085766 NUMBER OF RELEASES NUMBER OF RELEASES LAKE CHARLES COMPLEX LAKE CHARLES COMPLEX rCPDRUBLE RELEASES BY SHIFT-1386 085^^^ Sli NUMBER OF RELEASES o LAKE CHARLES COMPLEX SL 085768 LAKE CHARLES COMPLEX crn-ERCAUSES FOR TOTAL FEUUSES. 13C7 v PRdlB. (O.EK) LAKE CHARLES COMPLEX CAUSES FOR TOTAL RELEASES 1300 PROS. (27.EK) SL 085769