The valve stem for a funnel valve to a solution neutralization tank was found to be separated from the body of the valve. This valve is used for purging hydrogen gas from the vessel. The functional classification of this valve is safety-significant. The "as-found" condition of the affected valve prevented the valve from performing its intended design function.
An operator went to purge a process tank per standard operating procedure. The operator reviewed the previous shift's purge time and determined the next required purge time. The operator found that the tank had been purged earlier than expected on the previous shift. Because the earlier purge time was not recognized, the 12-hour purge frequency was exceeded.
An over-pressurization of two 55-gallon drums of waste phosphoric acid resulted in a material failure of the drum bottoms, releasing the contents of both drums (about 100 gallons) onto the facility floor. The spillage was collected within the sumps that are part of the facility's spill control system. The waste material had been packaged into DOT-specified containers earlier that day and the drums were placed into an assigned storage cell. That evening a staff member heard a noise in the high bay where hazardous wastes are stored.