Document wbxNyb4zpEgyMqJ1YDEnQ0OB
ESCAMBIA PLANT
INC.
INTEROFFICE MEMORANDUM
To: M. R. Chmura
pfOifljR. E. Davis Re: Monthly Status - November
Area ,lB11 Hazards Review
Dote: 3 December 1980
Copies: R- L- Duggan R. E. Jones T. J. Regan
The formal and final report was issued in November on the hazards
review conducted in Area "B" in October 1980. A CE for all modifi cations, except relocating the Wet Bay control room, has been sub mitted for Management signatures and approval. The estimate for relocating the Wet Bay control room will take approximately one more
month to complete.
RED: dl
R. E. Davis
AP00036294
PROCESS HAZARDS REVIEW
ESCAMBIA AREA B
AP00036295
SUMMARY
A Process Hazards Review of the Escambia Area B plant was completed. The plant was divided into five main areas and the major hazards were identified. The review group used the fault tree analysis and the failure mode and effect analysis to evaluate the hazards. A total of 52 hazards were identified and 45 recommendations for corrections and control measures were made. There were 27 recommendations made for equipment changes, 12 for inspection, PM and process/procedure changes and 6 recommendations for studies to be made.
The following table lists the 5 areas of the plant, and the number of hazards identified in each.
AREA
HAZARD
the hazards considered
NUMBER OF HAZARDS IDENTIFIED
AN
Ammonia Release
20
Material Exposure Vessel Rupture
3 7
Supply Failure
3
Decomp, of AN
1
Urea
Ammonia Release
2
Vessel Rupture
3
Solutions
Ammonia Release
4
Prills
NH^ Release
2
Decomp, of AN
1
Material Exposure
4
General
General
2
Total
52
A complete list of the hazards identified and recommendations made are contained in the following pages of this report.
AP00036296
PROCESS HAZARDS REVIEW ESCAMBIA AREA B
I. INTRODUCTION
A process hazards review was completed during the week of October 13-17, 1980. The review studied the Escambia Area B plant to identify potential hazards and recommend appropriate corrective or control measures.
II. SCOPE
The review included four production areas: Ammonium Nitrate, Urea, Solutions and Prills. The bulk and bag warehouses were also Included in the study. Along with the boundry limits set above, consideration was also given to steam, CC^, Nitric Acid, Ammonia and electricity.
The scope of the review included these items:
1. Systematic analysis of each segment of the process with respect to the effects of equipment failure, instrument failure, utility failure, and operator error.
2. Consideration of potential handling or processing problems with respect to raw materials, intermediates and final products.
3. Consideration of the adequacy of materials of construction.
4. Consideration of the adequacy of existing process control and alarm systems.
5. Recommendation of corrective or control measures.
III. PROCESS DESCRIPTION
Area B is divided into four interrelated production units: Urea, Ammonium Nitrate (AN), AN Prills and Urea-AN-Ammonia Solutions.
Urea is produced by the reaction of carbon, dioxide and ammonia at high pressure and moderate temperature. Carbon dioxide gas is supplied to the urea autoclave at 2900 psig. Ammonia liquid is supplied from the "A" Area ammonia plant storage spheres at 280 psig and is pumped to 2900 psig by a four stage reciprocating compressor in Area B. Ammonia is fed to the urea autoclave in a stoichemetric excess to carbon dioxide. The reaction of ammonia and carbon dioxide consists of two steps. The first reaction is the formation of ammonium carbamate and essentially goes to completion. The second is the hydrolysis of ammonium carbamate to urea and water and is only partially completed. The net reaction is exothermic and heat is removed by condensate in the autoclave tube bundle.
- 1-
AP00036297
III. PROCESS DESCRIPTION (cont'd)
The reactants leave the autoclave andJgo to the flash separator at 50 psig where the unreacted ammonia is flashed off to the urea off gas header at 25 psig. The bottoms from the flash separator go to the decomposer heater where the unreacted ammonium carhamate is decomposed back to ammonia and carbon dioxide. The products then go to the decomposer separator where the amrrfonia, carbon dioxide and water vapor are flashed off and enter the urea off-gas header. The urea product, 92% urea solution, goes out the bottom to the urea-ammonium nitrate mixer and to UAN storage or to the urea masar solution storage tank. Urea production capacity is approximately 60 TPD.
Ammonium nitrate is produced by the reaction of 56% nitric acid and ammonia gas. Nitric acid is received from the nitric acid plant and is stored in two day tanks. From the day tanks it is pumped to a nitric acid preheater and on to the No. 1 and/or No. 2 neutralizer. Ammonia liquid is received from the ammonia plant storage spheres at 280 psig. The ammonia is vaporized using cooling tower return water in a vaporizer and superheated using steam in the superheater. The ammonia is fed to the No. 1 and/or No. 2 neutralizers with or without urea off-gas. Conversely, urea off-gas can be fed to the No. 1 and/or No. 2 neutralizer with or without ammonia gas. A weak AN solution from the AN prill plant reclaim system is also fed to the neutralizers. The reaction of ammonia and nitric acid is exothermic and heat is removed by the vaporization of water iii the reaction mass to produce process steam. The No. 1 neutralizer operates at 0 to 10 psig and some of the process steam is used to preheat the nitric acid feed to both neutralizers. The No. 2 neutralizer operates at atmospheric pressure. From the neutralizers the 83% AN product overflows to the 83% AN surge tank where it is pumped to storage, to the low concentrator, to the UAN mixer or to the solutions plant.
AN prills are produced by prilling a 99.8% molten AN solution. 83% AN is pumped from storage or production to the low concentrator, where the con centration is increased to approximately 95%. The low concentrator consists of a thermosyphonreboiler, a vapor disengagement tank and a barometric condensor, which is supplied by cooling tower water. The low concentrator operates at approximately one-half atmosphere, and the product overflows to the 95% AN seal tank. From the seal tank the 95% AN is pumped to storage , to the UAN mixer, to the solutions plant or to the high concentrator. The high concentrator consists of a falling film evaporator, an air preheater, and a 99.8% AN surge tank. The falling film evaporator uses steam on the shell side and hot air from the air preheater on the tube (process) side to strip the water from the AN melt. Permalene, a patented prill hardening additive, is added to the 95% AN solution on the distribution tray in the falling film evaporator. The 99.8% AN solution melt gravity flows from the evaporator to the 99.8% AN surge tank from where it is pumped through a concentric pipecondensate flash cooler and. into the 99.8% AN head tank at the top of the prill tower. From the head tank the 99.8% AN either flows to a single prill plate where it is prilled in the prill tower, or overflows to the 95% AN seal tank. Air is pulled into the prill tower counter-current to the falling prills by one centrifugal and eight bifucator fans. The centrifugal fan pulls 'primary' air through the CFCA shroud and then through the Heil;high differential pressure venturi scrubber. Air exhaust from the high concentrator is also pulled through the Heil scrubber along with the prill tower shroud exhaust. The eight bifucator fans by-pass the CFCA shroud. The solid prills are collected at the tower base by a pebble collector belt and are transferred via conveyor belts and bucket elevator through an oversize classifying screen,
-2
AP00036298
III. PROCESS DESCRIPTION (cont'd)
a rotatry drum pre-dryer, dryer and cooling drum, an undersize classifying screen and a clay coating drum where kaolin clay is added to coat the prilled product. From the coating drum the finished prills are carried via conveyor belt and bucket elevator to the bagging hoppers or to hulk storage.
The solutions plant presently only blends four primary products. They are: ammonium nitrate (AN) solutions, urea-ammonium nitrate (UAN) solutions, ammonium nitrate-ammonia (Bay-Sol) solutions and ammonia-water (Aqua) solutions. UAN solution is blending continuously from urea production and adjustments are made to meet specifications in the No. 2 and No. 3 mix tanks. Bay-Sol solutions can be blended batchwise in the No. 3 and No. 4 mix tanks. Aqua solutions are blended batchwise in the Aqua solution mix tank.
IV. REVIEW TEAM
The Review Team consisted of:
1. H. J. Smith - Chemicals Group Safety 2. Lee J. Howard - Process Engineering - Industrial Chemicals 3. R. J. Shaw - Industrial Chemical Technology 4. R. E. Davis - Production Superintendent - Area B - Escambia 5. Dave Elliott - Production Engineer - Area B - Escambia 6. Bill Rockwell - Production Supervisor - Area B - Escambia 7. Ralph Scott - Process Engineer - Escambia 8. Lorn Paxton - Maintenance Engineer - Escambia
V. METHOD
The Area B plant was divided into five general areas for review. They were: Ammonium Nitrate, Urea, Solutions, Prills and General. A discussion was held to determine what hazards existed and which ones would be considered. Listed below are 13 hazards or concerns which were identified and the priority in which consideration was given to them. Listed beside each hazard are the areas of the plant where it was felt the hazard could occur.
Hazard
Area of Plant Affected
1) Ammonia Release 2) Decomposition of AN (Fire,
Explosion) 3) Nitric Acid Exposure 4) Equipment Rupture 5) Hot AN Exposure 6) Loading (Spill Exposure) 7) Dust Exposure 8) Hot Urea Exposure 9) COj Exposure 10) Permalene Products Exposure 11) Storage 12) External Fire 13) Supply Failure
AN, Urea, Solutions, ]
AN, Prills in Process, AN Urea, Solutions, Prills Urea, Solutions, Prills Solutions Prills, Storage
Prills AN, Urea AN
- 3-
AP00036299
Category: | [Equipment Changes | {Procedural Changes, Inspection & PM Items [ |cng Studies t {Rejected
Action Items from Hazard Review
General
Status as of. Pago 14 of
Action Status
Pages
1, 19
Management
A ctio n
Needed
Hqzard
50. Wet Bay Control Room health and safety hazard (people can get trapped there)
51. Confined AN in old 83% AN Tank
52. Gas Exposure in elevator
L -IQO lO. Di l. u </) a. a. <
Responsi bility
Recommendations
Cost Est.
H H 1 A Davis
50. Relocate control room to west side ground level of wet bay
w g ->4e-->o<6oom.aHo/ IuLoLEUaOWQn>
10/82
HL
A Elliott
51. Remove old 83% AN Tank
15, D0(
6/61
MH
Elliott
52. Install air bottle with 10 min. air supply in elevator.
1000
3/61
Remarks (Include Estimated Costs)
Being estimated - Cost may be $500M to $1. 5MM
AP00036300
Management
A c tio n
Needed
Category: I Equipment Changes [ jprocedural Changes, Inspection i PM Items | )ng Studies { {Rejected Action Items from Hazard Review Material Exposure
Status as of_ Pago 13 of
Action Status
Pages
1, 19
Hazard
48. Nuisance Dust Exposure in Dry Bay and Storage
49. Fozraaldahyde exposure
> _Oo *o" +"-*
4J S-
L>
6, A. <
Re spoils ibf.tity
Cost
Recommendations Est.
LH
2A
Elliott/ H. J. Smith
48- Initial Dust Monitoring to determine personnel exposing levels.
49* Change procedure for use to make safe
o. oi a/ ci.
wtc--. ote_>ma ttoi-- <eo-> 12/80
Remarks (Include Estimated Costs)
AP00036301
I
AP00036302
Category; * [Equipment Changes | {Procedural Changes, Inspection i PM Items | (Eng Studies | {Rejected
Action Items from Hazard Review
Material Exposure
Hazard
44.
Overflow of 83% AN Storage Tank
45. NO emissions from Nitric Acici Tanks
46. Leaks in nitric acid line pumps aid piping
47 Leaks in Permalenc handling system
vao>>>i oot-.
ao**-.-
<uc
Response hi.11 ty
Recommendations.
Cost Est.
L M ) A Elliott
44.
Investigate installation of high level alarm on 83% AN Tank-not safety item but equipment insulation loss
5000
L H 2 A Elliott
45. Vent tanks to Heil Scrubber
5000
HH
1A
Rockwell
46. a) Replace NA line flanges with heavy duty flanges b) Purchase 2 acid suits c) Purchase 2 pumps
10000
LM
3A
Rockwell
47. Install eye wash near Permalene mixing area for Sulfuric Acid
2000
3/81 1/81 3/81
f
Managemetv
A c tio n
Reeded
Category: | jEguipment Changes \ (Procedural Changes, Inspection & PH Items 1 jgng Studies I Rejected
Action I terns from Hazard Review
Supply Failure
Status as of Page 10 of
Action Status
Pages
1, 19
Mqzard
39. Overflow Nitric Acid Supply Tank
40. Vessel Rupture due to high steam supplypress ure
41. Overflow of NA Tanks due to power failure in Area KBn only
TJ *- C
> o -r-
<U i~ L. J t/> n. a. <n
Responsi-
, .,\. UUTty
Cost
Recommendations Eat.
PI M 1 A Elliott
39.a)Instail 2 position high level alarm on NA 10,000 tank
b)ReIocate 2* shut off 1,000 valve to tank
40. Same as #24 and 25 2000
HL
Elliott
41. Add to emergency procedures provision to block in nitric acid tanks
coafol u0. u05o
3/81
3/81
Remark* (Include Estimated Costs)
AP00036303
i'
f /
Management
A c tio n
Needed
ategory; |` {Equipment Changes | [Procedural Changes, Inspection 4 PH Items J |Eng Studies 1 [Rejected Action Items from Hazard Review Decomposition of AN
Status as of ____________1, 19 ' Page II ofPages
Action Status
Excessive Heat Input of High Pressure Steam
Sensitization of AN by contamination
Responsi bility
Recomjendations
Cost
Scott
42. Evaluate 350# Steam to limit pressure
LH
2A
Rockwell
Scott/ Elliott
43.a)Install catch pans for oil and grease on trunnion rollers of drying drums
b)Install separator in NH^ line to Permalene to remove oil.
2000 2000
rx ai E *->
On] oa
u o. s- B O OM u.oo
Remarks (Include Estimated Costs)
3/81 3/81
3/81
AP00036304
9
Category: | {Equipment Changes | "^Procedural Changes, Inspection S PM Items Action Items from Hazard Review
|Eng Studies t |Rejected
, StatfSfc-.
jli"
.Pages
1, 19
Management
A ction
Needed
Hqzafd
37. Release of NH* from atmos. ven\ from surge tank or spacing in surge tank with low level
;s.
mixinf of Permalene
<o t- o
o - -m a. a. .<
Responsihinty
Est. Recommendations Cost
L M 3 A Rockwell 37. a) Operator training 1000
b) Install low level alarm on level transmitters at surge tank
LM
3 A Rockwell 38. Install exhaust fan from mix tank
2000
AP00036305
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2
X
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a-4 3
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33 J ver
3
T3 UJ
w a3. t wl
<si 4 S
jjwOc2Q! f*V
Is Z Xp4
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AP00036306
iteg#ry: f {Equipment Changes f Procedural Changes, Inspection & PM Items | ]Eng Studies I '^Rejected
Management
A ction
Needed
Action Items from Hazard Review Vessel Rupture - Urea Plant
Hazard
Rupture of Autoclave
Rupture of K,Q. Drum and Decomposer Separator
Rupture of Flash Separator
XI
4J -o o
>- o
4->
co
5D.
So.
u <
Responsi bility
Recommendations.
HL 2 HL 2 HL 2
30. Continue annual PM check and daily inspections
31. PM on valves BPCV 9 and RV
32. PM on valve PC-7 PCV-4 and PSV 31508
AP00036307
Category; ( |Egviprnent Changes [[^Procedural Changes, Inspection & PH Items | |ng Studies 1 [Rejected
____________i. is_____ Page ^ -0f__ ____ Pages
Action Items from Hazard Review Ammonia Release - Urea
Action Status
Management
Action
Needed
H^iard
18. Operation of Relief Valves '9. Leaks in Equip, t Piping
01 DO O*- T+Jiwo n(-. Qt.- L>
Responsi bility
Recommendations
HM 11 M
28. Same as #20 b 29. Same as #17
nj Oi Mf-rO*. O COe n-m)
mUO
- 1MA 441J1 u0> O-. 0> 1O Oe 10
KlcJO
Remarks (Include Estimated Costs)
AP00036308
AP00036309
0
fi
3 a a3i
j ^ (Category:
c'"i
J .-3
a>a>: UO J.13V | < a
i.
rNo ^iH.^eqoad I ^
iEo. /f;j.a3Aas I
Equipment Changes j {Procedural Changes, In s p e c tio n 8 PM Itenis | ^ [ ng S tudies I [R ejected
o
3 3
AP00036310
Category; | |Egu1praent Changes | [procedural Changes, Inspection 4 PN Items { Ung Studies | [Rejected
, StatK IS of Pago j of
Action Items from Hazard Review
Vessel Rupture - AN
Action Status
Hazard
>> r-
+rJ- _Tc- +J c:
*O-A -rOtj oi- *Ov-
>01
O
U
cl
*r-
au.
-uM
<
Responsihility
.Recommendations
Cost Est.
21.
Rupture from Thermal Expansion #1 Neutraliser of piping that can be blocked in
H- - B
Scott
21.
Study-determine if materials are subject to thermal expansion
12. Rupture of fl Neutralizer
L L 3 A Elliott
22. Inspect rupture discs annually
Verify if R.D. is adequate size
13. Rupture of vaporizor, super heater on bypass heater
14. Rupture of high concen trator
i5. Rupture of storage heaters 83% Nitric-Acid ^0
H L 2 A Elliott H L 2 A Elliott H L 2 A Elliott
23. Install relief devices 5000
24. on steam line
25.
on two heaters 83% AN
Lower "D" heater to 150# steam
Investigate lowering steam header relief pressure
vf~i OE .fUJ 0k1E0.V41
con O O <o
H U Q U.UQ
Pages
U 19
Management
A ction
Reeded
AP00036311
Catefpry; [^Equipment Charges [^Procedural Changes, Inspection i PM Items | |Eng Studies | ^Rejected
Status as of
________ j\ t ]g
Page 2 ofPages
Action Itans from Hazard Review Ammonia ReJase (AN Plant)
i <V M
Hazard
+->
>> _c *r- C
01 o
>
oj
(/)
o Cik..
+- 4. u CL- *C
Responsi bility
Recommendations
Cost Est.
10. Auto clave let down valve fails open
LL 3
10. No action.
n. Flash separator flow control fails open
LL 3
11. No action.
12. Ammonia flow set high and pH control fails
LL3
12. P.M. (See Hazard 3)
13. Excess IlHj due to controller failure on vaporizer
LL 3
13. No action
14. Steam supply loss to super heater
15. Failure of control valve TRC 50-7 to super heater
16. flow set too high to process
L L 3 A Elliott
LL 3 LM3
14. Install low temp, alarm on exit of NH- in superheater
15. Same as 14
2000
16. Install high and low alarm on NH^ flow 2000
Action Status
I i
Management
A c tio n
Needed
i
Category: | [Equipment Changes | "[Procedural Changes, Inspection 6 PH Items [ Ung Studies [ Rejected Action Items from Hazard Review Ammonia Release - AN Plant
States 13 of Pagc^^bf
.Pages
1, 19
Management
A c tio n
Needed
Hazard
4^ Responsi i/> n. o- ve fai;11ty
Cost
Recommendations. Fst.
7. Leaks in equipment and piping
a) Flanges
HM
Welds
HM
Metal failure
Valve packing
^
Pump seal failure
Failure of tubes due to corrosion in super heater allowing NH^ into condensate
LM
Water vaporizer tube failure allowing NH^ in CTW Return
:o. Release of NH^ from relief
valves to NHj weigh tank
L M3 HM1
17.
a) No action
b) No action c) No action
d) No action
e) No action
18. No action required
Elliott
19- No action
2Q-Wlnstail orifice plate on NH, line to weigh tank
Rockwell
(bXnstall tail pipes on relief valves to get gas away
500.00
AP00036312
Category: | jEquipwent Changes | [Procedural Changes, Inspection & PM Items | [Eng Studies | ~[Rejected
Management
A ction
Needed
Action Items from Hazard Review Ammonia Release (AN Plant)
Atmospheric
Hazard
j _cs o
J- O
1. (
Responsi ble 1 ty
Cost Recommendation; Est.
Manual Valve Leak or open in error on 83% Surge Tank
Manual Valve Leak or open in error on Ammonia Vent Stack
pH controller fails on Neutralizer and Surge Tank Vent
Nitric Acid Pump Failure
Manual Valve Closed on Nitric Acid Line
LM oe wd LH oi wg
h LH oi wg
il LM oe wd
LL oo ww
3 2 A Rockwell Z 3 3
Nitric Acid Flow Control Valve Fails Closed
Low Level in Nitric Acid Storage Tank
Line Failure-Corrosion Leaks on Nitric Acid Line
Line Pluggage
LM oe wd
LM oe wd
LM oe wd
LL oo Ww
3 3 3 3
1. No action requiredoperator training
2. Raise stack to height
of 10*
500
3. P.M.
4. P.M. 5. No action required.
6. No action required.
7. No action required.
8. No action required.
9. No action required.
io *J Q O
UrUaWw--0- V
v- e *> i- e **
McUon Uo- Oo Qjo
AP00036313
I
AP00036314
AP00036315
/S J (X
M
AP00036316
INTEROFFICE
MEMORANDUM
To Dlstributl on
From M. R. Chmura
Distribution:
K. E. Arnold R. R. Baker J. J. Baliker P. L. T. Brian T. L. Carey J. L. Cost J. F. Dempsey J. K. Derby A. J. Diglio M. W. Ferris P. Fong, Jr. R. E. Gadomskl J. U. Gentile A. E. Greene W. D. Greer R. . Jones
&s>
,T
0
- Date 25 September 1980
Schedule-Process Hazard Reviews and
formal Plant Safety and Industrial Hygiene Audits_______________________
(Location. Organisation, or Dapartmanl)
Chemicals Manufacturing
(Location, Organisation, or Dapartmant)
M. C. Lee
J. F. Marschhauser A. K. McMillan E. F. Moherek R. W. Ormsby
D. J. Orr F. J. Ryan R. C. Sander
J. A. Saner J. M. Scigliano
.H. J. SmithW. J. Stueben
J. A. Sykes J. T. Wharton J. M. Wrba
The attached two schedules show dates for Process Hazards Reviews (PHR's) and formal Plant Safety and Industrial Hygiene Audits scheduled for Fiscal
1981. A total of twenty three (23) PHR*s have been scheduled. Each facility will receive at least one formal Safety and Industrial Hygiene Audit In Fiscal 1981. These formal audits will monitor safety performance and identify areas where improvements are indicated. Informal audits will also be conducted
where needed.
Martin R.Chmura
MRCrbkl
Attachments: 1. Schedule for Process Hazard Reviews. 2. Schedule for Formal Safety and Industrial Hygiene Audits.
(3201
AP00036317
SCHEDULE FOR FORMAL SAFETY AND indOstrial HYGIENE AUDITS CHEMICALS GROUP"25 SEPT. 80
Location Calvert City
Paulsboro City Of Industry Mi ddlesex
St. Gabriel Pasadena Escambia Cleveland Elkton S. Brunswick
Employee Safety
6-10 Oct. 80 WJS
10-14 Nov. 80 JWG/HJS
8-12 Dec. 80 JWG
12-16 Jan. 81 HJS
19-23 Jan. 81 WJS
9-13 Feb. 81 WJS
9-13 Mar. 81 WJS 11-15 May 81 WJS
8-12 June 81 WJS
13-17 July 81 WJS
Industrial Hyqlene
25-29 Aug. 80 JWG/HJS (completereport Issued)
10-14 Nov. 80 JWG/HJS
8-12 Dec. 80 JWG
12-16 Jan. 81 HJS
19-23 Jan. 81 JWG
9-13 Feb. 81 HJS
9-13 Mar. 81 JWG
11-15 May 81 JWG
8-12 June 81 JWG
13-17 July 81 HJS
Enqineerinq Safety
6-10 Oct. 80 MRC
10-14 Nov. 80 JWG/HJS
8-12 Dec. 80 JWG
12-16 Jan. 81 HJS
19-23 Jan. 81 MRC
9-13 Feb. 81 MRC
9-13 Mar. 81 MRC
11-15 May 81 JWG/WJS
8-12 June 81 JWG/WJS
13-17 July 81 WJS/HJS
Kev to Auditors
<
WJS - Bill Stueben JWG - Joe Gentile HJS - Joe Smith MRC - M. R. Chmura
AP00036318
(2) '
Faci1ity/Process/Product Calvert City - Catalyst Plant Escambia - Methylamlnes City of Industry - Total Plant
Dates Scheduled 7-11 Sept. 81 7-11 Sept. 81 J&e ^ w
14 - 18 Sept. 81
On Hold:
Calvert City - PVC Escambia - PVC
Notes: (1) Use common team members (2) Use common team members
AP00036319