Document 0JRq1xY2q8wNKgog14YKRyMgJ

/C p. 12*cl PITTSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION LAKE CHARLES, LOUISIANA Tqv C.O-7ZZ ETHYL CHLORIDE PLANT MANUAL December 6, 1965 r> v r, r ,11 - " - if ' Or<3et :t Court o' ;n i'^Q i Q i X i- "A & SL 008836 Manual TABLE OF CONTENTS INTRODUCTION ................................ ......................................................................................... 1 GENERAL DESCRIPTION .......................................................................................................... 2 SAFETY ....................................................................................................................................... 4 Emergency Homs ....................................................................................................... 4 Fire Protection ........................................................................................................ 5 General................................................................................................................. 5 Dock Area............................................................................................................ 7 Control Building............................................................................................ 8 Electrical Equipment................................................................................... 9 Relamping......................................................... 9 Grounding............................................................................................................ 9 Tools..................................................................................................................... 10 Procedures..........................*......................................................................................... 11 Sampling Methods............................................................................................ Safety Permit................................................................................................... General Fire & Explosion Rules ............................................................ General Safety Rules ................................................................................... 11 10a 11 13 Special Safety Equipment ..................................................................................... 14 CHEMICALS IN THE AREA....................................................................................................... 17 PROCESS DESCRIPTION .......................................................................................................... 35 1. Ethylene System ................................................................................................. 36 2. HC1 System .......................................................................................................... 37 3. EC Reactor System.............................................................................................. 37 A. Equipment................................................................................................... 37 1. Reactor................................................................................... 38 2. CatalystChamber ................................................................. 38 3. Reactor Coolers................................................................. 38 4. ReactorDump tank.............................................................. 38 B. Reactor Shutdown System .................................................................. 38 C. Operation................................................................................................... 39 D. Start Up........................................................................................................ 42 E. Reactor Dryer and ReactorFilter......................................................43 4. Flasher Dopp Kettle ..................................................................................... 44 ' 5. Bottoms Dopp Kettle .................................................................................... 45 6. Flasher Condenser ............................................................................................ 46 7. Primary Vent Condenser.................................................................................. 47 8. Secondary Vent Condenser............................................................................ 48 9. Vent Scrubber ................................................................................................... 4<) SL 008837 CONFIDENTIAL* Subject tv Protective Order of 14th Judicial District Court No. 91-ft*? 10. Primary Stripper Feed Drum ........................................... 50 11. Gland Seal Pump.............................................................................................. 52 12. Primary Stripper Feed Dryers and Filters.................................... 52 13. Primary Stripper and Reboiler.............................................................. 53 14. Heavies Still Feed Drum...................................................................... 56 15. Heavies Still.............................................................................................. 56 A. Reboiler.......................................................................................... 56 B. Condenser ..................................................................................... 57 C. Hvs. Still Bottoms Cooler................................................. 57 D. Hvs. Still Reflux Drum ..................................................... 57 16. Secondary Stripper and Reboiler ....................................................... 58 17. Product Surge Tank and Cooler................................................................. 60 18. Day Tank Area ...................................... 61 A. Day Tanks............................. 61 B. Vent Compressor ..................................................................... 61 C. Vent Condenser .............. 61 D. Transfer Pumps ................................................ 61 E. Rework Pump ................................................................................. 61 19. Dock Area .......................................................................................................... 63 A. Horton Spheres ............................................... 63 B. Excess Flow Valves.................................................................. 64 C. Turbine Flow Meters...................................... 64 D. Refrigeration Unit .................... 64 E. Brine Circulation Pumps............................. 64 F. Barge Loading Pumps................................................................. 64 G. Vent Compressor......................... 64 H. Vent Condenser.......................................................................... 64 I. Vent Condensate Receiver................................................... 64 J. Vent Condensate Pump................................................ 65 20. Cooling Tower......................................... 72 21. Refrigeration Unit....................................................................................... 73 INSTRUMENTS................................................ 76 PUMPS .......................................................................................................................................... 81 LABORATORY PROCEDURES............ .................................................... ..................................... 82 1. Ferrous and FerricChloride......................... 82 2. HC1 in Liquid EC.............................................................................................. 84 3. HC1 in Gas Samples .............. 85 4. H-0 in EC.............................................................................................................. 87 5. Chromatograph Procedurefor Liquid Sample........................................ 89 6. Chromatograph Procedure for Gas Sample ..........................*............. 90 ELECTRICAL SYSTEM .............................................................................................................. 91 OPERATING GRAPHS 1. C2H4 vs TPD ..................................................................................................... 94 2. HC1 vs C2H4 ..................................................................................................... 95 3. FeCl- vs C2H^ .................... 96 4. Product vs TPD ...................................... 97 5. Steam vs Rate, PrimaryStrapper ............................................................ 98 6. Steam vs Rate, Secondary Stripper ................................... i............... 99 SL 008838 CONFIDENTIAL*. Subject to Protective Order Of 14th Judicial District Court PROCESS FLOWSHEET MECHANICAL FLOWSHEET ELECTRICAL ONE LINE DIAGRAMS SL 008839 CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court. No. 91-1145 INTRODUCTION USES AND PURPOSE OF MANUAL This operating manual has been assembled with the following purposes in mind: 1. To aid the operators in becoming familiar with the EC plant. 2. To serve as a ready source of reference for the operators throughout their tenure at the EC plant. 3. To provide a set of basic procedures so that everyone is working under the same instructions. 4. To serve as a place where data, facts, information, etc. on the unit are centrally located and readily available. Like any new operating manual, it is expected that changes will be warranted in this write-up as operating experience is gained; please feel free to suggest these changes as it is intended that this manual be kept current and meaningful. It should be remembered that this manual is the property of Pittsburgh Plate Glass, Chemical Division, Lake Charles Works and may be recalled at any time. You are personally responsible for the safe keeping of this manual as well as the information therein. This is why the manual is numbered and charged to you. SL 008840 -1- CONFlUERTIALi Subject to Frot ctive Order tifh .indicial District Court GENERAL DESCRIPTION The Ethyl Chloride process used at Lake Charles is by no means unique, but since certain phases of the process are technical improve ments, you should not discuss the unit or its operations with personnel other than PPG employees. HC1 and Ethylene are reacted in the presence of a catalyst to form Ethyl Chloride (EC). The HC1 for the EC plant is manufactured by one of two methods. One method is to burn Cl^ and to produce HC1 which is absorbed, stripped, dryed, and compressed before coming to the plant. The other method is to thermally crack EDC to HC1 and Vinyl Chloride. The HC1 thus produced is separated from the other components and sent to the EC plant. The HC1 for the EC plant will be produced by one or the other method and sometimes a combination of both methods. The ethylene is furnished through a pipeline by another company. The catalyst used is Ferric Chloride. It is delivered in 135# drums from other companies. The rest of the plant consists of purification equipment. The spent catalyst is removed as tars in a Dopp Kettle network. Since the re actor is run with a stolchemetric excess of HC1 this HC1 must be removed and it is removed by stripping. The heavies formed in the reaction are re moved by distillation. The essentially pure EC is sent to day storage to be analyzed before being transferred to the dock storage Hortonspheres. The bulk of the EC produced is used in the manufacture of Tetra ethyl lead (Antiknock agent in gasoline). The other uses for EC are a very small part of the market but it may be used in the manufacture of ethyl- cellulose, manufacture of a polymerization catalyst, a solvent, a dewaxing agent or as a local anesthetic. As in all plants, safety is of the utmost importance. The safe SL 008841 CONFIDENTIAL; -2- Subject to Protective Order f 14th Judicial District Court Ho. 9X-IU5 operation of this plant depends directly on you, EC is a volatile, highly flammable material. The material is a gas at temperatures greater than 54F (at atmospheric pressure), and since this gas is heavier than air (2.2 times as heavy) any spills will result in a highly flammable material spreading over a large area. The process area is equipped with a sprinkler system for fire protection, and this system has a remote trip switch on the panel board. USE THIS TRIP in the case of spills. It will spray the area with water and prevent the spreading of flammable vapors. The water cannot hurt anything and it can prevent a dangerous situation. SL 008842 CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court 91-1145 -3- SL 008843 SAFETY CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court NO. 1-1145 EMERGENCY HORNS There are two distinct emergency horns in the area: the plant or Area "B" evacuation horn and the EC operating area siren. The Area "B" evacuation horn is a continuous warbling sound and may be activated from the EDC or EC-VC control rooms, or the guard house. The sounding of this horn will shut down all non-process equipment in Area "B" and will cause all non-essential personnel to leave the area. Area "B" includes all areas West of Columbia Southern Road. The Area "B" evacuation horn should be sounded in case of a major EC break, or if there is some reason to expect a major break, or if there is a possibility that EC vapors will escape the operating area. Whenever the evacuation horn is sounded the guards should be notified of the nature of the emergency if at all possible. If it is desired to evacuate the whole plant the guards will have to be notified and they will sound the plant evacuation. The guards are the only people able to sound the all-clear. The operating area siren is to evacuate all non-essential personnel from the operating area and to have all arcing devices in the operating area shut down. This siren is controlled by a switch on the panel board or by a switch located near the bottoms Dopp kettle. The area siren should be used in case of a minor spill or a possible spill. It is well to keep in mind the extreme flammability of EC. Should a spill occur, keep it from spreading if at all possible and eliminate all sparking devices in the area. One of the best means to prevent spreading is the use of the fire water system, use it and use it quickly. The arcing devices can be eliminated by sounding the siren or evacuation alarm. Evaluate the situation quickly and act quickly. It is much better to get someone wet or evacuate them than to have a fire or an explosion. -4- When you are in the operating area and the siren blows or you are in Area "B" and the warbler blows, see to it that all non-essential equipment is shut down (trucks, hysters, welders, etc.) and if you are non-operating personnel = get out of the area. All operating personnel should go to their respective control rooms, if possible. FIRE PROTECTION GENERAL Fire protection in the EC area is provided in three forms, water, dry chemicals and CO^. The dry chemical is the only effective way of fight ing an EC fire. Water is good for knocking down the fumes and keeping vessel cool. The CC>2 cylinders are only good for small fires or small electrical fires. CC>2 cylinders are located in the switchgear room and are to be used on small electrical fires. Anytime you are in doubt as to the type of extinguisher to use, use the dry chemical. It is good to avoid the use of the dry chemical on small electrical fires, as the chemical leaves a harmful residue. Throughout the plant are located 30# dry chemical units. On the perimeter of the operating area will be located a portable unit, this unit will be shared by EC and VC. The water protection is a manual or automatic sprinkling device, tripped by a deluge valve. The EC process area, the cooling tower, the EC day tank area, and the Horton Sphere area are each protected with its own deluge system. Heat Activated Devices (HAD's) are located throughout each area and a sudden rise in the HAD temperature will cause the deluge valve be open and the respective area to be covered with a water spray. The process area sprinklers may be manually tripped from the panel board or from the valve house. The cooling tower, day tank area, or Horton Sphere area have their manual trips located in each individual hose and valve house. Should SL 008844 CONFIDENTIAL: Subject to Protective Order pf 14th Judicial District Court UP, 91-1145 SL 008845 a fire break out in any of the areas the automatic system should trip. Do not be afraid to manually trip in any of the areas in case of a fire or spill in that area. Whenever any deluge valve is tripped an alarm will sound in the guard house, but the fire truck will not come unless the guards are notified or they can see the fire or smoke. Anytime a deluge valve is tripped, the valve must be reset before automatic pro tection is available again. The valve is reset by closing the water valve upstream of the deluge valve, removing the cover of the deluge valve and resetting the weight. The automatic system is a thermo-pneumatic fire detection system. The thermo-pneumatic system is designed to detect an abnormal rate of temperature rise and, in such a situation, cause a Suprotex deluge valve to open. When the Suprotex valve opens the water is allowed to flow into sprinkler lines and from the nozzles, covering the area with a water density of 0.25 GFM/ft2. The HADs are the heat sensing elements and are located at all strategic points in the process. The HADs are empty shells connected to the release diaphragm of the Suprotex deluge valve by a manifold of 1/8" FVC coated copper tubing. The HADs and the tubing manifold are pressurized with 24 oz. air pressure. An abnormal temperature rise in one of the HADs, as would occur in the event of a fire, will create a pressure rise in the units and the tubing manifold. This pressure rise will cause a diaphragm operated release mechanism to release a suspended weight. This weight drops and disengages the latch holding the deluge valve closed, thereby starting the flow of water to the distribution system. The water is dispersed in the area by sprinkler heads, which are located so as to provide a spray over all exchangers, surge tanks, pumps, and skirts of columns. The manual trip lever is the handle located on the Suprotex deluge valve. When pulled, this handle releases the weight. CONFIDENTIAL: Subject to Protective Order -r,_ of 14th Judicial District Court nn qi -n CONFIDENTIAL! Subject to Protective Order t 14th Judicial District Court No. 91-1145 A change in environment temperature will not trip the system because the Suprotex valve has a compensating vent valve in the diaphragm. This valve is sized so that a slow pressure build-up in the supervisory air (HAD system) system will bleed through the valve to the other side of the diaphragm thereby equalizing the pressure. As may be seen from the description of the supervisory air system, an accidental break in the HADs or tubing manifold will not trip the deluge valve. Anytime the system has a break in it, all automatic fire protection for this system is lost. Anytime the supervisory air pressure gets below 16 oz. an alarm will sound. Check the alarm out immediately as you are in danger of losing your protection. The alarm will sound if any single cir cuit of the supervisory air system developes a leak. When the alarm sounds check the supply pressure and the overall supervisory air pressure. If both of these are normal then a particular circuit has a leak, but enough air is being bled into the system to maintain the required 24 oz. pressure. Auto matic Sprinkler will have to be called to find and repair the leaking circuit. To silence the alarm the electrical power to the valve house will have to be shut off, the horn disconnected and power put back to the valve house. This power will come from the emergency circuit. Fire protection exists until the supervisory air is about 6 oz. or less. DOCK AREA In the dock area the Horton Spheres are not protected by water spray, but the pumps and the equipment platform are. The protection of the equipment is accomplished by HADs and a Suprotex valve just like the day tanks or production area. The bottom halves of the spheres and legs are protected with "ALBI" fireproof paint. This paint, when heated, will swell and insulate the sphere from the fire. SL 008846 -7- There are water turrets located on the North side of the tanks. In case of a fire these turrets should be used to keep a water stream on the spheres, to keep them cool. There is a foam nozzle located midway between the spheres on the North side. This nozzle may be used to blanket a layer of EC trapped in the dyked area. The foam is not very effective in fire fighting, but will retard the vaporization of the EC if there is no fire. The dyked area is designed to hold the contents of a full sphere. To drain rainwater from the dyked area, open the valves in the drain lines located on the South side of the dykes. Since the dyked area drains to the river the drain valves should never be left open without a man standing nearby. NEVER DRAIN EC TO THE RIVER. In case of a spill or fire in the area try to contain the EC in the dyked area, do not attempt to drain it to the river. If there is an EC spill remember that there are many sparking devices in the dock area, try to get everything downwind shut down and evacuated. If there is a fire keep the spheres cool with the water turrets. CONTROL BUILDING The control building is pressurized to prevent accumulation of any vapors inside. Since it is a pressurized building, non-explosion proof elect rical equipment is used and smoking is permitted inside. The positive pressure is maintained by a fan which draws its intake air across an activated carbon filter. Should a major break occur, the filter would be unable to eliminate all contaminents, therefore the fan should be shut down. To prevent any vapors from entering the building, when the fan is off, instrument air bleeds should be opened. (Do not bleed the air system down by taking too much). To prevent dust from accumulating in the control room filter hags are in the suction of the air conditioner. For any problems with the air conditioner, notify the supervisor. nnooan SL Q0oo47 CONFIDENTIAL: -s- Subject to Protective Oraer nth Judicial District Court Ho. 91.-1145 ELECTRICAL EQUIPMENT The characteristic of EC is such that the operating area is classi fied as Class I, Group D by the National Electric Code. The methods and materials of installation are those recommended by Factory Insurance Associa tion. In general, the installation is Class I, Group D, Division 2. Motors are TEFC (Totally Enclosed Fan Cooled), lighting is vapor-tight, and all arcing devices are explosion-proof with seal-offs. RELAMFING AND RECEPTACLES Vapor-tight fixtures are used in the process area. The relamping procedure will be to first determine the lamps which need changing by turn ing on all lights. Then, turn off all lights and re lamp. To simplify this procedure, circuit breakers for lights in the process area and control lab oratory have been grouped in the lighting panels. Globes and guards must be replaced after relamping. GROUNDING Grounding in the EC plant has been given special attention due to problems peculiar to the handling of hydrocarbons. Grounds for motors and other electrical devices are contained in the conduit supplying the device and connected to the device frame internally. Motor change-outs should be checked to see that the ground has been replaced. Due to the tendency for hydrocarbons to build up a static electricity charge as a result of movement or agitation, a system of jumpers for pipe flanges has been installed to provide metallic continuity of the piping systems that contain flammable materials. Al] vessels are grounded at 2 points. The result is a system of lines, tanks, and vessels operating at ground potential. This will not prevent the generation of static charges but should provide SL 008848 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 adequate leakage to ground to prevent the accumulation of dangerous charges and the resulting spark. The nearness of the radio transmitting station north of the process area presents a problem in that metal objects will act as receivers of radio frequency energy. It is not practically possible to prevent this effect. It is known that the energy picked up will be amplified if the height of the object is a multiple of the transmitter wave length. The height of the stills approach this condition, but the grounding system on the stills should elimi nate personal hazard. A particular hazard is created by the use of cranes with long booms. Under certain conditions, depending on boom length and crane location, it is possible to pick up a voltage high enough to burn the person handling a load that is suspended from the crane. This will occur even if the crane is grounded. It is also conceivable that an arc would occur if the crane hooks touch a grounded object. Particular attention should be paid to this problem if the crane height is greater than 90'. It is obviously important that the grounding system be maintained intact. This should be kept in mind when performing maintenance work on any equipment in the EC plant. TOOLS Special spark-proof tools are not required unless there are EC vapors present, or a possibility that EC vapors will become present. Check with opera tions prior to starting each job to determine the type of tools needed. SL 008849 -10- , r Prtectivf Order Of 14th Judicial District Cour No. 91-1145 ORGANIC AREA SAFETY PERMIT To be used to pass restricted equipment into the Organic Area and to be_endorsed for thge use oof svuch equipment in the 1hyl Chloride. Unit. To: 3oYm Location: Dfifap Date: 17 Mm/ 4S' Truck-Equipment: . Please Check 1. Have workmen been provided with proper safety equipment? 2. Are adjacent areas and equipment safe? 3. Has adequate fire protection been provided? 4. Is presence of operator required? Yes ! No X X X X RemarksUtill fflfllfC 2 trip*. Will Approved: __________* SeCO If a siren or emergency horn sounds, I am to turn off my equipment immediately and evacuate the area on foot. laru*_ _ _ _ ^mimpp loyee' s #5 ignnaature WELDING OR BURNING PERMIT This permit, when signed, allows welding or burning at: fitjot vuth..UJ*xf product raaUv 'I^(Location)1-- It is good for: Date /7 fJat/ Time AM AfcvCl 6S"To: Date Time s. Special Comments: taJll] ckcl< fillH) T if fi 'Htc/1 Vi W tvucl % ie $i)lecl i n Soy o>lc|i SbnttVk*, WoUl^, Signed: (Area Product^a. Supervisor) SL 008850 -10a- CONFIDENTIAL: Subject to Protective Order o 14tkr Judicial District Court Ho, *1-11*5 V. COWFlttENTIAl/: Sufc^ect to Protoctivender pf 14th Judicial District Cburt PROCEDURES Uo W*Ui* SAMPLING METHODS Sampling techniques used in this plant are different than those used in most other plants. EC is never purged to the atmosphere because of the fire hazard. Samples are caught in steel bombs and therefore, a visual check is impossible. All bombs must be thoroughly cleaned, and then purged with nitrogen before any EC is introduced into the bomb. The bombs are equipped with a standleg so that a vapor space is always assured whenever the bomb is filled in the prescribed manner. The bomb will always have to be filled with the bomb in the vertical position. The bomb has a marked top and it should always be up. In order to obtain a true sample a high pressure liquid stream will be circulated through the bomb to some low pressure stream, i.e., a pump dis charge to a pump suction. Be sure the low pressure stream is connected to f the standleg connection. Do not run the circulation too long as the inert may be dissolved out and the bomb liquid filled. Any time a bomb is filled it should be checked (tilting or shaking) to be sure it has some vapor space in it. Failure to have a vapor space, or failure to have an inert gas in the sample bomb will result in someone having a real bomb in their hands. *58800 lg GENERAL FIRE AND EXPLOSION RULES 1. Personnel entering the organics area will deposit lighters, matches, regular flashlights, etc., at the gate to this area. Safe flashlights have a label showing MSA approval for flammable areas. 2. Anyone entering an operating area should first checl with operating personnel. 3. Smoking will be permitted only in the main control buildings -11- COWfJENTIAL: Subject to fcrcstective OrtJe* tf 14th Judicial iDl^trict Court No* 91-IMS (except the laboratory), where permanent lighters are provided. 4. A vehicle permit signed by an operating supervisor will be required for any vehicle to go into the chained-off roads. 5. An equipment permit signed by the operating supervisor will be required before the following equipment can be carried into the EC area: (a) Welding machine (b) Cutting Torches (c) Electrically driven drills (d) Any electrical equipment except explosion-proof flashlights. (e) Gasoline engine driven equipment not previously covered. (f) Lighters, blow-torches or any flame producing equipment. (g) Grinders or chipping equipment (h) Sandblasting equipment. 6. Only explosion-proof flashlights will be permitted. 7. In case of an emergency warning, (siren or plant howler), all vehicles or equipment that are in the area on permits will be shut off immediately and the occupants will evacuate the area on foot. 8. Do not dump ethyl chloride or other flaramables into openings, such as sewers or other underground cavities, where harmful vapors could be evolved. 9. Do not leave samples or containers of flammable material sitting around to give off vapors. 10. Always put liquid EC or the other flammables into tanks through standlegs or through bottoms nozzles. Falling liquid can generate static electricity. 11. All steam-out nozzles or hose and purge equipment must be properly grounded to reduce the possibility of an arc from an accumulated static charge. -12- SL 008852 CONFIDENTIAL.* Subject to Protective Order 14th Judicial District Court No. 91-1145 12. Do not permit air to enter any of the process equipment that contains a flammable. 13. Be sure all tank cars or tank trucks containing flammables are properly grounded before unloading begins. This includes a jumper around a non-conductive unloading base. 14. Fire protection equipment is different. Know it well! Report all damages immediately. Do not use the fire hoses for any other purpose. 15. It is intended that all personnel will obtain periodic re fresher courses on fire-fighting techniques. GENERAL SAFETY RULES 1. Pumps and Equipment -- any pump or pieces of equipment that is removed from the process stream must be thoroughly cleaned and inspected by a foreman before it is permitted to leave the area for the main shop or other work areas. 2. Regular plant utility hoses are not to be used for solvents, because they will become weakened and unsafe to use with pressure. Use the special hose provided 3. The laboratory hood fans are to operate continuously. Do not attempt to run analyses without the fan being in service. 4. Use Full-Face, Chemox or Scott Air-Pak, masks for protection against organic vapors. 5. Do not permit chlorine to be heated above 300F, as it will rapidly corrode most metals at higher temperatures. 6. Clothing that has been wet with EC should be removed immediately and the body thoroughly washed with soap and water. Severe frostbite can result from allowing EC to evaporate from the body -13- SL 008853 # CONFIDENTIAL; Subject to Protectiv or clothing on the body. * 11,3 7. Clearing of Tanks and Process Vessels -- The area Supervisor and maintenance supervisor will see that all vessels or tanks are cleaned and checked with an explosion meter before declaring them suitable for maintenance. Clearing Procedure: (a) The tank or vessel will be emptied of its contents and all valves will be closed and tagged. (b) The vapor contents of the tank will be purged with an inert gas. (c) Blinds will be inserted in all connecting lines. (d) Purge the equipment with plenty of air. (e) The equipment will then be checked with an explosi- meter before work is begun. When a man is to enter the tank, it will first be checked for sufficient C>2. The apparatus for testing for sufficient oxygen is either a flame or a special metering device. These tests can be run only by a supervisor, (f) Safety belts and safety lines will be required in top exit tanks. 8. If the emergency warning sounds, all personnel not needed for control purposes should walk upwind (or crosswind, if in fumes), to a safe location and remain there until the all-clear sounds. Those personnel required for operation should remain on the job, while taking safety precautions necessary to remain in the area. 9. Tagging - Same as used throughout the plant. See General Section of Production Department Manual. SPECIAL SAFETY EQUIPMENT 1. Stretchers (1) (a) Located inside control room 2. Chemox masks (3) (a) Two in control room (b) One at main gate 3. Full Face Masks SL 008854 -14- (10) All purpose cannister (a) Three located in Control Room (b) One located in day tank area (c) Two in Shipping building (d) Two at the main gate (e) Two at the dock area CONFIDENTIAL: Subject to Protective Order 14tn Judicial District Court No. 91-1145 4. Scott Air Pak ........ (6) (a) Two in control room (b) One in supervisors office (c) One in HC1 area (d) One in TE Catalyst bldg. (e) One in EC Catalyst bldg. 5. Cylinder Type with connecting regulator, hose, and mask .... (1) In EC control room The following is a run-down on the type situations for which each of the masks will be used: (a) Scott Air-Pak -- this unit is good for any concentration of gas and can be used for periods up to thirty (30) minutes. The unit can be put on in a few seconds and because of this, its primary use is for major gas breaks requiring quick response to get valves closed or injured men out of contaminated areas. The point to remember with this unit is that it has a life of only 30 minutes and when using it one should not remain in a contaminated area for a period of more than 20 minutes. Note: the Scott-Air Paks in the EDC area only have a 15 minute life . (b) Chemox -- this unit is good for any concentration of gas and can be used for periods up to one hour. It is a unit which chemically generates breathing oxygen and because of this, several minutes are required to get this unit operating properly. The primary advantage of this unit is its long life. Because of this, the unit should be used in cases where one is required to enter and remain in a contaminated area for longer periods. With this unit one should not remain in a contaminated area for more than 45 minutes. (c) Full Face All-Purpose -- this unit is good for weak concentrations of gas. One can equip himself with this mask in a few seconds. SL 008855 It should be used only in weakly contaminated areas and for escape -15- purposes. (d) Cylinder Type With Connecting Regulator, Hose and Mask -- these units are good in any concentration of gas. They are to be used in the event of gas being pulled into the control room. The important point about using these units is to get the units on before the room becomes excessively contaminated Since the control rooms are pressurized, contaminating gases can enter only through the intake of the pressurizing unit. When contamination is detected, the pressurizing unit should be shut down and instrument air bleeds behind the panel board and in the laboratory should be opened. SL 008856 CONFIDENTIAL: Subject to Protective Order of J4th Judicial District Court |)o. 91-1145 -16- CHEMICALS IN THE AREA In the course of discussion of the EC plant many abbreviations are used. Since everyone is not necessarily familiar with a majority of the chemicals used in Area "B", a quick review is listed. CaCl2 HC1 H2SC>4 NaOH N2 02 H2 ch4 C2H4 C2H6 EC EDC MC Per TCE Tri VC VDC Calcium Chloride Chlorine Ferric Chloride -gas- Hydrogen Chloride -liquid-(mixed with water) Hydrochloric Acid, Muriatic Acid Sulfuric Acid Caustic, Sodium Hydroxide, Cell Liquor is about 10% NaOH Nitrogen, Inert Oxygen Hydrogen Methane, Natural Gas Ethylene Ethane Ethyl Chloride Ethylene Dichloride (There are two EDCs - 1,1 and 1,2. 1,2-EDC is the most common one.) Methyl Chloroform, 1,1,1 - Trichloroethane Perchloroethylene, Tetrachloroethylene 1,1,2 - Trichloroethane Trich1oroe thylene Vinyl Chloride, Chloroethylene Vinylidene Chloride, 1,1 dichloroethylene There are many more chemicals in the area, and if you need to know the names or abbreviations see the operating foreman. SL 008857 -17- CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 NAME: Calcium Chloride FORMULA: CaCl2 MOLECULAR WEIGHT: 110.99 BOILING POINT: > 1600C MELTING POINT: 772C SOLUBILITY IN WATER: 59.5 parts CaCl2/100 parts H20 at 9C 347 parts CaCl2/10O parts H20 at 260C DENSITY: 2.512 g./cc. at 25C RELATIVE VAPOR DENSITY: Normally a solid FLASH POINT: None EXPLOSIVE LIMITS: None HAZARDOUS PROPERTIES: Generally speaking, calcium compounds should be considered toxic only when they contain a toxic component (such as arsenic, etc.) or as calcium oxide or hydroxide. The hydration of the anhydrous salt is exothermic (21.7 cal,/mole to form the hexahydrate). Thus, when driers are being flushed out with water there is the possibility of heat and some splashing which may carry CaCl2 solution into the operator's eyes. If CaCl2 solution enters the eye(s), a sustained water flush will be most effective in removing the material. SL 008858 CONFIDENTIAL: Subject to Protective Order i 14th Judicial District Court No. *1-114$ -18- NAME: Caustic Soda (lye) FQFMULA: NaOH MOLECULAR WEIGHT: 40.01 BOILING POINT: 2532F VAPOR PRESSURE: Normally a solid, but can be mixed with water to form a solution FREEZING POINT: 604F HAZARDOUS PROPERTIES: When mixed with water, will react violently, splashing caustic solution on anyone nearby. Caustic soda in the form of solid, flake, or liquid attacks any tissue upon contact. The degree of injury depends upon the extent and duration of contact, temperature of the materials and concentration of the materials. TREATMENT: Flush the contacted area immediately with an abundance of water. Remove any clothing or equipment that has been saturated with caustic. After thoroughly flushing the contacted area of the body with water, report to First Aid for further treatment. Eyes should be irrigated at once with plenty of warm water for at least 15 minutes anytime caustic comes in contact with the eye. SL 008859 -19- CONFIDENTIAL: Subj ct to Protective Order of 14th Judicial District Court No. N-U4* NAME: Cell Liquor FORMULA: Aqueous solution of NaOH LIQUID DENSITY 77F: 10.0#/gal.,, 1.1 gm/ml HAZARDOUS PROPERTIES: Cell liquor is an aqueous solution of sodium hydroxide (caustic) and salt and as such should be handled with the caution given any caustic solution. This material has a markedly corrosive action upon all body tissues, and skin contact may result in moderate to severe chemi cal burns if the exposed surface is not washed immediately. Eye contact is quite painful and can result in impair ment of vision. TREATMENT: Speed in removing cell liquor from contact with the body Is important to avoid injury. Removal of all contaminated clothing and thorough washing of the exposed surface is essential. If the eyes are in volved they should be irrigated at once with plenty of warm water for 15 minutes. Call a physician. SL 008860 CONF IDENTIC Subject to otecti ve Ord.^t Of 14th -20- NAME: Chlorine (CI2) FORMULA: Cl2 MOLECULAR WEIGHT: 70.91 BOILING POINT: -30F VAPOR PRESSURE (? 75F: 92 psig FREEZING POINT: -148F LIQUID DENSITY ? 77F: 11.6#/gal., 1.391 gm/ml RELATIVE VAPOR DENSITY: 2.45 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC: 0.35 to 2 ppm DETECTABLE ODOR CONC: 3.5 ppm HAZARDOUS PROPERTIES: Liquid chlorine is very dangerous to the eyes as is chlorine gas. High concentrations of chlorine gas can cause pneumonitis and edema of the lungs. Lung irrita tion is one of the most serious effects of chlorine. Cl2 is about 2\ times as heavy as air, therefore, it has a tendency to collect in the low spots or stay near the ground. TREATMENT: Remove patient from toxic area and loosen all constrictive clothing about the neck. Oxygen should be administered in all cases to pre vent cyanosis and relieve the pain of deep respiratory effort. Notify a physician. SL 008861 subject to P 14th >"?iC1|l-ll45 o Court -21- NAME: Ethane FORMULA: C2H6 MOLECULAR WEIGHT: 30.07 BOILING POINT: -I28F FREEZING POINT: -277F RELATIVE VAPOR DENSITY (air =1.0) 1.04 AUTOIGNITION: 950F EXPLOSIVE LIMITS: 3 - 11% ODOR: Odorless HAZARDOUS PROPERTIES: Ethane is a flammable gas. It is the main impurity in the ethylene, and may reach high concentrations in the vent streams. Ethane is a very dangerous explosion hazard upon exposure to heat or flame. It can react vigorously with oxidizing materials. Ethane is moder ately toxic, but the slight effects disappear as soon as the patient is removed from the exposure. The main danger with C2Hg is asphyxiation. The ethane will dis place the oxygen of the air causing the victim to suffocate. TREATMENT: Remove the patient from the contaminated area, perform artificial respiration if breathing has stopped. Report to First Aid. SL 008862 / CONFIl>ENTI*V: of nth -22- NAME: Ethyl Chloride FORMULA: C2H5C1 MOLECULAR WEIGHT: 64.52 BOILING POINT: 54F (Gas under normal conditions) VAPOR PRESSURE @ 75F: 1130 mm FREEZING POINT: -228F LIQUID DENSITY @ 68F: 0.893 RELATIVE VAPOR DENSITY (air = 1.0): 2.22 FLASH POINT: Open Cup -45F Closed Cup -58F AUTOIGNITION: 966F EXPLOSIVE LIMITS: 3.6 - 12.07. MAXIMUM ALLOWABLE CONC.: 1000 PPM ODOR: Pungent HAZARDOUS PROPERTIES: The liquid is harmful to the eyes, and if spilled on the skin will cause frostbite. The vapor gives some warning of its presence because it is irritating, but it is possible to tolerate exposure to it until one becomes unconscious. EC is the least toxic of all the chlorinated hydrocarbons. It can cause narcosis, but the effect are usually transient. Continued exposures may cause some kidney deterioration. Inhalation of EC vapor in concentrations of 1% (by volume) produces narcotic and anesthetic effects, concentrations of 4% or greater may produce deep or even fatal anesthesia. Although EC is not extremely poisonous, any exposure is very dangerous because of the extreme flammability of the material. When EC is burned phosgene and HC1 are formed, so never approach burning EC without a gas mask. Any spill of EC will result in an explosive mixture being formed and because of the high density of the EC gas, the mixture will tend to stay near the ground. It will take very little to explode EC vapors; static electricity spark, friction spark or an arcing device are all dangerous when EC is spilled. TREATMENT: Remove the injured person from the contaminated area, if breathing has stopped perform artificial respiration. In any case make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes. If at the end of 15 minutes eye damage is still apparent continue washing until the doctor arrives or gives new instructions ci 008863 23 "" CONFIDENTIAL: "kject to Protective Order of Judicial District Court No. 91-144-5 NAME: Ethylene FORMULA: C2H4 MOLECULAR WEIGHT: 28.05 BOILING POINT: -155F FREEZING POINT: -273F RELATIVE VAPOR DENSITY (air =1.0): 0.98 AUTOIGNITION: 1009F EXPLOSIVE LIMITS: 3 - 34% ODOR: Sweet HAZARDOUS PROPERTIES: Ethylene is a flammable gas. It is a very dangerous explosion hazard upon exposure to heat or flame. It can react vigorously with oxidizing materials. Ethylene is moderately toxic, but the slight effects disappear as soon as the patient is removed from the exposure. The main danger with C2H4 is asphyxiation. The ethylene will displace the oxygen of the air causing the victim to suffocate. TREATMENT: (See Methane Treatment) Remove the patient from the area, perform artificial respiration if breathing has stopped. Report to First Aid. SL 008864 -24- CONFIDENTIAL: Subject to of 14th duai NAME: Ethylene Dichloride (EDC) FORMULA: CH2C1CH2C1 MOLECULAR WEIGHT: 98.97 BOILING POINT: 182.3F VAPOR PRESSURE @ 75F: 75 mm FREEZING POINT: -31.8F LIQUID DENSITY f? 68F: 10.45#/gal., 1.253 gm/mls RELATIVE VAPOR DENSITY: 3.41 (air =1.0) FLASH POINT: 65F Open Cup; 55F Closed Cup EXPLOSIVE LIMITS: 6.2 to 15.9% by vol. in air MAXIMUM ALLOWABLE CONC: 75 to 100 ppm DETECTABLE ODOR CON: Unknown HAZARDOUS PROPERTIES: Ethylene dichloride is a flammable liquid and a dangerous fire hazard. It is toxic by inhalation, by prolonged or repeated contact with the skin or mucous membranes, and by ingestion. Excessive contact gives rise to symptoms such as headache, depression, mental confusion, fatique, loss of appetite, nausea, vomiting, cough, loss of sense of balance, and visual disturbances. It has an anesthetic effect, and, in high concentrations, is immediately irri tating to the eyes, skin, nose and throat. It can cause dermatitis upon prolonged or repeated contact with the skin. Ethylene dichloride can cause serious eye damage. TREATMENT: Quick removal from exposure is important. Ethylene dichloride should be removed from the patient's person, his respiratory tract, skin, or gastrointestinal tract as quickly as possible. If breathing has/ ceased, start artificial respiration. If material gets in the eyes, wash promptly with copius quantities of water. If ingested, the patient should be made to vomit. Notify a physician. SL 008865 CONFIDENTIAL* Subject to Protective Order of I4th Judicial District Court No. 91-1145 -25- NAME: Ferric Chloride FORMULA: FeCl3 MOLECULAR WEIGHT: 162.2 BOILING POINT: 590F VAPOR PRESSURE <a 75F: nil SUBLIMATION POINT: 572F SPECIFIC GRAVITY: 2.8 RELATIVE VAPOR DENSITY: Normally a solid FLASH POINT: None EXPLOSIVE LIMITS: None HAZARDOUS PROPERTIES: Ferric chloride presents no particular problem in handling. However, in the anhydrous form it may be injurious to clothing, and all contamination of both skin and clothing should be washed off immediately. In the case of eye con tact, flush immediately and thoroughly with water and then rinse with a weak solution of sodium bicarbonate or boric acid. A physician should always be consulted in such cases. Ferric chloride will seriously stain clothing and skin when it is contacted so it is advisable to wear gloves and aprons when handling it. Ferric chloride is extremely hygroscopic (absorbs water), and when this takes place, heat release occurs. Before opening a drum, the bleed valve should be opened to release any pressure that may have been generated in the drum. When taking material from a drum, remove the desired quantity quickly as possible and immediately seal the drum to f>r,Vent it from absorbing moisture from the air. ^ SL 008866 I 14th Judic.ia- vljuDecricsivtreicOt rCdoeur Mo. 91-1145 -26- NAME: Freon - 12 (dichlorodifluororaethane) FORMULA: CC12F2 MOLECULAR WEIGHT: 120.92 BOILING POINT: -29C MELTING POINT: -158C f VAPOR PRESSURE: @ 16.1C, 5 atmospheres I RELATIVE VAPOR DENSITY: 4.17 (air - 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC.: 1000 ppm in air DETECTABLE ODOR CONC.: Unknown HAZARDOUS PROPERTIES: Dangerous: when heated to decomposition, it emits highly toxic fumes of phosgene and fluorides. Never allow any open flames to come in contact with F-12 or any vessels containing it. SL 008867 of 14th Judicial District Court No. 91-U45 -27- NAME: Freon-22 (chlorodifloromethane) FORMULA: C1HCF2 MOLECULAR WEIGHT: 86.465 BOILING POINT: -40.8C. MELTING POINT: -146C. VAPOR PRESSURE: 24C., 7,600 mm. Hg. RELATIVE VAPOR DENSITY: 3.87 (air =1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC.: Unknown DETECTABLE ODOR CONC.: Unknown HAZARDOUS PROPERTIES: Freon-22 is very dangerous when heated to decomposition. It emits highly toxic fumes of chlorides and fluorides. Never allow any open flames to come in contact with Freon-22 or any vessels containing it. SL 008868 CONFIDENTIAL: Subject to Protective Order Of I4tb Judicial District Court No. 91-1145 -28- NAME: Hydrogen FORMULA: H2 MOLECULAR WEIGHT: 2.02 BOILING POINT: -423F FREEZING POINT: -434F RELATIVE VAPOR DENSITY (air - 1.0) 0.069 AUTOIGNITION TEMP; 1085F EXPLOSIVE LIMITS: 4-74% HAZARDOUS PROPERTIES: Hydrogen is a flammable gas. As may be seen from the explosive range, any concentration is highly dangerous when exposed to heat or flame. Hydrogen gas itself is only slightly toxic, but will displace the 02 in the air causing suffocation. Symptoms will be the same as methane, TREATMENT: Remove the patient from the contaminated area, perform artificial respiration if breathing has stopped. Report to First Aid. SL 008869 CONFIDENTIAL! Subject to Protective Order f 14th Judicial District Court No* 51*1145 -29- NAME: Hydrogen Chloride FORMULA: HC1 MOLECULAR WEIGHT: 36.47 BOILING POINT: -121F VAPOR PRESSURE I? 75F: 36,000 nnn FREEZING POINT: -I74F LIQUID DENSITY: Normally a gas RELATIVE VAPOR DENSITY: 1.26 (air =1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CON: 10 ppm for 8 hour working day DETECTABLE ODOR CONC: Unknown HAZARDOUS PROPERTIES: Anhydrous hydrogen chloride is a gas which has a corrosive action upon the skin or mucous membranes. In this form, it will cause rapid and severe burns. It is particularly dangerous to the eyes. It is not flammable; however, the gas is highly soluble in water, forming hydrochloric acid, which attacks most metals with the evolution of explosive hydrogen. TREATMENT: Immediate removal from the toxic area and thorough flushing of the patient's body and/or eyes with large quantities of water is of primary importance. Contaminated clothing should be removed from patient while he is being showered with water. It is essential that all affected body surfaces be washed with copius quantities of water for a sufficient time to remove all hydrochloric acid. No attempt should be made to / neutralize the acid with alkaline solutions. Medical assistance should be summoned at the earliest possible moment. / SL 008870 COHF10BNT1RM Order ct Court -30- NAME: Methane, Natural Gas FORMULA: CH4 MOLECULAR WEIGHT: 16.04 BOILING POINT: -258F (gas under normal conditions) FREEZING POINT: -296F LIQUID DENSITY <? 68F: Flammable Gas RELATIVE VAPOR DENSITY (air =1.0): 0.54 EXPLOSIVE LIMITS: 3% to 297. by volume in air MAXIMUM ALLOWABLE CONC: 3% to prevent fire, 33% for breathing DETECTABLE ODOR CONC: Odorless: It is a mercaptan that is put in it to give it odor. HAZARDOUS PROPERTIES: Methane is a simple asphyxiant gas. The gas has no toxic effect, but will deprive the lungs of oxygen when mixed with air. Harmful effects are noticed when the methane is greater than 33%. The first symptoms are rapid breathing and air hunger. Mental alertness is diminished and muscular coordination is impaired. Later judgment becomes faulty and all sensations are depressed. Emotional instability often results and fatigue occurs rapidly. As asphyxia progresses, there may be nausea and vomiting, prostration and loss of consciousness, and finally, convulsions, deep coma and death. TREATMENT: Move the patient from the contaminated area. tion if required. Report to First Aid. Give artificial respira / /' SL 008871 effective order m W 4At*. NAME: Nitrogen FORMULA: N2 MOLECULAR WEIGHT: 28.02 PHYSICAL APPEARANCE: Colorless, Odorless, Inert Gas SPECIFIC GRAVITY: 1.0 with relation to air. (Air is 78% N2) HAZARDOUS PROPERTIES: Even though nitrogen is a very safe, inactive gas, it has some inherent dangers since it is used so universally throughout the plant. Its prime use is for padding and sweeping of equipment that has, or has had, EC in it. The hazard involved is that a vessel may have insufficient oxygen or that nitrogen is used to purge the vessel instead of air, before man-entry. Therefore, in the EC plant, every vessel that is entered not only must be first checked for flammability, etc., it must also be checked for sufficient oxygen. Not only that, nitrogen lines, as well as toxic lines must be isolated from the vessel before entry and a clean air sweep provided. TREATMENT: Remove person from the oxygen deficient area. Administer artificial respiration if necessary. (See Methane for symptoms). SL 008872 CONFIDENTIAL*, to Protective Order ofS1u4btjhecJt udicial D. o,,*t-trleict Court Ho. 91-1145 -32- NAME: Sulfuric Acid FORMULA: H2S04 MOLECULAR WEIGHT: 98.08 PHYSICAL APPEARANCE: Colorless to cloudy liquid HAZARDOUS PROPERTIES: It is highly corrosive to most metals, particularly at concentrations below 75%. This reaction produces H2 gas. At concentrations above 75%, H2S0^ may be handled in steel provided the temperature is never greater than 100F. It is very reactive with water or organic materials with heat being evolved. Contact with the body produces a rapid destruction of the tissue. The acid will continue to destroy the skin until it is washed off. The destruction of the skin will result in a painful and a slow healing burn. PROTECTIVE EQUIPMENT: Use rubber gloves and face shields whenever working with ^SO^. Use a slicker suit whenever tranferring acid, entering the shielded area around the HC1 dryer, or where there is any danger of an acid spill. TREATMENT: Flush the contacted area with an abundance of water. Remove any contaminated clothing or equipment. After thoroughly flushing the affected area, report to First Aid for further treatment. Treat for shock in case of severe bums. If any of the acid has been swallowed do notinduce vomiting; if the patient is conscious, wash his mouth with water and feed him as much water as he can drink, get medical help as quickly as possible. SL 008873 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 -33- NAME: Vinyl Chloride (chloroethylene) FORMULA: C^Cl MOLECULAR WEIGHT: 62.50 BOILING POINT: 8F VAPOR PRESSURE 75F: 2700 mm (Gas under normal conditions) FREEZING POINT: -244F LIQUID DENSITY ? 68F: 0.908 RELATIVE VAPOR DENSITY (air = 1.0): 2.15 FLASH POINT: Open Cup -107F Closed Cup -162F EXPLOSIVE LIMITS: 4-22% MAXIMUM ALLOWABLE CONC: 500 PPM for 8 hours ODOR: Faintly sweet (smells like phenol when inhibited) HAZARDOUS PROPERTIES: Vinyl Chloride is very much like Ethyl Chloride. It is not very poisonous, it is extremely flammable, and it has a narcotic effect. Continued exposures may cause some kidney deterioration. Inhalation of vapors greater than 500 PIW may produce a slight narcotic effect. At concentrations of 4% or greater VC vapors may produce a deep or fatal anesthesia. The main danger with VC is the extreme flammability of the vapors. VC when burning will form phosgene and HC1, so never approach a fire without a gas mask. Any spill of VC will result in an explosive mixture being formed and because of the high density of the VC gas, the mixture will tend to stay near the ground. It will take very little to explode the VC vapors, static electricity spark, friction Bpark or an arcing device are all dangerous when VC is spilled. TREATMENT: Remove the injured person from the contaminated area; if breathing has stopped, perform artificial respiration, in any case, make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes, then get the person to First Aid. SL 008874 Subject to Protective Order of 14th dudi cial istr-ict Court Ho. 91-U45 -34- PROCESS DESCRIPTION The EC plant is somewhat similar to the EDC plant or the MC section of the Tri-Ethane' 1 plant. The reaction and catalyst removal is exactly like the MC plant. The stripping and purification is like the EDC plant except that a stripper has been substituted for the neutralizer. Since EC is a gas under normal atmospheric conditions, the EC Process must be a pressure system. The pressure on the condensers will enable the con densation to be done by cooling tower water. The pressure differentials in the separation and purification areas are to aid and isolate the controls of each system. The reactor pressure effects the reaction rate. The reactor is designed to operate at 140 psig but an attempt will be made to operate at 90 psig. If successful, conversion can be made at the lower pressure, the reaction pressure will not be raised. If the pressure must be raised, the compressors will need spacer rings and the HC1 stripper pressure in the HC1 plant will have to be raised. The flows on the mechanical flow sheet are at 140 psig. Since the tern- * perature and the liquid flows remain the same, only the gas flows are in error. The process flow may be traced on the Process Flowsheet. The HC1 and C2H4 are premixed in a sparger ring and injected into the bottom of the reactor. To remove heat of reaction, a liquid stream is removed from the top of the reactor cooled and fed back into the bottom of the reactor. This stream has a small sidestream that goes through the Catalyst Addition Chamber for the addition of the FeCl^ catalyst. The vent from the reactor, which is HC1, V C2H/" and EC, goes through an analyzer, the reactor PCV and to the Primary Vent Condenser. A liquid stream is drawn from the reactor and fed to the Flasher Dopp Kettle. In the Flasher the catalyst and tars are concentrated and sent to the Bottoms Dopp Kettle, where the remaining EC is boiled away and the tars sent to the Tar Buggy for disposal. The EC that is vaporized in the Flasher is condensed in the Flasher SL 008875 CONFIDENTIAL: Subject to Protective Order ot 14th Judicial District Couch Condenser. The inerts from the Flasher Condenser and the Primary Vent Con denser are sent to the Secondary Vent Condenser which is cooled with 0F Freon. The inerts from the Secondary Vent Condenser go through a PCV that con trols the pressure of the Flasher and Primary Stripper systems. From the PCV the inerts go to a scrubber or to an absorber in the HC1 plant. All of the condensate from the three condensers is collected in the Primary Stripper Feed Drum. The crude EC liquid from the primary feed drum is fed through a dryer to the primary stripper where the HC1 is removed. The overhead from the strip per goes to the Primary Vent Condenser. The stripper bottoms overflow to the Heavies Still Feed Drum. The liquid from the Heavies Still Feed Drum is fed to the Heavies Still where the heavies are removed. The still bottoms are cooled and sent to EDC for reclaiming. The overhead from the Still is condensed in the Heavies Still Condenser and collected in the Heavies Still Reflux Drum. The inerts from the Still Condenser go through a PCV to keep the Still pressure constant and then they go to the Primary Vent Condenser. The liquid from the Reflux Drum is sent to the Still as reflux and to the Secondary Stripper to remove any HC1 that may have been formed in the Still. The overhead from the Secondary Stripper goes through a PCV and back to the Primary Vent Condenser. The Stripper bottoms overflow into the Product Surge Tank and from here are pumped through the Product Cooler to the Day Tank Area. The EC is stored in the Day Tanks until the analysis is complete and then it is pumped to the Horton Spheres in the Dock Area. 1. Ethylene System The ethylene for the EC Reactor comes from the ethylene metering sta tion that is located North of the EDC-MC control room. At the metering station the C2H^ enters at 600 psig, it is reduced to 300 psig and heated to 100F, it then is metered through a mass flowmeter then reduced to 165 psig. At this SL 008876 CONFIDENTIAL: Subject to Protective Order OX 14th Judicial District Court vi,; in i is point, the comes through the fence to PPG where it goes through PPG's mass flowmeter and is ready for distribution to EDC, MC and EC. The C2H4 to EC flows through 4" line that is located downstream of the meter. There is a block valve in the line to EC. The 4" line goes underground at the PPG metering station and comes out of the ground at the NE corner of the EC pro cess rack. If the reactor must be run at a pressure that is too high for the ^2^ to enter the reactor bottom, the whole PPG metering station pressure may be raised. The C2H^ line is split into 2 meter runs along the north side of the process platform. Whenever it is planned to operate the reactor at less than 60 TPD, use the top 3" line. From the metering station the ethylene line goes across the platform to the ethylene FCV and from the valve, through a seal loop, check valve and into the sparger ring. The C2H4 FCV has a solenoid on it that will close it in the event of a reactor shutdown. The C2H4 fed depends on the desired rate, see fig. 1. 2. HC1 System The HCl, regardless of whether it comes from the HC1 or from the VC plant, will come to the EC plant from the HCl compressors. The HCl line is a 4" line that comes down the pipe rack, through the middle of the EC process rack, has a double meter run (the top 3" line for reactor rates of less than 60 TPD), goes through a FCV, through a seal loop and through a check valve into the sparger ring. The HCl FCV has a solenoid that will close it in the Z' event of a reactor shutdown. The pressure of the HCl will depend on the reactor pressure and can vary from 125 psig to 165 psig. During the initial startup of the plant 4% excess HCl will be fed to the reactor. See the HCl feed graph, fig. 2. SL 008877 3. EC REACTOR SYSTEM 4. Equipment CONFIDENTIAL.: -37 1 ( SRV) (Sparger) (Recirculation) Reactor 64A-59-8 - The EC reactor is a steel vessel 9' ID x SI'S" seam to seam. The design pressure is 225 psi to full vacuum. The capacity of the reactor is 13,042 gallons with a liquid height of 26-i', The safety valve is a 31A; the sparger design consists of a 6" distribution ring around the reactor about 2* from the bottom. From this ring four 3" spargers stick 4'2M into the reactor and have 51 5/16" ID holes drilled into the bottom side. These holes are spaced further apart towards the middle of the reactor to give a uniform concentration of the inlet gases throughout the reactor. The recirculation liquid enters the bottom of the reactor through a T that has horizontal elbows on the two discharge ends to give the liquid a tangential dis charge and to aid in distribution. 2. Catalyst Chamber 64A-60-595 - The catalyst addition chamber is an 18,: OD x 22" seam to seam tank. The top is an 8" 300# Tube Turn quick-opening closure. The "0" ring is a 8Tg x 9 x \ Viton ring. Design pressure is 200 psig at 135F. 3. Reactor Coolers 64A-71-777 & 778 - The reactor coolers are 34" OD x 16' tubes. The shell side is two pass; the tube side is four pass. The design pressure of the tube side is 250 psi at 130 F. and the shell side is 150 psi at 300 F. There are 880 3/4" OD x 14 BWG seamless steel tubes. The exchangers are to remove 8,864,000 BTU/Hr, by cooling 1920 GIM of reactor liquor from 130 F. to 105 F. The 709 GFM of cooling tower water on the shell side is to be heated from 90 F, to 115 F. 4. Reactor Dump Tank 64A-60-594 - The Reactor Dump Tank is 10' ID x 23'8". The capacity of the tank is 15,120 gallons with no outage. The design pressure is 225 psi at 200 F. to full vacuum. The SRV is a 3K4. B. Reactor Shutdown System The EC Reactor has an automatic shutdown on the feed streams to the reactor. The purpose of this system Is to prevent the feed streams from back- feeding one another or to shut down the feed streams in case the reaction ceases. Each feed stream has a solenoid on the FCV that will shut if the 1IC1 flow is lost, or if the C2H4 flow is lost, or if the reactor overpressurizes (goes above 165 psig), or if the emergency shutdown button is pushed. The emergency system is shown on Dwg, 64A-7700. The shutdown system may be completely bypassed by SL 008878 CONFIDENTIAL: Subject to Protective Order 14th Judicial District Court No. 01-1145 CONFIDENTIAL: object to Protect!v turning on the bypass switch that is located on the shutdown system box behind the panel board. Should the shutdown system activate, it will be 5 minutes before the FCV may be opened again. The shutdown system is ready for operation when the light comes on about 4 seconds after the start button is pushed. It is well to remember that the light is the indicator of the cycle of the shutdown system. Anytime the light is off, the shutdown system will close the solenoid on the FCVs (Start-up) To start up the reactor push the start button and hold it in until the light comes on (about 4 sec.). At this time you now have 5 minutes to get flows through the HC1 and 02^ valves; if at the end of 5 minutes, both are not flowing then the system will shut down and you will have to wait 5 min utes more before starting up again. If start-up is successful, the timer will run to the shutdown position and stop (5 minutes). The timer will rest at this point until the shutdown system is activated, i.e., no HC1 flow, no 02^ flow, high (165 psig) reactor pressure, or the stop button is pushed, then the timer restarts, locks out start-up for 5 minutes, then it shuts down again until the start button is pushed. C. Operation The reaction between HC1 and proceeds at a slow rate unless catalyst is present. That is why the two gases may be premixed in the sparged ring. The reaction is HH HH SL 008879 HH II HH Since the reaction is rapid with a catalyst present, it is dangerous to have the gases mixed where catalysis could take place. If HC1 and are to leave the reactor vent together they could contact FeCl^ in the piping, start reacting, liberating heat, which makes more reaction, which makes more heat, and this would continue until the pressure and temperature would be -39- CONFIDENTS AL: Subject to Fiot^ective Order o 14til Judicial District Court No. 91-1145 sufficient to rupture a line or a vessel. To prevent this from happening two things are done. One is the feeding of HCl in excess of that required for reaction. The unreacted HCl prevents any C^H4 from getting in the vent by reacting with all of the 02^. To begin with, the reactor will run with 4% excess HCl. This will probably be trimmed back after better operating techniques are learned. The second thing done is the installation of an analyzer in the vent stream from the reactor. By using the analyzer the exact HCl excess required will be determined. As the gases are mixed with reactor liquor carrying catalyst, the reaction to EC takes place liberating a large amount of heat. To remove this heat, liquor is removed fran the top of the reactor and pumped through two exchangers and back into the bottom of the reactor. (Temp) The reaction temperature of 125F gives the optimum reaction and therefore care should be taken to keep the reactor temperature at this figure. The temperature is controlled by the amount of heat removed in the reactor coolers. (Recirculation) If the reactor liquor flow is throttled, too much cool ing will take place, and the tars and catalyst will deposit on the tubes requiring unnecessary cleaning of the coolers. For this reason, control the reactor temp erature by throttling the cooling tower water discharge from each cooler. Always y- / keep reactor liquor flowing through both exchangers, but if one cooler can remove y all the heat, stop the CTW flow to the other. The velocity of the reactoriiquor through one exchanger would be high enough to cause erosion. The reactor liquor coming out of the exchangers should be 105F or warmer. (Pressure) The reactor pressure will be an unknown until some plant experience is gained. The reaction takes place readily at 140 psig and reluctantly at 90 psig. The plant will start up at 90 psig. This means that the temperature will have to be very closely controlled. The reactor pressure is controlled by the PCV on the reactor vent stream. The PCV is located on the second deck, South -AO- SL 008880 of the Flasher Condenser. confidential? Subject to Protective Order Of I4tb Judicial District Court No, 91-1145 The impulse point for the PCV is on the reactor vent line above the top platform on the reactor. (Catalyst) The catalyst used for this reaction is Fe Cl^. The Ferric Chloride comes in 135# drums. The ultimate usage of FeCl^ when the plant is up to design rates is 60#/hr. For this reason the catalyst chamber is designed to hold 1 drum of catalyst. The chamber is designed to have a slow flow up through the catalyst and out the side of the chamber. The slow flow will dissolve the catalyst and only the soluble catalyst will be added to the reactor. The chamber is in parallel with the heat exchangers, so if a larger flow through the chamber is desired, the flow through the exchangers will have to be throttled. The need for catalyst will be indicated by an increase in the vent flow and a decrease in reactor temperature. The catalyst addition frequency will be every 2 hours during the initial start-up. After everything is lined out, larger additions will be made to determine the optimum addition rate. This means during low reactor rates that less than a drum of catalyst will be added at a time. See the FeCl^ addition graph, fig. 3. To add catalyst close the 4" ball valves upstream and downstream of the catalyst chamber. Then pressurize the chamber to 200 psig with N^ from the Ng bottles. Open the 1" valve on the Kettle bottom and bleed the EC into the 4" line. When the pressure of the chamber approaches the line pressure, start bleeding Nitrogen into the chamber. When all of the EC is out of the chamber ( you can tell by listening y' to the N2 bubbling into the 4" line) close the bottom drain valve and open the 1" purge line. Sweep the chamber with nitrogen until all EC vapors are out (2 to 3 minutes). While adding catalyst a small flow of ^ should be kept going through the chamber so that no air enters the chamber. After adding the catalyst be sure all air is purged out before closing the chamber back up and putting it into service. Note: the purge line is kept free of explosive mixtures by purging continously with N^. The Nitrogen purge flow is indicated by the rotameter i -41- SL 008881 located near the North side of the catalyst chamber. Check this flow after each catalyst addition. The product is removed from the reactor through a level control valve. The normal draw off point will be a nozzle 22'4" from the bottom tangent line. (Level) The operating level should be kept around 28y. Loss of recirculation will occur if the level gets below 24'. If the level gets below 22'4" (bottom nozzle on sight glass) no liquor can be withdrawn through the product line. If product is to be removed from the reactor when the level is less than 22'4" then the product stream will have to be fed from the recircula tion system. By closing the normal draw off valve on the reactor and opening the 2" valve on the recirculation system, the product may be taken from the recirculation stream. When the level is low the lower recirculation suction point will have to be used. D. Start-up Normal start-up of the EC reactor is fairly straight forward. With the reactor full of liquor and the proper catalyst in the liquor (about 3900 PIM FeClg) the reaction will take place as soon as the proper temperature and pressure is reached. Start the reactor liquor circulating through the coolers. On one cooler cut the CTO off completely and on the other allow just a small flow of CTO to flow through the inlet valve. Just after the inlet valve is a 1" steam valve: open this valve. The steam and water flow should be varied so the water temperature into the cooler is never warmer than 120F. When the reactor liquor temperature reaches 105F, push the start button and start feeding HC1. When the reactor pressure is up to 90 psig (or the operating pressure), start the C2H4 flow. When the reactor starts warming up, the steam flow to the cooler will have to be decreased and the COT flow increased. Control the CTW flow by the discharge valve after the reactor has SL 008882 -42- CONFIDLWTI Mi Subject to Pi otecti. Order Of 14th Judicial District court. Ho - L-1l4 5 started heating up. After the reactor is wanned up to 125F the HC1 flows and the C^flows may be brought up to rates. These adjustments should be made in small increments, with the HC1 always increased first. Any decrease in rates is made by decreasing the flrst* Anytime the reactor liquor is below the recirculation valve for start-up the normal method of recirculation can not be used. There is a valve located 7%' from the bottom of the reactor that is tied into the recirculation system. If the reactor is started up using this valve no product can be re moved until the normal circulation system is used. If the reactor has no level, then crude EC will have to be added to the reactor. The moisture in this liquid may be removed by circulating the reactor liquor through the reactor dryer. The moisture should be less than 1000 PPM before any catalyst is added. Enough catalyst should be added to bring the FeCl3 content to 3900 PPM. The new charge is then started up in the normal manner. E, Reactor Dryer and Filter SL 008883 1. Reactor Dryer (64A-73-56) - The Reactor Dryer is 30" OD by 6'0" tan. to tan. The capacity of the dryer is 990# of CaC^. The design pressure of the dryer is 225 psig to full vacuum (3 200F. The SRV is a 1E2, The bottom support is a 13 ga. type 304 SS mesh cloth located on a steel grate. (The grate is split for removal.) The head is designed to hold up to a 24" wide fibreglass roll. The floating support is a 1" expanded metal. 2. Reactor Filter (64A-72-103) - The Reactor Filter is 9-9/16"OD by 42" high. The filter holds 18 10" filter elements. The elements are triple stacked. The housing is 316 SS and the gaskets are teflon. The original elements are C75A105 designed to stop 75 micron. The element size is fairly independent so replacement may be made with any 10" element. 3. Operation - The dryer and filter will be operated only during start up. This is because the dryer would become clogged very quickly with Ferric Chloride. The dryer is designed for a flow rate of about 70 gal./min. The filter will handle 36 to 180 gal./min. The disposal method for the spent dryer will be determined by the condition of the EC in the dryer. After all the liquid is drained, the material should be swept with nitrogen until no EC is left. The nitrogen purge may be sent to the vent by tieing into the vent line. There is a valve located in the vent line near the dryer for this purpose. -43- CONFIDENTIALt Subject to Protective Order of 14th Judicial District Court 4. FLASHER POPP KETTLE A. Equipment - The Flasher Kettle is a scraped side, jacketed vessel that is 84" in diameter and 96" on the straight side. The capacity of the kettle when filled to the top of the jacket (78" from the tangent line) is 2000 gallons. The gross volume is 2600 gallons. The jacket area is 180 ft.^. The duty of the kettle is 2,300,000 Btu/hr. The kettle design pressure is 85 psig to full vacuum. The jacket is designed for 25 psig. (Agitator) The driver for the agitator is 15 hp and 1150 RFM. The agitator speed is 20 RIW. The agitator has a tripod step bearing on the bottom end. (SRV) The safety relief valve for the kettle is a 3L4. The jacket has no relief valve because the 25 psig steam system is relieved. (Gas Outlet) The vapor outlet is designed so a dish and doughnut may be installed if foaming becomes a problem. The Flasher Dopp, agitator, and driver equipment numbers are 64A-60-602, 64A-61-86, and 64A-50-1613 respectively. B. OPERATION The feed to the flasher is a liquid drawoff from the reactor. The liquid feeds through the LCV located on the West side of the kettle platform and into the kettle. Any rework material can be fed to the / kettle by feeding through the rework line which joins the kettle y?eed / line downstream of the Reactor LCV. The Flasher Kettle is de/igned to concentrate the spent catalyst and the tars about 10 times. The steam flow to the jacket is controlled by the level of liquor in the kettle. The concentrated liquor is removed from the bottom of the kettle through a steam traced line to the Bottoms Dopp Kettle. The feed to the Bottoms Kettle is a gravity drain and is controlled by SL 008884 CONFIDENTIAL: Subject to Prot ctive order Of 14th Judicial District Court No. 91-1145 throttling the valve at the Bottoms Dopp. There is a Strahman Valve located on the bottom of the Flasher that is to be used if the normal drain is plugged. There is a thermocouple located in the bottom of the kettle and one located in the vapor line. The bottom temperature will be correlated to the tars in the kettle, and this temperature will be used to control the blowdown to the Bottoms Kettle. C. Start-Up - The kettle starts up fairly easy. When an operating level is reached in the kettle, steam should be slowly opened to the jacket. The agitator is never shutdown unless the kettle is completely empty. Steam flow can be controlled by level or put on manual, as with a constant steam flow the level will decrease until an equilibrium level is reached. With the steam on manual, be sure the bottom temperature does not get too high before the equilibrium level is reached. 5. BOTTOMS DOPP KETTLE A. Equipment The Bottoms Dopp Kettle is a scraped side, jacketed vessel that is 36" in diameter and 36" on the straight side. The capacity of the kettle when filled to the top of the jacket is 150 gallons and the gross volume is 185 gallons. The heat load of the kettle is 210,000 Btu/hr. The kettle design pressure is 85 psig to full vacuum. The jacket is designed for 25 psig. (Agitator) The driver for the agitator is 5 hp and 1750 RFM. The agitator speed is 37 RFM. (SRV) The safety relief valve is a \\ H3. The jacket is not relieved. The Bottoms Dopp, agitator, and driver equipment numbers are 64A-60-603, 64A-61-87 and 64A-50-1614 respectively. SL 008885 -45- to ProtcUve order Of 14th Judicial X>i*trict Court B. OPERATION The feed to the Bottoms Kettle is gravity fed from the bottom of the Flasher kettle. The flow to the kettle is throttled by the globe valve at the inlet to the kettle. The feed to the kettle is determined by the concentration being done in the Flasher. The vapors from the kettle are fed to the Flasher or to the Flasher vapor line. Normal feed is to the Flasher. The steam to the jacket is controlled by a field mounted PCV. This valve is controlled by adjusting the bolt on the compression spring. Turn the bolt clock wise to increase steam pressure, and always reset the lock-nut when finished adjusting. When tars are to be drained from the kettle, stop the feed to the kettle and concentrate the tars so as little EC is lost as possible. Then hook up the tar-buggy to the drain connections and to the vent line and then slowly open the Strahman valve on the bottom of the kettle. When the kettle is empty, put the kettle back in service. Leave the tar buggy connected to the vent line as long as it is in the area, but open and drain the drain line between the kettle and the buggy. The thermocouple for the Bottoms Kettle is located in the vapor outlet. Tar concentration will be determined by experience. The material in the Reactor Dump tank may be fed directly to the Bottoms Kettle. C. START-UP There are no special problems with the kettle operating or starting up. Never shut down the agitator unless the Kettle is completely empty. Observe the tar thickness to control steam, 6. FLASHER CONDENSER A. EQUIPMENT 64A-71-780 - The Flasher Condenser is 18" OD with 14' tubes. The shell side is single pass with side to side segmental baffles at 16" intervals. The tube side is 4 pass. The design SL 008886 -46- CONFIDENTIAL: Subject to Protective Order f 14th Judicial District Court No. 91-1145 pressure of the tube side and the shell side is 150 psig. There are 244 3/4" OD x 14 BWG seamless steel tubes. The exchanger is designed to remove 2,190,000 Btu/hr by condensing 14,336 #/hr. of EC at 139F. The cooling tower water is to be heated from 90F to 110F. B. OPERATION The Flasher Condenser condenses the vapors that are boiled off in the Flasher Kettle. These vapors should be essentially pure EC. The vapors from the Bottoms Kettle may be fed directly to the Flasher Condenser, also. The cooling tower water should be throttled with the discharge valve from the exchanger to give a tem perature of 110F. The first taP under the exchanger on the conden sate line is a sample point. The condensate from this exchanger should run about 110F, and it is gravity fed to the Primary Stripper Feed Drum. The inerts from the exchanger leaves at about 110F and are fed to the Secondary Vent Condenser. The inerts are the dissolved HC1, C2H5, H2 and the non-condensed EC. 7. PRIMARY VENT CONDENSER A. Equipment 64A-71-779 The Primary Vent Condenser Is 10" OD with 16' tubes. The shell side is single pass with side to side segmental baffles at 16" intervals. The tube side is 4 pass. The design pressure of the tube side and the shell side is 150 psig. There are 72 3/4"OD x 14 BWG seamless steel tubes. The exchanger is designed to remove 610,000 Btu/hr by condensing 3,816#/hr of mostly EC and cooling 1809#/hr of inerts to 90F. The well water is to be heated from 78F to 90F. B, Operation The Primary Vent Condenser condenses and cools the vapors from the Reactor, Primary Stripper, and the Secondary Stripper. The vapors enter the exchanger at 122F and are cooled to 90F. CONFIDENTIAL: SL 008887 Subject to Protective Order Of 14th Judicial District Court Mo* 91-1145 Cooling this stream from 110F to 90F nets a savings of 15 tons of refrigeration, so all attempts should be made to keep the inerts stream as cool as possible. The well water discharge from this condenser is fed to the cooling tower as make-up. Should the water required for this exchanger be more than cooling tower make-up, throttle the 3" gate valve that is located above the addition basin. By throttling this valve the excess water is spilled to the sewer. The discharge water temperature should be kept around 90F, by throttling the discharge valve. A close watch should be kept on the tubes of this exchanger. Any time the plant is down the tubes should be examined until some history has been built on well water cooling. If severe corrosion is observed then the exchangeYmay be put on cooling tower water. (Stub-outs are provided on the cooling tower headers). The inerts from this exchanger (mostly HC1 and EC) are sent to the Secondary Vent Condenser. The condensate gravity feeds to the Primary Stripper Feed Drum. The first tap under the exchanger on the condensate line is a sample point. 8. SECONDARY VENT CONDENSER A. Equipment 64A-71-786 The Secondary Vent Condenser is 14"0D with a 16* U-bundle. The shell side is designed for pool boiling with a deentraxning section while the tube side is 2 pass. The design pressure of the shell side is 300 psi and of the tube side 150 psi. There are 58 3/4 x 14BWG seamless steel tubes. The exchanger is designed to remove 365,000 Btu/hr by condensing 1819#/hr of essentially EC and cooling 909#/hr of inerts to 2F. The cooling is done by boiling Freon 22 in the shell side, where the pressure is 24 psig. B. Operation The inerts from the Primary Vent Condenser and from SL 008888 the Flasher Condenser are fed to the Secondary Vent Condenser. In CONFIDENTIAL: Subject to Protective Order -48- of I4th Judicial District tour No. 91-1H5 this condenser the last of the salvageable EC is reclaimed and sent to the Primary Stripper Feed Drum. The vents are fed into the tubes of the condenser. The non-condensables and the condensate come out of the bottom of the head and are fed to a vapor-separator. The condensate is fed from the bottom of the vapor separator to the Primary Stripper Feed Drum. Sampling of the condensate may be done on the first valve under the vapor separator. The valve located in the vapor separator bottom is for draining. The inerts are fed from the top of the vapor separator through a PCV. This PCV controls the pressure on the Flasher Dopp, Bottoms Dopp, the Primary Stripper and the Primary Stripper Feed Drum. From the PCV the inerts may go through the valve on the same level as the PCV to the EC scrubber, or the inerts may be sent through the valve at the PCV bypass height to #2 Absorber in the HC1 Plant. The tempera ture of the freon in the condenser shell is controlled by the recipro cating compressors. The normal pressure will be 24 psig,which is about 2F. Full operating controls are discussed in the refrigeration machine discussion. The vent system (Primary and Secondary Condenses) may be bypassed. The vents from the Primary and Secondary Strippers as well as the Still vent may be sent to the PCV direct. The result ,, would be a loss of EC. 9. VENT SCRUBBER A. Equipment 64A-67-20 The vent scrubber is a Haveg column 2'ID by 10' high. The material of construction is Haveg 41 composite and all gaskets are Teflon envelope with asbestos filler. The column is designed for 10 psig pressure at 200F. The column is packed with 6' of 1%" Intalox saddles. The support plate is a chemical porcelain SL 008889 U. S. Stoneware figure 808 gas injection plate, split into 3 pieces. CONFIDENTIAL: Subject to Protective Order -49- of 14th Judicial District Court The two liquid inlets are spargered into the middle of the column. The column will neutralize 5,700#/hr of HCl with 95 GFM of water. The outlet temperature should be 180F. B. Operation The vent scrubber is designed to handle a sudden loss of reaction. With the advent of the Wet HCl system it became feasible to absorb and reclaim the excess HCl, so for the great part of the time no HCl will be sent to the scrubber. When the scrubber is in use, the Cooling Tower blowdown may be used for the majority of the neutralization. Enough well water should be added to keep the outlet liquid temperature less than 180F. When the tower is not being used enough water should be added to keep a seal on the bottom as EC and N2 are continuously purged through the tower and to the vent stack. All purging of evacuated vessels, catalyst addition chamber, or Dryers will be sent through the Scrubber, out the top and to the vent stack. The vent stack is a 3" Haveg line that runs from the top of the vent scrubber to the top of the Hvs Still. The top 5' of the line is constructed of nickel pipe and 9" from the top of this is a nickel mesh flame arrestor. The vent line has a steam snuffer at the top to extinguish any fire. During electrical storms, it is expected that anytime flammables are vented, the stack vent will be ignited. When ever the vent is burning, go to the Northwest comer of the platform and open the valve in the 1,; line that takes off the steam to the Hvs Still Reboiler line just before the control station. This 1" line will inject steam into the vent and smother the fire. When the fire is extinguished, shut the steam back off. 10. PRIMARY STRIPPER FEED DRUM A. Equipment 64A-60-596 The Primary Stripper Feed Drum is 5'0" in SL 008890 CONFIDENTIAL: -50- Subject to Protective Order of I4th Judicial District Court Mo. SL 008891 diameter and 15'6" tangent to tangent. The capacity of the Drum is 2430 gallons with no outage. The design pressure is 100 psi and full vacuum at 175F. The three liquid inlet lines have anchored standlegs. The SRV is a 2J3. B. Operation The Primary Stripper Feed Drum was designed for 30 min, retention % full to full. The equalization of this tank feeds back to the inlet to the Secondary Vent Condenser. Close attention should be paid to this line. If the vent is too cold, too much HC1 will be condensed and will be boiling back off in the drum. Also, if the Vent Condenser becomes plugged, it is possible for vapors to come down the equalization line through the Drum, up the Vapor Separator condensate line and out the vent. A loop was avoided in the condensate line because corrosion pro ducts will collect and plug the loop. Liquid is removed from the bottom of the drum and pumped to the Primary Stripper through a LCV, a CaCl2 dryer, and a filter to the top of the Primary*Stripper. The Primary Stripper Feed pump is the sample point for the Primary Stripper Feed Drum. The high pressure point is in the dis charge line at the "T" and the low pressure point is on the suction header. The feed to the Primary Stripper is normally level controlled. To flow control this column would require close attention, as there is very little surge time in the feed drum. When the operation dictates that the feed should be flow controlled, it is possible to switch to the flow controller. Behind the instruments there is a 3 way valve arrangement that is marked so that the control mode may be switched from flow to level by opening and shutting the correct valves. -51- CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Should the contents of the Primary Stripper Feed drum get abnormally high in moisture, the contents of the drum may be recir culated through the dryers and back to the drum by making use of the 2" line that is located in the filter discharge manifold. This may be done with or without shutting down the stripper and may be done with either flow or level control. Probably flow control would give the smoothest operation. 11. GLAND SEAL PUMP A. Equipment 64A-55-848 The Gland Seal Pump is a Lapp Pulsafeeder CPS-1 designed for 2 GPH at 150 psig. The pump will pump up to 6.6 GPH at 450 psig. The diaphragm is Teflon as are the valve and cap gasket. The valve seat is 316 SS. B. Operation The Gland Seal Pump is to furnish a clean liquid for the seals on the Reactor Recirculation pumps. The Gland Seal Pump takes its suction from the suction line of the Primary Stripper Feed Pumps. The pump then pumps the material through a rotameter, through a back pressure valve and to the seal of the operating pump. The backpressure valve should be set to keep the gland pump discharge 5 psi above the discharge pressure of the Reactor Recirculation Pumps. The flow to the seal should be set for 2 GPH. All flow adjustments are made by varying the stroke length on the pump. Do not throttle the discharge of this pump, even though it has a built in relief valve 12. PRIMARY STRIPPER FEED DRYERS AND FILTERS SL 008892 A. Equipment 1. Dryer 64A-73-57 & 58 - The Stripper Feed Dryers are 30"OD by 6'0" tangent to tangent. The capacity of the dryers is 990# of CaCl2. The design pressure of the dryer is 150 psi to full vacuum at 200F. The SRV is a 1E2. The bottom support is 13 GA type 304SS mesh cloth located on a steel grate. (The grate is split for removal.) The Head is designed to hold up to a 24" wide fibreglass roll. The floating support is l1 expanded metal 2. Filter 64A-72-101 & 102 - The filters are 9-9/16"OD by 32" -52- CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 The filter holds 12 10" filter elements. The elements are double stacked. The housing is stainless steel, the gaskets are Teflon. The original elements are C75A105 designed to stop 75 micron. The element size is fairly independent so replacement may be made with any 10" element. B. Operation The dryers and filters are arranged so that either filter may be used with either dryer. The dryers should dry over 215,000# of fairly wet EC. Under normal conditions the dryers will last for months. High CaCl2 use indicates trouble. To empty the spent dryer the EC may be pushed from one dryer to the next with nitrogen. Besure and check pressures before tieing in the nitrogen. When pushing material out the bottom of the dryer be sure and observe the material through the bulls-eye. Any cruddy or water phase will come out first and should be disposed of as it will harm the good dryer. After all of the liquid is drained, then the material should be swept with nitrogen until no EC is left. The nitrogen purge may be sent to the vent by tieing into the vent line. There is a valve located in the vent line near the dryer area. 13. PRIMARY STRIPPER AND REBOILER A. Equipment 1. Still 64A-67-17 The Primary Stripper is a vessel 22" OD by 37*8" tangent to tangent. The skirt is 14'10". The column has 2 12' packed sections. The packing used is 1" Intalox saddles. The column internals are as follows: the top section has a hold down plate and a distribution plate at the top and a gas injection support plate and a redistribution plate at the bottom, the bottom section has a gas injection support plate at the bottom. The SRV is a 1%H3. 2. Reboiler 64A-71-781 The Primary Still Reboiler is a 8-5/8" 0D shell with 55 3/4" 13BWG tubes that are 8'0" long. Both the shell and tube are designed for 150 psi at 400F. The exchange has an expansion joint. The reboiler should vaporize 5,071#/hr of EC by condensing 793#/hr of steam at 5 psig. B. Operation The Primary Stripper is to remove the soluble HC1 from the forward EC stream. The HC1 and any other lights are taken over head from the column to the Primary Vent Condenser. The still operates SL 008893 at the system pressure of 50 psig. The feed to the column is in essence CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court SL 008894 both a feed and a reflux and is fed to the column at the top of the top section. The steam to the reboiler is flow controlled. The actual flow rate will be determined by HC1 analysis of the Hvs Still feed. Figure 5 shows a preliminary correlation and should be used until a better graph is obtained. Any increase in steam flow will increase the overheads which will increase the level in the Primary Stripper Feed Drum which in turn, increases the feed. The net result is an increase in the bottom temperature of the stripper which will result in less HC1 in the bottom stream. The purified EC is over flowed from the bottom of the still to the Heavies Still Feed Drum. The overflow system is designed to keep a constant head on the reboiler liquid and to prevent any flooding of the reboiler. This type of arrangement makes the column easy to operate but hard to start-up and shut-down. In the case of this column, small amounts of material high in HC1 content may be spilled into the Hvs Still Feed Drum without doing any harm, but the net result of continuous bad material being overflowed is a high vapor loading of the Hvs Still and condenser, a high load on the Secondary Stripper, a higher operating cost and a possible out of spec, product. There are three thermosyphon reboilers in this plant and a brief review of the principles of this type of reboilers is merited. The principle of the thermosyphon reboiler is to obtain a rapid circula tion through the exchanger tubes by vaporizing part of the liquid in the tubes and allowing the vapors to leave the top of the exchanger and enter the side of the column below the first tray or support plate. (This is the same principle that may be observed in a percolator coffee pot. The vaporized material lifts the liquid up the tube.) The vaporized material| is replaced by the liquid which comes down from the CONFIDENTIAL: Subject to Protective Order of 14th Judicial'District Court *7 n t it 0 r first tray in the still through a liquid leg into the bottom of the exchanger. This vaporization creates a natural circulation of liquid (thermosyphon) through the reboiler, thus eliminating any need for pumps. The rapid circulation rate through the exchanger accomplishes two things: First, a high rate of heat transfer to the liquid due to the high thermosyphon liquid velocity is obtained. Second, this high liquid velocity lessens the chance of the formation of scale or tars on the exchanger walls and thereby either eliminates the need for cleaning or greatly extends the time between cleanings. Three very important items must be remembered when starting up and operating a thermosyphon reboiler; First, never let a reboiler run dry or operate with a low level. This allows some or all of the tubes to become dry and heat up to the temperature of the steam. This excessively high temperature can cause baking of tars onto the tubes, decomposition of the material in the reboiler, and formation of more tars which can plug the reboiler tubes. Second, when starting up a cold reboiler, drain all accumulated steam condensate out of the shell of the exchanger and begin feeding steam slowly. The trap should be bypassed until the condenser is warmed up. Any condensate in the shell will cause a steam hammer and-hofr uLuam hitting the tubr-waids x_dxy. Third, never run a reboiler with a high level. If the liquid level gets above the vapor line, the thermosyphon action will stop and result in a drastically reduced heat transfer. Whenever a reboiler becomes flooded the steam should be shut off and the liquid level drained to an operating level. A flooded thermosyphon will develop a high steam pressure due to the loss of circulation which results in a high temperature difference and probable coking. SL 008895 "55_ CONFIDENTIAL: Subject to Protective Order of 14t> Judicial District Court No. 91-1145 C. Start-up The Primary Stripper can never be started up with a flooded reboiler as long as the overflow line is left open. To start up the column, start feed to it, when the reboiler shows an operating level slowly start steam to the reboiler; enough feed should be maintained to keep the liquid level in the column just below the overflow line. When shutting down the column, stop the steam and then stop the feed. This will allow the column to dump, but keeps the reboiler full, 14. HEAVIES STILL FEED DRUM A. Equipment 64A-60-597 The Heavies Still Feed Drum is a 9' OD by 21* tangent to tangent tank. The capacity of the tank is 10,880 gallons with no outage. The design pressure is 100 psi to full vacuum at 225F. The liquid overflow line from the Primary Stripper is the only standleg in the tank. The SRV is a 3L4. B. Operation The Heavies Still Feed Drum is designed for 2 hours retention half full to full. This drum is the only surge capacity in the plant and its purpose is to give the Hvs Still a constant feed. The Hvs Still Feed stream comes from the bottom of the drum, through the Hvs Still Feed pumps, a FCV, and to the Hvs Still feedpoints. 15. HEAVIES STILL A, Equipment 1. Heavies Still 64A-67-1S The Hvs Still is a 44" OD by 50' tangent to tangent. The skirt is 16*6". The column is designed for 100 psi to full vacuum at 300F. The column has 36 Koch Flexitrays each with 103 type "A" caps. The trays are on 12" intervals and are made of carbon steel with the bolts 410 SS and the nuts 304 SS The valve caps are 410 SS with some 14 ga and some 16 ga. The man ways are removable from either side. The feed nozzles are located on trays #20, #22, #24, or #26, reflux is on tray #36. The pot contains 6.58 gallons/inch. The SRV is a 4P6. 2. Heavies Still Reboiler 64A-71-782 The Heavies Still Reboiler is a 20" OD shell with 349 3/4" 13BWG tubes that are 10' long. The shell is designed for 150 psi.at 500F and the tubes are designed for 150 psi at 250F. The exchanger has an expansion joint. The reboiler should vaporize 327,000#/hr of EC by condensing 5,740#/hr of steam at 25 psig adding 5,369,000 Btu/hr. " - CONFIDENTIAL: -56- Subject to Protective Order t 14th Judicial District Court SL 008896 ive Order stiict C>lt 3. Heavies Still Condenser 64A-71-784 The Hvs Still Condenser is a 20" OD shell with 308 3/4" OD 14BWG tubes that are 16'long. The shell side is single pass withside to side segmental baffles at 24" intervals and the tube side is 4 pass. The design pressure of the shell side is 150 psi at 300F and the tube side 150 psi at 150f. The exchanger is designed to remove 5,250,000 Btu/hr by condensing 36,714#/hr of EC at 150F with 210,000#/hr of cooling tower water. The CTW is to be heated from 90F to 115F. 4. Heavies Still Bottom Cooler 64A-71-509 The Heavies Still Bottoms cooler is a 8" diameter shell with 48 3/4" 16 BWG tubes that are 8' long. The shell is designed for 150 psi at 250F and the tubes are designed for 150 psi at 125F. The exchanger is 1 shell pass with two tube passes. The shell baffles are on a 24 inch pitch. This exchanger is a reclaimed exchanger with a mixture of tubes in it. About 1/3 of the tubes are plugged. 5. Heavies Still Reflux Drum 64A-60-598 The Hvs Still Reflux Drum is a 5' OD by 13% tangent to tangent tank. The capacity of the drum is 2,130 gallons with no outage. The design pressure is 100 psi to full vacuum at 225F. The liquid drain from the condenser is the only standleg. The SRV is a 2J3. B. Operation The Hvs Still is to remove any heavies that might be formed in the reactor or brought in with the HC1 feed. The product EC plus any lights is taken overhead to the Hvs Still Condenser. The pressure on the column is maintained at 60 psig by a PCV on the inert discharge of the condenser. If no inerts are present then N2 will bleed into the condenser until the pressure is maintained. This is a likely spot to cause the vent condenser to overload by leaking N2 through the valve and carrying EC to the vent condenser. The heavies are collected in the bottom of the tower and periodically blown to the EDC plant disposal. Originally the bottoms will be piped to flasher system at EDC. When the exact bottoms concentration is known the final storage of bottoms will be determined. The bottoms should never be allowed to get any higher than the top of the sight glass nor any lower than the bottom of the sight glass. If the blowdown is taken from the side of the column rather than the bottom of the reboiler, too much bottoms cannot be removed. The blowdown will be taken from the bottom of the reboiler until all moisture problems are eliminated. SL 008897 -57- Subject Of 14th J The column is designed to run at a reflux ratio of 1 to 1. The feed should enter on tray #22 under normal conditions. The re- boiler is to be handled like all thermosyphons, as explained on the Primary Stripper Reboiler. Sample points are located every 4 trays to withdraw a liquid sample. Thermocouples are located every other tray in the downcomer. The normal mode of control will be steam flow controlled by the bottom temperature. In order for the column to be temperature controlled, some bottoms will have to be built up and a proper thermocouple for control located. Until the bottoms are built up the column will operate on manual. The level in the reflux drum controls the feed to the Secondary Stripper, the reflux to the Hvs Still is flow controlled. One pump pumps both the reflux and the Stripper feed. Any HC1 that is formed in the still by cracking will go with the product stream or be vented back to the Secondary Vent Condenser. 16. SECONDARY STRIPPER AND REBOILER A. Equipment 1. Still 64A-67-19 The Secondary Stripper is a vessel 22" ID by 37'8" tangent to tangent. The skirt is 12'10". The column has 2 12* packed sections. The packing used is 1" Intalox saddles. The column internals are as follows: The top section has a hold down plate and a distribution plate at the top and a gas injection support plate and a redistribution plate at the bottom. The bottom section has a gas injection support plate at the bottom. The SKV is a 1%H3. 2. Reboiler 64A-71-783 The Primary Still Reboiler is a 8-5/8" OD shell with 55 3/4" 13 BWG tubes that are 8'0" long. Both the shell and tubes are designed for 150 psi with the tube side at 250F and the shell side at 500F. The exchanger has an expansion joint. The reboiler should vaporize 4,136#/hr of EC by condensing 633#/hr of steam at 5 psig. B. Operation The Secondary Still is to remove all traces of HC1 that are in the product stream. Some HC1 will come from cracking in the Hvs Still. The Secondary Stripper is designed to remove HC1 down to 1 PHi, it is expected that the bottoms will run between 1 and 10 PPM. SL 008898 -58- SL 008899 The HCX and any other lights will go overhead from the still through a PCV to the Primary Vent Condenser. The PCV is to control the stripper pressure at 60 psig. This higher pressure will isolate it from the rest of the system and prevent surging. There is no attempt to purge any inerts into the system. As with the Primary Stripper the feed is both a feed and a reflux and is fed to the top of the first packed section. The steam to the reboiler is flow controlled and the actual flow rate will be determined by HC1 analysis of the product stream. Figure 6 shows a preliminary correlation and should be used until a better graph is obtained. If too much steam is used the result will be an increase in the operating costs of the stills, however, if too little steam is used the product will be out of spec. The column is designed to handle some rework along with the normal feed. The rework plus the feed should run less than a total of 70 GFM. The product grade EC is overflowed from the bottom of the still to the Product Surge Tank. The overflow system is designed to keep a constant head on the reboiler liquid and to prevent any flooding of the reboiler. This type of arrangement makes the column easy to operate but hard to start-up and shut-down. C. Start-Up To start up the Secondary Stripper the Product Surge Tank must be recycled back to the Hvs Still Reflux drum. Material should be fed to the Stripper until the reboiler has a level, then the feed cut way back. Slowly heat up the reboiler, but always keep the level in the bottom of the stripper overflowing. Continue to increase the steam until the Product Surge Tank contents show an acceptable HC1 content, then send the stream to the day tank. To shut down the Stripper the product stream should be sent to the Heavies Still Reflux Drum and then the steam to the reboiler stopped. CONFIDENTIAL: Subject to Protective Order 1 -59- of 14th Judicial District Court Ho. 91-1145 Because of limited surge volume available in the back end of the plant, feed to the still should be stopped before shutting down the stripper. 17. PRODUCT SURGE TANK A. Equipment 1. Product Surge Tank 64A-60-599 The Product Surge Tank is a 4' OD by 10%' tangent to tangent vessel. The capacity of the tank is 1040 gallons with no outage. The design pressure is 100 psi to full vacuum at 225F. The liquid overflow line from the Secondary Stripper is the only standleg in the tank. The SRV is a 1%H3. 2. Product Cooler 64A-71-785 The product cooler is a Brown Fintube multitube exchanger. The exchanger is Model 06-1BO00-320 There are 7 fintubes in each bundle. Each tube is 7/8 OD with a 0.083" wall and a length of 20'. The design pressure is 500 psi at 650F for both the shell and tube. The surface area is 261.1 ft . The exchanger is to cool 15,221#/hr (35.2GFM) of EC from 139F to 110F by heating 21.6 GFM of CTW from 90F to 115F. B. Operation The Product Surge tank is level controlled. The product stream is pumped through a level control valve, through the Product Cooler and to the Day Tank Area. Under the Product Cooler there is a valve with an extension handle on it. This valve is the last valve before the day tank valves, and should be closed whenever any material is being reworked to prevent the reworked material from contaminating the line. The rework line (line #507) begins in the storage area at the Rework Pump and goes all the way through the area to the feed line to the Flasher Dopp. From this line the material may be fed to the Flasher Dopp or to the reactor. The rework line has ties to the suction and discharge of the Primary Stripper Feed Pumps, the Hvs Still Feed Pumps, the Hvs Still Reflux Pumps, and a tie from the discharge of the Product Cooler. By the use of this rework line material can be moved to any part of the plant from any part of the plant. SL 008900 -60- CONFIDENTIAL: Subject to Protective Order i4th Judicial District Court Ho. 91-1145 18. PAY TANK AREA SYSTEM A. Equipment 1. Day Tanks 64A-60-604, -605, -606, -607 Each Day tanV is 12' OD by 54'8" seam to seam. The capacity of each tank is 52,270 gallons with no outage. The design pressure is 75 psi and full vacuum at 225F. The SRV is a 6R8. The production line and the 3" recirculation lines are the only standlegs. 2. Vent Compressor 64A-56-145 The vent compressor is a Corken Model D-290-107 with no aluminum parts. The compressor operates at 850 RHi and compresses 12,7 CFM at 90F from 40 psig to 200 psig. This compression requires a 1\ hp, 1850 RPM motor. The SRV is a Farris model 2740 set at 250 psig. 3. Storage Vent Condenser 64A-71-789 The Storage Vent condenser is 6" OD with 10' U-tubes. The shell side is single pass with side to side segmental baffles at 6" intervals. The tube side is 4 pass. The design pressure of the shell side is 200 psi and the tube side 150 psi, both at -15F. There are 6 3/4" OD x 14BWG seamless steel U tubes. The exchanger is designed to give 15F inerts leaving at 200 psi. The SRV is a 1D2. 4. Transfer Pumps 64A-55-849.-850 The transfer pumps are designed to pump 250 gallons apiece at 125' of head. The pumps are Gould's 3196 2 x 3-6 with a 5-3/4" impeller. 5. Rework Pump 64A-55-851 The rework pump is designed to pump 40 GPM at 200' of head. The pump is a Gould's 3196 1 x 2-8 with a 7" impeller. B. Operation The day tanks are designed to hold approximately 1 days production. Actually with a 10% outage the tanks will hold about 22 hours of production at design rates. The tanks are designed for a common equalization system, and for this reason care should be taken to see that a tank is never isolated. If for any reason a tank is isolated, a close watch on the tank should be maintained to prevent either over or under pressurization. Each tank is equipped with a Varec and a level transmitter. If trouble with the Varec is suspected there are taps on the level transmitter system for a temporary sight glass installation. There are two withdrawal lines on each tank. One line goes to the rework pump which will pump EC back to the process area. The other line goes to the transfer pumps where the EC may be SL 008901 pumped back to any of the tanks or to the tan! car loading facilities or to the Horton Spheres. EC may be pumped back from the Horton Spheres, or pressurized from a tank car, bypassing the pumps into the pump suction -61- CONFIDENTIALi Subject to Protective Order of 14th Judicial District Court 1 14n i _ C line and from this line into any tank. The transfer pump suction line is insulated to prevent EC from vaporizing in the suction line when the pumps are not in use. Some trouble may be ex perienced with the rework pump in getting it to start pumping. When this happens it is best to try to fill the suction line with cool EC. The material in the dock line will normally float against one of the spheres. ANYTIME THE LINE IS CLOSED GOING INTO THE SPHERES THE BLOCK VALVE IN THE BYPASS ABOUND THE PUMPS AND THE SUCTION BLOCK VALVE ON ONE TANK SHOULD BE OPENED TO GIVE EXPANDING EC A PLACE TO GO. Under normal conditions both suction lines on the bottom of each tank will have the valve closed. Due to flucuating levels in the tanks and sudden temperature changes, it was necessary to install a vent system for the tanks. The vent system will bleed in nitrogen when the pressure is low and will purge Ng and EC when the pressure is high. To prevent a loss of a large amount of EC a compressor and a refrigerated con denser were installed. Whenever the pressure in the Day Tank vent system goes below 15 psig, nitrogen will be bled into the system. Whenever the pressure goes above-40s psig (this pressure will depend upon what is acceptable to our customers), a valve will open in the suction line to the compressor and the compressor will start-up. 1*7 ^ The compressor discharges to the vent condenser where psig is maintained by a PCV in the inert gas discharge of the condenser. Brine from the HC1 plant at 5 F. is circulated through the tubes of the condenser. The inert discharge should run about 15 F. The condensate goes through a float chamber, a LCV, and to #3 or #4 Day Tank. The float chamber and LCV prevent vapors from the tanks irom SL 008902 * CONFIDENTIAL: Subject to Protective Order Qt 14th Judicial District Court to. 91-1145 entering the condenser and artificially loading the condenser. The vent compressor has a distance piece which is swept with Nj from one side with the Inerts and any leakage leaving the other side and going to the vent. There is a nitrogen PCV that will bleed into the vent condenser whenever the pressure in the con denser is less than^tpsig. The compressor may be bypassed, if necessary, with a resultant loss of EC. The tank car loading area has a line to the suction of the compressor. Material should be pulled from the tank car and put through the vent system only after analysis has shown the material to be iij spec. Any off-spec material should either bypass the vent system, or if it is put through the vent system, the condensate should not be collected in the day tank. Anytime off-spec material is being sent through the vent system, be sure and isolate each tank from the system to prevent further contamination. Anytime a tank is to be opened up, the compressor will be used to pull a vacuum on the tank. After a vacuum has been pulled, the tank is to be purged with nitrogen; and since there should be little EC in the N^, this purge may be sent straight to the vent condenser. (The venting pressure will have to be lowered to a pressure less than the pressure.) When the vessel purge shows no flammables, then the tank should be isolated and air purged through it if it is to be entered. 19. DOCK AREA SYSTEM A. Equipment 1. Horton Spheres 64A-60-610. -620 Each Horton Sphere is 43%' in diameter. The capacity of each tank is 323,000 gallons with no outage (at 85% full 275,000 gallons). The design pressure of the spheres is 75 psi at ambient temperatures. The vacuum rating is 6.39 psi vacuum. There are no standlegs. The SRV is a 8T10. CONFIDENTIAL: Subject to Protective Order SL 008903 "63- of 14th Judicial District Court No. 91-1145 SL 008904 2. Atwood-Morrill Excess Flow Valves These valves are la the barge loading line to prevent the contents of the sphere from being dumped Into the lake In case of a rupture during loading. The valves will allow up to 1000 GFM to flow before closing. 3. Turbine Flow Meters These are Foxboro Turbine Flow Meters, Model 81-F5A1-4, nominal 4" size, range is 18 to 1050 GIM. 4. York Refrigeration Unit The York compressor is a 10-ton unit designed to cool 60 GIM of brine from 5 F. to 0 F. The unit includes: A. Compressor, 64A-56-128, York Model FX 3049-5BE, 3 3/4" x 3", 4 cylinder V/W Refrigerant 22 compressor operating at 1170 RIM. This unit has an automatic 50% capacity reducer, a forced feed lubrication system, an oil filter, an oil heater, suction strainer, internal relief valve and the other normal accessories. B. The condenser, 64A-71-541, is a York Model 805 4-pa#s horizontal Shell and tube type with copper tubes and tube sheets, steel shell, cast iron water heads and relief valve. The total area is 101 ft. . The exchanger is 8 5/8 diameter with 37 5/8" tubes, 5 %' long. The tubes are extruded fin copper tubes. Th shell side is designed for 300 psi; the tube side for 150 psi. C. The Brine Cooler, 64A-70-49, is a model C1208, 4-tpass horizontal shell and tube flooded type furnished with 16 gauge extruded finned steel tubes, steel shell, cast iron water heads, bullseye sight glass, relief valve, float controller and an area of 190 ft.The exchanger is 12" diameter, with 48 3/4" extruded fin, seamless steel tubes. The shell is designed for 225 psi at 300 F. and the tubes for 150 psi at 120 F. 5. Brine Circulation Pumps - 64A-55-654 & 655 The brine circulating pumps are designed for each pump to pump 57 GIM at 78* of head. The pumps are Durco DCHD1R 1^ x 2-9 with 8%" impellers. 6. Barge Loading Pumps - 64A-55-858 & 859 The loading pumps are designed for each pump to pump 600 GIM at 100' of head. The pumps are Gotilds 3196, size 3 x 4-11 with 10 11/16" Impellers. 7. Vent Compressor - 64A-56-147 The dock area vent compressor is a Corken Model D-490-107 with no aluminum parts. The compr ssor operates at 850 RIM and compresses 27.3 CFM from 40 psig and 90 F. to 200 psig. This compressor requires a 20 HP, 1850 RIM motor. The SRV is a 3/4" Farris 2740 set at 250 psig. 8. Dock Storage Vent Condenser - 64A-71-930 The dock storage vent condenser is 8 5/8"OD with 8' U-'tubes". Ttie^shell side is single pass with side to side segmental baffles at 6" intervals. The tube side is 2-pass. The design pressure of the shell is 300 psi at -20 F. and the tube side is 150 psl at -20F. There are 20 3/4" OD x 16 BWG seamless steel U-tubes. The exchanger is designed to give 15 F. inerts leaving at 200 psi. The SRV is a 1DZ. 9. Vent Condensate Receiver - 64A-60-609 The vent condensate tank is 36" ID by 7'10" tan to tan. The capacity of the tank is 425 gallons with no outage. The design pressure of the tank is 275 psi to full vacuum at -20 F. The SRV is a 1 1/2F2. The vessel has one standleg which is the condensate line. The sight glass is a frost-free. CONFIDENTIAL: 64- Subject to Protective Order of 14th Judicial District Court No. 91-1145 10. Vent Condensate Pump - 64A-55-639 The Vent Condensate Pump Is designed to pump 10 GPM at 109' of head at 3450 RFM. The pump will run at 1750 RPM. The pump is an Ingersoll-Rand 1CRVM with a 5%" impeller. B. Operation Each Horton Sphere is designed to hold one barge- load of material. Both barge tanks are to be loaded out of one sphere. From the sphere to the suction of each pump is a common line. Each barge tank is fed through an individual line from each pump. Since the EC spheres cannot be taped before each shipment, an accurate means of determining the amount of EC shipped was needed. . It was felt that Verac gauges on the spheres would serve if they were double checked. To check the Verac a flow meter was installed in the loading lines. The flow meters will also serve to keep the barge tanks filled equally. The rate of flow can be read as total gallons through each turbine meter. At the pump discharge there is an equalizing line between the two pump discharge lines. Once the EC is past this point, it flows in separate lines through the turbine meters to the barge tanks. When it is desired to pump EC back to the plant, it may be pumped from the discharge equalizing line through the 3" line into the transfer line. With the lines closed going into the spheres the EC will come back to the area. When it is desired to recirculate a sphere or transfer from one sphere to another, the EC is pumped through the equalizing line into the transfer line, with the appropriate sphere opened and the Day tanks and the other sphere closed. This line is also used for expansion liquor also. When the barge is finished being loaded, the block 89o$ valves at the loading arm and at the sphere bottom are closed. Tha- --*|lt 1f-Hn^ l i > - This allows any thermo- __ expansion of the liquid in the barge lines to the sphere. CO Subject to Protective Order of 14th Judicial District Court . -65- NO. 91-1145 From the turbine meters the EC flows underground to the EC loading dock. At the dock the EC flows through an excess flow valve, through the loading arm and into the barge tank. The ex cess flow valve is an Atwood-Morrill and should allow up to 1000 GIW to flow through before closing. This valve works on the principle of comparing the flow through the valve against the downstream pressure. When the pressure difference becomes greater than the designed A P, the valve will close. The valve is opened by switching the downstream pressure tap to the upstream side by means of a manifold. (The manifold is a 3-way valve activated by a foot pedal.) When the barge is being filled, the displaced gases will return to the top of the sphere the liquid is being removed from. For this reason the chemical analysis of a barge vapor space must be known before it is equalized back to the tanks. If the vapors are contaminated they could contaminate a sphere of good material, as well as get impurities into the sphere to contaminate pure EC that is put into the sphere later on. For this reason the sphere that is not being loaded from should be isolated. DO NOT FORGET TO PUT THE SPHERE BACK INTO THE VENT SYSTEM AFTER LOADING. If analysis shows impurities in the barge vapors, the vapor may be sent direct to the vent recovery system. The vent compressor may be used to pull the vapors from the barge, but will not pull the vapors fast enough to load the barge at the same time. When it is desired to transfer material from a barge to the sphere, only one loading line can be used and that is the line from SL 008906 -66- 0 the western loading arm (line 645). Material transferred back through this line does not flow through the turbine meter. The north meter run will be blocked, forcing the returned EC to flow through the 6" takeoff at the meter run downstream block valve. From the takeoff the returned EC will flow through two block valves and into the 12" pump suction line and then to whichever sphere is open. In between the two block valves on this return line is a bleed. Whenever the line is not being used, the block valves will be closed and the bleed open. This is to assure that all EC flowing through the turbine meter enters the barge. The vent system on the spheres is the same as the system on the day tanks. The system will bleed in nitrogen when the pressure is low and purge nitrogen and EC when the pressure is high. To prevent a loss of a large amount of EC a compressor and a refrigerated condenser were installed. Whenever the pressure in the spheres goes below 15 psig, nitrogen will bleed into the system. Whenever the pressure goes above 30 psig (this pressure is dependent on accept ability to the customer) a valve will open in the compressor suction line and the compressor will start up. The compressor discharges through a water cooler to the vent condenser where 200 psig is maintained by a PCV in the inert gas discharge of the condenser. Brine from the refrigeration unit is circulated through the tubes of the condenser. The inert gas discharge should run about 15 F. The condensate' is gravity fed to the Vent Condensate Receiver. Since the receiver vapors can return to the condenser, the material o in the receiver will be near 0 F. and any samples of this material will expand when warmed to ambient temperature, so be extremely SL 008907 "67` CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 careful in collecting a sample. When the Vent Condensate Receiver is nearly full, a sample of the material will be analyzed; and if it is in spec, the material will be pumped to a sphere. If the condensate is out of spec, it will have to be disposed of, probably back to the Bottoms Dopp Kettle. Whenever the pressure on the vent condenser goes below 5 psig, nitrogen will be bled into the condenser. The inerts from the PCV go to a vent stack to be vented to the at mosphere. The vent compressor has a distance piece which is swept with nitrogen, and this nitrogen along with any EC is vented from the vent stack. The vent compressor may be bypassed, with a much higher loss of EC resulting. When one is full and the second sphere is nearly full, the transfer rate from a day tank might have to be slowed down to about 200 GR1. The compressor will handle gases dis placed by a liquid at 200 GFM. If it is imperative that the normal transfer rate be held, then someone will have to bypass the compressor and lower the setting on the vent condenser inert PCV from 200 psig to 45 psig. This will result in EC being vented, and appropriate steps should be taken to see that the EC doesn't carry into an area where a spark might start a fire. The refrigeration unit is a 10-ton unit built by York. This is the same unit that was in the old HC1 plant. The unit has a 50% un loader, and a 100% shutdown. The unit when operating on automatic o will 50% shut down when the brine temperature is 0 F. and will shut down when the brine temperature is -8 F. When the unit is on manual, the 100% unloader is bypassed, but another low temperature cutout will operate when the brine temperature is -15 F. When the unit shuts down due to low temperature, it will start back up by itself. SL 008908 CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court No. 91^1145 To start the York unit, put water on the Freon condenser, start brine to recirculate (be sure the brine has no load on it until the temperature is down around 5 F). Operate compressor at 50% capacity or throttle suction valve to prevent motor overload during pulldown. Place HOA switch in auto position. This will allow compressor to operate and maintain correct brine outlet temperature. Compressor will start and stop automatically. The compressor will operate at 100% capacity cooling brine oo from 5 F. to 0 F. and on drop in brine temperature near setting desired, the compressor will operate at 50% capacity. This re duction in capacity will prevent excessive short cycling. Should temperature continue to drop to setting of operating thermostat in i automatic circuit, then compressor will automatically stop. As brine temperature warms to thermostat high setting, compressor will again start. To shut system down, place HOA switch in off position. Stop brine pump. Compressor operation is protected with High and Low pressure cutout in R-22 system. In case of high pressure cutout (caused from lack of condenser water,dirty condenser tubes - closed valves); the system can or should be started after correction is made. This is accomplished by a reset button. High pressure cutout setting is 240 psig. Low pressure cutout setting is 12 psig and cut in at 20 psig. In case of oil failure, the compressor will stop and can only he restarted by reset button in cover. (Min. 5 minutes) The cause SL 008909 CONFIDENTIAL*. Subject to Protective Order f 1.4th Judicial District Court No. 91-1145 of oil failure should be checked to see that system oil is suf ficient for operation in compressor base and oil receiver. Oil pressure cutout setting at 20 psi pressure differential between oil pressure and suction pressure and cut in at 30 psi differential. A third thermostat is also provided with a setting lower than the other two thermostats for protection of tubes in brine o cooler. This setting of -15 F. is Above the freezing point of the brine mixture used. This is an emergency thermostat only and will allow the machine to restart when temperature increases to a safe setting of the thermostat. Solenoid valve on oil receiver will open when compressor starts and will close when compressor stops. A hand throttling valve located in the oil line is to be throttled so as to allow oil (mixed with Freon) to flow from the cooler to the oil receiver in a small quantity to allow 2,000 watt oil heater to go on and off periodically. Approxi mately 7 minutes on and off is satisfactory. Oil heater in compressor base is on when compressor is shut down and off when compressor is in operation. The oil heater in oil receiver is on and off continuously to boil Freon off and leave only oil for compressor operation. This circuit should be closed at all times. Pilot light is lit when heater is on. Refrigerant level in the cooler is controlled with H,P. float drainer. Float will open when liquid Freon is condensed in con denser and allow refrigerant to flow to the cooler. System should be charged for operating charge only, so that refrigerant level in the cooler under full load conditions is high enough to wet top row of tubes. Observe level through cooler sight glasses. Excessive SL 008910 -70- confienti*V* cou: charge of Freon will cause slop over on machine and cause serious damage. System should be completely evacuated of all moisture before charging with R-22. See printed Service Instructions for evacu ating procedure. Services of York Service Engineer should be called upon in getting system ready for charge of ft-12 and start up. With all of the equipment at the dock, there is only one alarm. This alarm is sphere high pressure, and it is located on the EC panel board. Whenever anything goes wrong with the brine or re frigerated unit, the ultimate result will be a high pressure, but this might not show up for a long time. For this reason the round made at the dock area should include a close check of all equipment. The valving in the dock area is extremely important and should be left in only one way when no one is in the dock area. The valving is as follows: . 1. The 12" suction lines to the pumps are closed except when in use. 2. The vent system is open from both tanks to the vent stack, except for the PCV's. The route is through the compressor and the vent condenser. 3. The barge loading lines are closed at the loading arm and allowed to equalize back to the spheres through the thermo-expansion equalizing line. 4. The transfer line is always open to one sphere except when loading a barge. Last but not least, whenever pulling the sphere pressure down with the compressor, never pull down to a vacuum. SL 008911 -71- CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court No. 91-1145 20. COOLING TOWER A. Equipment 20A-71-790 The cooling tower Is a Fluor Model 1F60E-144-2424 C4P counterflow with a 6* parabolic fan stack, red wood distribution pipes, polypropylene nozzles, polypropylene ("Poly-Grid) fill, vibration cut-out switch, sheathed with 8 oz, corrugated fiberglass reinforced polyester, adjustable pitch SS fan with 4, 14' blades to run at 229 RPM, 112 hp Thomas Flexable Coupling and a FW45A speed reducer. The tower is one cell 24' x 24' and 35' high constructed of heart redwood, and treated to 0.75#/ft. retention with Erdalith. The tower will cool 3,000 GEM of water from 115 F. to 90F. The fan motor will operate at 1750 or 825 REM requiring 40/10 hp. B. Operation Excessive vibration will shut the cooling tower down. Anytime it shuts itself down, open the vibration switch box (by the fan motor) and see if it is tripped. Other than this, there is very little else that can go wrong with the tower. Rocks and dirt can plug the distribution section. The water in the basin should not be allowed to be cooler than 75F. During winter months the fan can be slowed down and if the basin water is still too cold, the louvers on the air intake may be arranged to allow only a small amount of air to enter the tower. During hard freezes the north side of the tower should be blocked off to prevent icing. The cooling tower water treatment and blow down will depend on the chemicals used and the hardness of #8 well. The control levels will be given by the operating foreman. The make-up water for the tower comes from a water-cooled con denser in the EC plant. Normally all water flowing through the condenser will be sent to the tower. When this water flowrate causes the basin to overflow, then some of the cooling water should be diverted to the sewer. This is done at the chemical addition basin on the east side of the cooling tower. When the cooling tower make-up requires more water than the condenser requires, then a float control valve will add the extra water automatically. The CONFIDENTIAL: SL 008Q 1 7 -72- Subject to Protective Order 03of 14th Judicial District Court No. 91-1145 21. REFRIGERATION UNIT A. Equipment 1. Compressors - 64A-56-143 & 146 The EC refrigeration compressors are Carrier 5H80, reciprocating complete with automatic cylinder unloaders. The compressors will operate at 1160 RIM with a dis charge pressure of 228 psig and a suction pressure of 24 psig. The refrigerant used will be F-22. 2. Freon Condenser - 64A-71-775 Carrier 5H100 shell and tube with copper tubes, steel tube sheets, 14" Qu shell, 97 3/4" long with 6 water passes. The condenser is designed to remove 630,000 Btu/hr. by heating 110 GM of CTW from 90 F. to 103 F. 3. Motors are 40 hp. 1200 RIM 4. Liquid level control valve. B. Operation Like all compressors there are two cardinal rules to observe. 1. Never start the compressor with the discharge valve closed. 2. Never run the compressor with liquid in the suction line. The EC refrigeration requirements were such that one unit would not do the job. By running two units in parallel, and using Freon 22, a full 35 tons of refrigeration could be achieved. The suction of the compressors is 24 psig and 0 F., while the discharge is 229 psig. Whenever both units are in operation the oil equalizer as well as the gas equalizer must be open. If these plug or are closed, all of the oil will accumulate in one compressor, causing damage to the other. Each compressor is equipped with an unloading device, activated by the suction pressure, which allows the compressor cylinders to be cut out one at a time to reduce the capacity of the unit stepwise. This system is used to avoid excessive "on-off cycling" of the compressor when operating at low capacities. The capacity control valve is located on the compressor end cover at the opposite SL 008913 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91' -5 end from the compressor drive. When this valve is turned counter clockwise as far as it will go, all eight cylinders are in operation and the compressor is fully loaded. By turning the valve clockwise, the cylinders are unloaded one at a time until only two cylinders are left loaded. This can lower the capacity of each compressor by one-fourth. Safety control devices on the compressor include an oil failure switch which shuts off the compressor motor if the differential be tween the oil pressure and the compressor section pressure drops below 35 psi. This switch has a line delay device which takes approximately 1 minute to cut the motor power after the oil pressure drops. This is a thermal switch which must be given 3 minutes to cool before it will reset. The compressor also has a high discharge pressure cut-off which cuts off the compressor driver if the compressor head pressure goes above 260 psig. This cut-off resets at 200 psig. A low suction pressure cut-off is also used to stop the compressor if the suction pressure drops below 15. This resets at 30 psig. Other auxiliaries on the compressors are an oil filter, a crank case heater and a suction strainer. The crankcase heater comes on automatically when the compressor drive is turned off. This keeps the compressor oil warm so that the Freon will not dissolve in it while the unit is down and cool. The heater is turned off auto matically when the compressor drive is turned on. The suction strainer is located in the suction line. During the initial start-up of the machine, the strainer will be equipped with a felt sock to filter out scale and particles present in new piping. This sock should be changed after the first 50 hours of operation. If it is clean, leave it out; if not replace it for another 50 hours. SL 008914 -74 COHPlOEHTlALt Subject to Protective Order or 14til Judicial District Court No. The compressor heads are cooled by circulating a stream of well water through them. The well water should be throttled to give the discharge water a temperature of about 100 F. The compressed Freon leaves the compressor as a gas and enters the Freon condenser where it is condensed. The liquid leaves the bottom of the condenser, flows through a level control valve, through a filter dryer and into the bottom of theSecondary Vent Condenser. The LCV is controlled by a small float chamber located under the condenser. The Secondary Vent Condenser is the Freon surge tank and enough Freon should be kept in the system to keep all of the tubes in the Secondary Vent Condenser covered. From the bottom of the Secondary Vent Condenser a 3/8" line returns to the compressor suction line. This is the oil return line. The oil will settle at the bottexn of the Secondary Vent Condenser and must be returned to the compressors. The oil return line must never be left open when the compressors are down. For this reason, there is a solenoid in the line that will shut whenever neither compressor is running. Do not depend on this solenoid. Always close the block valve in this line just before stopping the compressor. When the compressors or compressor is running, the block valve should be open about \ of a turn. Enough steam should be on the line to keep the oil about ambient temperature out of the heated area. If the oil level in the compressors continues to fall, then open up the throttling valve in the oil line a little more. It is well to remember that Freon can flow down this line as well as oil, if the valve is opened too much; and if this Freon is not vaporized, it will fall into the cylinders and cause the heads of the compressor to be blown off. SL 008915 -75- CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 INSTRUMENTATION General One of the major requirements in a plant like the EC plant is smooth, uninterrupted control of the plant streams in order to ob tain specification grade product. A distillation column cannot be operated with varying flows. Columns like the Heavies Still can take hours to level out after an upset, and rapid changes in operating con ditions can cause such upsets with resulting poor quality product. To obtain the desired type of control, the EC plant has been equipped with automatic instruments wherever practical. A thorough job of instrumentation has been done on this plant, but certain points must be understood to get full and efficient use of the instruments. The instruments are the operator's tools, and how he uses them determines how efficiently the plant will operate and how good will be the quality of the product produced. All important control points in the EC plant are transmitted to the operating room where they are continuously recorded or indicated. The first indication of trouble within the plant will generally be from these Instruments. These should be continuously checked for Indications of abnormalities. Most of the records and/or indicators will be read and logged on the data sheets. The instruments serve as your safety guard. All points in the plant which can cause serious trouble or operating difficulties have been equipped with alarm devices to give warning when abnormalities occur. If an alarm sounds for any reason, it should be checked immediately. DO NOT IGNORE THE WARNING SYSTEM. It is there for your protection as well as for protection of the equipment. SL 008916 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Alarm System When an abnormality occurs, it will be alarmed by a horn blowing and by a flashing light on the panel board. Under normal operation, the warning lights will show green as long as a piece of equipment is in operation. If a high flow, high pressure, high level, etc., occurs, the horn will blow and the warning light will flash red. If a low flow, low pressure, or low level occurs, the horn will blow and the warning light will flash amber. Pumps are also connected to warning lights. As long as a pump is in operation, the light on the panel board will show green. If for any reason a pump is shut down or stops, the light will flash red. In almost all motors in the area, the alarm horn will blow in addition to the flashing light. The motors that are not connected to the horn are on intermittent service and not continuously operating units. The horn will continue to blow and the light flash until an acknowledge ment is made. This is done by pressing the acknowledgement button located at the bottom center of the panel board. When this button is pressed, the horn will stop and the light will stop flashing. But, until the trouble is corrected, the light will show either red or amber, depending upon the nature of the trouble. When the correction is made, it will change back to green. Checking Alarms A failure in the alarm system could result in serious trouble. For this reason, the alarm system should be checked periodically to be sure it is functioning properly. To check it, pull out on the acknowledgement button and turn it to the high alarm. Check all warning lights to see if they show red. If they do not, there is either a burned-out bulb or a defect in the circuit - either of which should be corrected immediately. Repeat this procedure for both the SL 008917 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court o. 91-1145 normal and low alarm position. Make this check at least once per shift. Safe operation depends upon this sytem's functioning properly. Recorder-Controller Operation The recorder-controller instruments are Taylor Transcope Recording Receivers and are provided with manual and automatic operation. Under normal conditions, these will be operated on automatic control, but during start-up or shutdown, or possibly in the case of trouble, the manual control can be used. When on manual control, the process valve can be operated from the panel board by regulating the output pressure to the control valve with the set point adjusting knob on the lower right hand corner of the instrument facing. The automatic valves go from full open to full close (or vice versa in the case of an air pressure closing valve) at an output air pressure variation of 15 to 3 psig. This pressure is indicated on the scale at the top of the controller (on the Instrument facing at the panel board.) The approximate opening of the valve is indicated by this scale, i.e., 9 psig output is half open, 6 psig and 12 psig are 1/4 and 3/4 open or vice versa, depending on valve action. The output pressure will remain at the value set by the set point adjusting knob while the instrument is on manual control, and the valve opening will not vary. When the instrument is on automatic control, the set point is ad justed to the desired control point by the set point adjusting knob. The Instrument will then attempt to regulate the process to this control point by opening or closing the automatic valve. At proper control, the set point and the indicator pen wiTjL remain opposite each other. The if opening or the closing of the automatic valve to maintain this condition will be shown by the variation in output air pressure. SL 008918 -78- CONP1DENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 The recorder-controllers can be readily switched from manual to automatic, or from automatic to manual control, but care must be exercised when doing this. If the indicated control point and the instrument set point do not correspond when the switch is made, a snap action of the automatic valve will occur. This will serve to upset the system as well as being hard on the instruments. The following procedures should be followed when making the transfer to avoid "bumping" the system during the change-over. Manual to Automatic l..Set the transfer lever at the "Seal" position. This isolates the control valve from the controller air circuits and seals the pressure that is on the control valve at that time. 2. Adjust the set point adjusting knob until the set pointer indicates the same output pressure as the output gauge. 3. Set the transfer lever to the "Automatic" position. The process is now on automatic control. Automatic to Manual 1. Note the output pressure and then set the transfer lever at the "Seal" position. 2. Adjust the set pointer with the set point adjusting knob until it corresponds to the same pressure as noted in step one. 3. Set the transfer lever to the manual position. The process is now on manual control. Set Point Changes The number one rule for operation of this type of plant is smooth steady control. The purpose of automatic instruments is to provide this control and they should be handled with this in mind. The instrument set point can be set at the desired control point, and the instrument will regulate the control valve until this point corresponds to what is actually occuring in the process. By raising or lowering the set point, the control point is changed accordingly. SL 008919 *79- COHPIt>BTl,'V! nrAer Select to rrotect.v,^ ^ . It must be remembered though, that when a set point change is made, the instrument will attempt to correct for this change immediately. If a large change is made, this could result in complete opening or closing of the automatic valve which could be severe enough to upset the system. Use small stepwise adjustments and give the system time to "catch-up" before making the next step. This will result in a smooth change and little cycling of the process. SL 008920 -80- PUMPS Pumv Manufacturer Vent Condensate Ingersoll-Rand Reactor Recirc. Goulds 3189 Primary Stripper Feed Goulds 3196 Hvs. Still Feed Goulds 3196 Hvs. Still Re flux Goulds 3196 Product Pump Goulds 3196 Gland Flush Lapp Transfer Goulds 3196 Rework Goulds 3196 Cooling Tower Goulds 3406 Sanitary Hydr-O-Matic Barge Ldg. Goulds 3196 Dock Brine Recirc. Durco Size 1 CRUN 8x10-11 Impeller CaDacitv Head 5 1/2 10 GPM 109 @3450 10" 1928 GIM 75* Motor 1 HP 40 HP 1x2-6 1x2-6 5 3/8" 5 3/4" 46 GPM 43 GPM 115' 136* 5 HP 5 HP 1%x3-6 5 1/8" 90 GPM 105' 1x2-6 4 1/2" 38 GPM 80' CPS-1 2 GPH 150 psig 2x3-6 1x2-8 5 3/4" yri 250 GPM 40 GPM 125' 200' 6x8-14 14 1/8" 2000 GPM 150' 3x3 Self- 7 5/32" 100 GPM Priming 3x4-11 10 11/16" 600 GPM 50' 100' DCHD1R 8 1/2" 1% x 2-9 57 GPM 78' 5 HP 3 HP 1/3 HP 15 HP 10 HP 100 HP 5 HP 20 HP 5 HP SL 008921 -81 COWTSuve order ct to protectIV Cou! ANALYTICAL PROCEDURE FOR ETHYL CHLORIDE OPERATION METHOD EC-LC-1 1. TEST: Ferrous and Ferric Iron as FeCl^ 2. SAMPLE: Ethvl Chloride Reactor Crude 3. SAFETY PRECAUTIONS: Chlorinated hydrocarbons are toxic and breathing of vapors and repeated contact of liquid with skin should be avoided. FLAMMABLE! 4. APPARATUS & REAGENTS: a. Bausch & Lomb, Model Spectronic 20, 25 Ml curvettes b. 1.0 Ml pipette c. 100 Ml volumetric flasks d. 50.0 Ml volumetric flasks (2) e. 2.0 Ml pipette f. 5.0 Ml plpetters (3) g. Ethanol, 95% h. Hydroxylamine hydrochloride, 10% i. Ortho-Phenanthroline, 0.3% j. Potassium acid phthalate, 4% 5. PROCEDURE - GENERAL: a. Chill a 1.0 ml pipette in dry ice chest. b. Pipette 1.0 ml of chilled liquid ethyl chloride into approximately 50.0 mis. of 95% ethyl alcohol in a 100 ml volumetric flask. c. Make up to volume with 95% ethyl alcohol. PROCEDURE - FERROUS IRON a. Pipette 2.0 ml of above dilution into a 50 ml volumetric flask. b. Add 5.0 mis of 4% potassium acid phthalate. c. Dilute to volume with 95% ethyl alcohol. _82- CONFIDENTIAL: Subject to Protective SL 008922 of nth Judicial District Court 'I No. 91-11^5 PROCEDURE - TOTAL IRON: a. Pipette 2.0 ml of dilution into a 50 ml volumetric flAsk. b. Add 5.0 ml of 4% potassium acid phthalate, 5.0 ml of 10% hydrochloride and 5.0 ml ortho-phenanthroline. c. Dilute to volume with 95% ethyl alcohol. d. Measure absorbance of resulting solutions within 30 minutes at 512 mu using a distilled water blank. CALCULATIONS: **6 Each absorbance unit is equivalent to 353 x 10 GMS of total iron as FeCl^. FERROUS IRON AS FeC^: %FeCl2 = Absorbance x 353 x 10 ^ x 100 Wt. of Sample %FeCl = Absorbance x 0.0353 Absorbance x 19.3 = % FeCl J .00ml x 0.917 J TOTAL IRON AS FeCl^: -6 %FeCl3 = Absorbance x 353 x 10 x 100 Wt. of Sample %FeCl_ = Absorbance x 0.0353 Absorbance x 19.3 = % FeCl 0.002 ml x 0.917 J FERRIS IRON AS FeCl^: % FeCl^ = % total - % Ferrous SL 008923 -83- ANALYTICAL PROCEDURE FOR ETHYL CHLORIDE OPERATION METHOD EC-LC-2 1. TEST: HC1 Determination in Liquid Ethyl Chloride 2. SAMPLE: a. Primary Stripper Product b. Heavies Still Overhead c. Secondary Stripper Bottoms 3. SAFETY PRECAUTIONS: Chlorinated hydrocarbons are toxic and breathing of vapors and repeated contact of liquid with skin should be avoided. FLAMMABLE] 4. APPARATUS & REAGENTS: a. Mag-Mix b. Teflon covered stirring bar c. 2.0 ml pipette d. 250 ml beaker e. Sodium Hydroxide, 0.10N f. Phenophthalein indicator 5. PROCEDURE: 1. Chill a 2.0 ml pipette and approximately 150 mis. distilled water in a 250 ml beaker in dry ice chest. 2. Pipette 2.0 ml of chilled liquid ethyl chloride into the chilled H 0 while stirring with Mag-Mix. 2 3. Stir approximately 2.0 minutes. 4. Titrate to a Fhenolphthaleln end point with 0.10 N NaOH. 5. Record titer. CALCULATION: 7. HC1 = T x N x 0.03647 x 100 Wt. of Sample % HC1 - T x 0.3647 = T x 0.20 2.0 x 0.903 6 ppm HC1 T x N x 0,03647 x 10 Wt. of sample T x 36470 2.0 x 0.903 SL 008924 ppm HC1 - T x 2000 READ % HC1 OR m HC1 FROM CHART -84- CONFIDENTIAL* biect to Protective Order 4th Judicial District Cour No. 91-1145 ANALYTICAL PROCEDURE FOR ETHYL CHLORIDE OPERATION METHOD EC-LC-3 1* TEST: HC1 Determination in Vent Gas 2. SAMPLE: a. Reactor Vent Gas b. Plant Vent Gas 3. SAFETY PRECAUTIONS: There will be some EC gases in the vent and should be treated as a toxic, flammable material. 4. APPARATUS & REAGENTS: a. Gas burette, 100 ml b. Leveling bottle, 250 ml c. Orsat measuring burette d. Confining solution 5. PROCEDURE: a. Sampling (1) Place approximately 200 mis of confining solution in leveling bottle. Change confining solution once/week. (2) Fill connecting tube from leveling bottle to gas burette by elevating leveling bottle to allow a small amount of confining solution fron leveling bottle to flow into gas burette. (3) Connect gas burette to sample line and purge with sample approximately 5.0 minutes. (4) Close sample valve and burette stopcocks so as to leave a slight pressure in gas burette. Disconnect from sample point. (5) Allow gas burette to come to room temperature and bleed off pressure by quickly rotating top stopcock. Continue until pressure is equalized. (6) Open bottom stopcock of burette and allow confining solution to flow into gas burette and absorb HC1. DO NOT SHAKE BURETTE. (7) Close bottom stopcock of gas burette and invert burette to facilitate absorption. (8) Right burette, open bottom stopcock and allow additional confining solution to flow into burette. SL 008925 -85- COHF1DSWTC1*1'5 blect to Protectiv Oraer 4th Judicial District Court (9) Connect gas burette to Orsat measuring burette and transfer unabsorbed gases t measuring burette. (10) Disconnect gas burette and allow confining solution to flow back into leveling bottle. b. HC1 Determination (1) Measure volume of residual gases and record as Z HC1. (2) Save residual gases for analysis by gas chromatograph. 86 SL 008926 I coo** ANALYTICAL PROCEDURE FOR ETHYL CHLORIDE OPERATION METHOD EC-LC-4 1. TEST: Karl Fischer Moisture Determination 2. SAMPLE: a. Primary Stripper Product b. Secondary Stripper Bottoms 3. SAFETY PRECAUTIONS: Flammable and toxic liquids and vapors. Avoid contact with skin and breathing of vapors. 4. APPARATUS & REAGENTS: a. Karl Fishcer Titrator b. Karl Fischer Reagent c. Karl Fischer Grade Methanol d. Pyridine, Reagent Grade 5. PROCEDURE: a. Turn switch on. Drain titration vessel and refill to red mark with dry methanol. (If sample contains free HC1, add 10 mis of pyridine) b. Add concentrated Karl Fischer reagent until, by visual observation, the end point is approached. Make final adjustment with standardized Karl Fishcer reagent from burette until the end point is indicated by a meter reading of 10. DO NOT GO BELOW 10. c. Just before sample is added to the titration vessel, check to see if meter is holding between 10-12. If not, solution must be readjusted to the end point before adding the sample. d. Pipette 20 mis of chilled liquid ethyl chloride with a chilled pipette and drain into titration vessel. e. Stopper titration vessel and start titration with full burette. Deliver Karl Fischer reagent at approximately 1 drop/second. Titrate to the end point as indicated by a meter reading of 10. End point is reached when meter holds between 10-12 for 20 seconds. If meter drifts above 12, continue titration until end point holds 20 seconds. 6. CALCULATIONS: ppm ^0 Final KF titer x N x 1.000.000 Grams Sample SL 008927 87- conrivEtmhLt order oi n 91-1145 ppm HO = Final KF Titer x K * Grama Sample Where N = Normality as obtained by titrating 20 mis of a methanol standard as described in the above procedure. Methanol stand will be labeled as "Grams 1^0/20 mis." N = Grams ^0/20 mis KF titer for this standard And K - N x 1,000,000 ppm H^0 - KF titer x K x 0.0005 gL 008928 -88- of Protective Orde] of 14th Judicial District Coi Wo. 91-1145 ID-632/2 0. C. PROCEDURE FOR ETHYL CHLORIDE METHOD WO. 0. C. - 12 - EfcCl-1 Sample; Ethyl Chloride Product Instrument; Wilken* G. C. Model 1520 Column Packing; 2056 Diieodecyl Phthelete on Gee Chrorn P, 70/80 Mesh Column Size; 5.0 Meter x lA" Stelnlese Steel Tubing Column Temperature; Start; 70*C Finish; 175*0 Recorder; Carrier Gas; Cell Temperature; Injection Ftort; Sample Size; Heating Rate; 6*/min., 3 min. after sample Injection. Minneapolis-Honeywell Sensitivity; - 0.05 to 1.05 m.v. Helium Outlet Flow; 80 ml./min. Inlet Pressure; 75 psig 225*C Current; 250 m.a. "A" (Hithalate) Injection Port Temperature; 150*C 0.005 ml. Sample Phase; Liquid Sample Inject; Syringe1 Beak Measurement; Beak Height x Beak Width at l/2 Height Calculation of Results; Internal Normalisation Component Ethyl Chloride Retention Time, Min, from Air Beak 1.8 Calibration Factor, Wt. # Baals - EDC 1.000 0.90 1. Syringe must be chilled in order to retain liquid C2H5CI in syringe. SL 008929 -89- CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 S' _ r> W-632/3 G. C. PROCEDURE FOR ETHYL CHLORIDE METHOD NO. G. C. - 12 - EtCl-2 Sample; Ethyl Chloride Reactor Vent Gas Instrument: Wllkens G. C. Model 1520 Column lacking: Deactlgel (Silica Gel) Column Size: 5.0 Meter x l/U" Copper Tubing Column Temperature: Start; 70*c Finish: 175*C Heating Rate; 10*/mln. following sample Inject. Recorder: Carrier Gag; Cell Temperature: Minneapolis-Honeywell 15 Sensitivity; - 0.05 to 1.05 m.v. Helium Outlet Flew: 80 ml./min. Inlet Pressure: 75 pslg 225*C Current: 250 m.a. Injection Port: Sample Size; "Brt (Deactlgel) Injection Port Temperature: 150*C 1*0 ml. Sample Rase; Gas Sample Inject: Gas Valve Peak Measurement: Fbak Height x Jfcak Width at l/2 Height Calculation of Results: Peak Area x Calibration Factor f sample Size Component Hydrogen (Ha) Nitrogen (Na) Methane (CH4) Ethane (C0H5; Ethylene (CaH4) Ethyl Chloride (CaHijCl) Retention Time Calibration Factors Min, from Injection (CaH* - 1.000) (Sample felze - 0.25 mlTT 0.7 1.0 1.4 U.5 8.0 30.0 1 51.5^0' 0.855 1.092 0.653 1.000 0.U20 By Difference O.OOO8332 O.OOIO65 O.OOO637 0.000975 0.000U10 1. When Ha la not present or can be measured. 2. When H2 la present but cannot be measured. SL 00893 -90- ELECTRICAL SYSTEM The electrical ties in the EC plant are fairly straight forward. Dwgs. 62A-7100, 64A-7100-01-02 show the ties and typical circuitry necessary for each motor. The only thing unique about the EC electrical system is the fact that the 13.8 KV source may come from either EDC or Per-Tri. Because of this, many different arrangements may be used in feeding the organics area; see Dwg. 20A-901-1. Normally the power for EC-HC1-VC will come from Per-Tri through breaker 0-408 and disconnect 0-503. The Per-Tri power comes from powerhouse bus #1, Air Circuit Breaker 0-309 in the EDC switch room will normally be closed, with disconnect 0-502 open. The cable is hot but protected. Never keep the cable hot by opening 0-309 and closing 0-502, as any fault in the cable will cause the EC-HC1-VC plants to come down by opening 0-408. Until the H-138 feeder cable from the powerhouse to EDC is increased in size, it will carry only EDC, Per-Tri, EC-HC1 but not VC. Before any tie that would connect EC-HC1-VC, when VC is operating, to the EDC cable the area super vision will have to determine the relative loads of the plants. In case of an emergency, leave the units down until the proper decision can be made by the area foreman. Emergency ties may be made by the shift engineers until the VC plant is running. Anytime a tie is made, even though it is an emergency, be sure and take your time and do all things in proper sequence. Any omissions from safe practices are forbidden. When the EC-HC1 bus loses power, the shift engineer should proceed immediately to the EC-HC1 switchroom and take a quick look at the 13.8 system, SL 008931 -91- CONFIDENTIALt Subject to Protective Order Cf 14th Judicial District 4,Court No. 91 -.1)4 5 odor, and a visual check of the general area will suffice. If ozone or damage is present, then finish shutting the plants down. If the trouble appears to be elsewhere: 1. Call Powerhouse Switchboard Operator (417) and tell him you are switching load from PH Bus #1 to PH Bus #4. 2. Open disconnect 0-503 (feed from Per-Tri). 3. Close disconnect 0-502 (feed from EDC). If power is back on the bus and stays on, then start back up the motors. If power is not back, then nothing can be done. Per-Tri CANNOT be tied to the EDC bus without considerable delay as disconnect 0-404 is interlocked with the powerhouse OCB, i.e., the OCB in the powerhouse will have to be opened and the key removed and used to open disconnect 0-404. The same thing is true with the EDC disconnect 0-301. Normal switching of the power source for EC-HC1-VC will be done by Maintenance with the cooperation of Operations. Although Operations will never make this switch, it is well that they know how and serve as a double check. The procedure is as follows: 1. Close 0-309 (in EDC) momentarily (be sure 0-502 is open); if it doesn't drop out, then the cable from EDC to EC has no fault. Be sure 0-309 is open before proceeding. 2. Close 0-502 (in EC). 3. Call Powerhouse Switchboard Operator (417). Notify him that load is going to be switched from PH Bus #1 to PH Bus #4. The operator is to check and see that the synchronous tie breakers are closed. Then the powerhouse operator is to equalize the voltages on the two buses. The voltage meters that must be equal are the ones on the EDC and the EC buses in the respective switchgear rooms. 4. After voltages are equal, close 0-309 (in EDC). 5. Open 0-408 (in Per-Tri). 6. Open disconnect 0-503 in EC, SL 008932 -92- No. 91-nIi There are many other combinations of operating and switching that may be done. Each procedure is similar to the one given above. It is best to remember that all of this switching is done with 13.8 KV present and therefore any ties made into a faulted bus will cause some damage. Anytime a tie is made into a bus that might have a fault, the consequences of the arcing damage must be weighed against the dangers of the plant having only emergency power. SL 008933 COHFIDEimM,* Subject to Protective Order Of 14th Judicial District Court No. Sl-IMS SC F H SL 008934 rs r K J OS /av  A,`t ., fy o d u c i P looJ G P M SL 008937 SL 008938 11- Slant aih JMOOT*FL40<' WKLL WATCR ii`-i*o**Pnoa ' ftTKAM 2-ITII-PUIOI WO Na ---- -- ft ---------------------- ------- K ______________________________________\__________________________________: l ------------------------------------------------------------------------------------------------------------------------------------------ D REVISIONS TO /3.S KV eus Uc, 4 (H-138) SC OWQ. SOA-196 JW D*SC 0-401 k 1400 A,. COU1 ftoTWVoUMSaE.SvRL*.mtwf ._*0a-136) E OC-MC 13.8 KV BUS QgecA. CCUTMUOUS) disc o-aos eooA GoutoooA 1./B. (KM*4Ml, SM 0-901J yV W TftAMiF. MO.l<OC> &A~T S/W1CM iTStt 1MH f'fClwOoIS0woC44w0iO-4K3.n04s/3./* o-aof] Q jp* i ICi *III ) A tWrjw?6wof.K>Va4as(MeJ I AW5.V34TWJtflfIfmAr4tt?e-A*eM *60U BUS MO. I CEDO SEE DWG. SOA-166 4SOU bus NIX e(MC) SEE DVi. 61A-276 (3.8 KVi BUS UO. i CH-104-1 SEE DW&/20A-I9S supwwegoue*wciuumi m 0M6UML Oty*. !M *91 4 Aaoa BC-MCi BOS r**i4.tas toxst tty**, SJSM * BV*. 2M KI7 6OSD0fOPS0OCAAAR0C-tL4O.f0tM.1! PER-TRl 13.6 KY 51/5 ftfOOA COAJTtNUOUS) T*. ,0150 0*402 /&OOA GOU% J MM. i.va Si 347SMW oTo/MmUf* Ate/ unurUru|muu 13.3KV3/4/30V`. v 0/5C o-<4oa a>'60OA. COil* ^ X OOOA. L*fe 9. -PSsO*-TRis1osmKumm 1M t li.8KV/**0V nnnpnn onoi-npupWt AWRMMIW 4ov. SEE ObWusE. u6aSi AO-7eSbO-tOpO 4S0V. BUS NO. 2 OAW-W/} SEE OWE. 6EA-7808 (; _\.\ae1os20Oc0AAo..-CsLoo.Buz.p I li/OJSC 0-501 O1i6S90C000. 440*Ci5AO0*9/* L I,/owe 0*504 / 6004 COA/f. pd 0004 i.A. / 600 4. OSU^C p/ 6004 i.A JLraUrA3(Na) 3I36.3iOWOO/4M6V0A* i *"pC5t.P7g6 'ZSfA*4L#0Ofiy TYf* rrrrm /T34O#73U5A/ORJVtSO/?AO4a3MAo*9O(P0^T0VJ SnO r$ S3ALC& TO 4SOY SOS MO. 3 (tfCt) 4BO\L BUS via 2 fsc) Sfif /DW4. 644- 7/CO See OM6. S4A.JIOO EC-HCL /3.8 KV -f-- 4u /* .XJU~)4~J.r1r.-..' I FUTURE 430 W TRANSF I'Jf). 1 3^500 MO*, 4~C ( H 370 4 /44X. COAJp Q2O0A CO/UpfJUOU^ icS-ISu+c.t*s/st2.eA.a4itiKKi VVTA.e*us* ua.1 EE* IMB Uff TYPC C, F| 5f/UOS TO EC-HCL 2400V BUS MO. 1 SEE DW6. *44-7100 COHFIDKHTlMut Abiftct to Prot ctiv Order 14tb Judicial District Court Ho. 91-1US 00894' SL RtFtRtNCt DRAWINGS BA-iss is. a kv. one Lime oia&bam I5S &ac. KMT OUC l/U O/MffAM A- 270 TRI-efNAOC PtAUT 0*J itA/0 O/AtRAM ASOO HCL PLANT ONE LtWt OlAERAW iSA 730C PiP TR/ PIAK/T CRB LiUC D/A6PAM WA7IOO EC- HCL PLANT ONE LINE DIAGRAM PITTSBURGH PLATE CLASS COMPANY LAKE CHARLES. LOUISIANA m Hl-ifkidXL Q&Ak/iSS area CBAdfidS/TS OU6 Uuh B/AGPRM mm or NC -- JKOS-PA.2M-.Jlf.cL--mw.mrfr^tae.-tflgl-jlg . r&L Z*.M-a-tCZ>. .'Cfi'/I TO me ALARM coatroc avmtr TRAMS* 490-/90* VnX'V /'ASS' R0R O'JOT RRSm BBC (S BAB &A - 90/) mrts mort-mok^ <X j .v o-sax /zoo a coat to* a *m w o-sd* { moo A. COAT. oaa a- la room, zt.l. rxmecd't\soor 'Amc,o~X m/4*rtr SC-ACL 498 TAAASR /KU A/OXO*C 'MAT9A*JVt0C4+SGARLfLLBDORT TfR TWiV^AW*A/WVV B. T3X -4'J-C , n-JL SOCMCMjCOO* -*=-3&-r#- ? - '-< - ^v?- ,, !y^>;s-',^-r: ,imh remoem o-4C9 mam w-w (S BW*. 90A'9Oi) T tV) * * I--Qj TT T. ( rutors , P4ZM 0/SC. 0OCOMWCT O/SCORtrttr RRSL 0/SC- RftM, &AC. 0-30/ O'SOL O-SOS O-SO* O'SOS 490 8 TZARS* sm.O'JOt ASA. 0-/0* *80 * THAW, *OC 9. A/&. J ROOM tot. MM AtA-mt #0-2 TAAASR. JYO / Eleyat/cn oe enont of ec-hcl /3.E KV SEAN LOOK/NO SOUTH. C-SOS /2CCA COATCOO ALB l C - HCL S3 S KV BOS (/Zoo A. co/vr) /- c cm/z TO SC ALARM 9gc _zmiO ec ALARM 0-4'04 *00 4 COAST *00 A. LB ruse T.re. rrre cl-/,/cos 4~C tJ -4A*/4 /3*V 0S9C0-A*CTLAAA-SR. S/8 Z /ooO m va J A, ssAtea oat ttrf A_oP/rsvs/\._>WiVW/s3S.9.rs-x.4* A 9, C+*i r/LL0 X/^7 aa/saaa/v S~4 -SC . /Z -yt SOO MCM ,*OQV ;~3f " " moo a ex A TX/X o - SOS coo A. COAT *80 ALA. ease z tc rrre cl ; r, ao - tro a / * o" t, x - *A. */ , tsttr ec -mcl 9.4 AS TAOMSX RO. / 9SOO AYA, SCAi.CC ORY T/RS ,, f* v , // A' v'v i> runsa* 0908. TRAMS*. AO. / r* *7j^ 7%S&fa*m^- &.? 2.4 Mr c+ s, e/aeo OQ^r t,y.swss jrj* <; 2-o~Cj Vc noMCM, ffiru 9 Z> \-------- t-VV k -------- (!(]- -Twj - - y r jf+O -------X K&X -->-4*0UNO "bcr. " /2 2X9Si r--&--! | ^R388-,MW 'fl/n/j# MnwMf SW&R. Si/S A/a 2.1ECV ir d C -HCL 2+60K SUS.'mO- t" REVISIONS A oooeserso Za/4&00(4v.h>a0c9. * tLCfi. fO>S'9f- IE6EME) 0 R/RA RT SRTRdOCR J] Rt/s/tmvrroH \j RUSSO DtSCONRCT f` str/rcA AOtLOUT Tree AX- 490r swam. asm. xoseo motLOOT Te/YTREASHASRRt/-' 4*0 r n/seo COTOOT + SIfS0 ROTOR STARTSA t/R/TARR NLS - ROM L OAO BMCAX 18-L OAO Sms** RAT/AO C0MT- CONTINUOUS RAT/AO met comm ao./ cat,mu 9400 MCI ACL ACL ACL came mom cmoom.3m emm mom me* comm catms cserm erras cmtoo 9008 9/08 SSOO 2200 CRT. ms CRT. AO. 8000 9JOO RCC BOS 7900 RT4/A0 CRT. AS CRT AO. 9/00 9400 __0000. iKAtae sec. CRT 40 9200 ACC BUS TTOO RCC BOS rtoo 0909. TRAMSR A3.2 SC. BR4RR rorume SRAC a&sS'.- - ianm SAAR* SRARe 3RAC3 54IC/ ROTORS rvrumr SRAC SRACt ELEVATION or ERQNT OE 480 V. Stvar. LOO/C/NG MONTH (T/fANSE NO. 3 ) fStt 6v<S LtA-lTStj ~s COHPIMMTIALt ELEVAT/ON 0E rNONT OEfSOV. StVON. LOOE/N0 month (TNA NSE HO. 2) C SEE DH6, "+A- 7I0Z) ' ~/L~ ~ ------------- Subject to Prot ctive Order m3 llt> Dletgict Court So, 91-1145 r ----r --- ----1 ' :* 1 1 1 k 1 j r ----- - ) i i---------------- -- ' t! i................\ k i t i 1 i j; L. - J j L I . J . EUTuE/E TUA ROTORS ~~ (?) lii--isr jwd) a, *r*/--" - ` * 2400 9 BOS J RTR/MO ROTORS 9 MSG* STARTRS OR ROSSO m/sc. ' t , ; | &R Wtt f^*rv%zi> f o/sc,0Hm$cr) &- ' " 1 1 | \ ELEV. OE ENONT OE EC-HCL 2H KV SUE NO. / SW/TCH/NO CENTEN (BUS 0-L40) {2.4 KV TEAMSE NO. /) \ * j " *S` jf at- , -tf-'T'-i- `-Wr- SL 008942 fowte rCitJ&J L -e ? r j PJnSBURGH PLATE GLASS COMPANY CMftUCM ONMOm LAKE CHARLES,LOUISIANA EC - HCL PLANT ELECTRICAL OWE LIKE DIAGRAM 490 VOLTT 2.4 A 13.6 KV SYSTEM^ DWG. Nft54A-.ZiflQ*L m INCOMING TERMINALS 7804 780/ 78OS 7SOG SUS 7800 780 9 78/S / 78/0 / 78// t /OO AMP / TRANSFER PANEL TSOZ 7803 3t 7E/2 /2SA CB WELDING % 7213 A 7807 $ ac.s> 7808 78/4 78/6 / FUTURE 78/7 2 2 2t FUTURE FUTURE FUTURE FUTURE FUTURE FUTURE H ABO \A /-JO. (<9sr EXPO. G4 a-^/oo} ^2-JmC.,G-%. SCO/ten CM.CS COOS' aso k" ACS ) X* A alternate n eoieouoc* C*Cnr <3<y. COM3. PCS 4 4/NB. ?TRANSPUT R*N2L 1 tn**6 4 * ? s T/I& 7SSL (TtP) V aflsiw^d ulA-a-j r**MK *-,!C/t*OW~nrY~, "flE" .JWf A " r-Li -- et*E8o&wucy -_, n* _r 1 ragf ijdC H 1 *) . , toe) XX U)HELOiNG W) 1e*e*cae?p/t*eacl3* I'!' "-/'/r/j'1\ T I SJJLaj *MA, *4, rr*T* 48Q-jtQft*o V, r^4^r|| A"e* mrrt X4M TO CK ( Aeteo r, m. t Mr. ao*c*. H-19-4T f.P&. A apoee> Gtrr r An<^itav1 8 * /E.r >*w^Y . jl.. stxtte* /-t*.-t -J*M t'Pwlmoir*&/Lw UncofunewDLwce*o- " 1-MOTOR CO NTAO L CENTRA SHALL SE PASRtCATEO ASA GENERAL ELECTR/C'S SPECtPtCAT/ONS PCR 7 700 L/RE AO TOA CONTROL CENTERS. YERT/CAL SECT* OAS A AS TO SE 40`H/GR, 20"RlD 4 J3~ SEER SOA PLUG /A STARTSAS ON ONE StOS SALT. 2 - A/AtAO /S 70 BE REMA CLASS / .TYPE 3- J* ENCLOSURE TO SC /VE/iA TTPE /. 4 - RowsA sum y . 420 vol t; j pha sc , s o cre c s. $-CONTROL POWER: *20 HOLT, SO CYC L . USE A SEPARATE CONTROL TRAMSCORREA TOR EACH STARTSA 4- PROV/BE A 300 AAA SROURB SOS WpE/GHT & XHAHErER MOLES TOR EACH YERT/CAL SECT/OM OT MO TOR COR TROL CER TER T- MALA HOR/ZOHTAL SOS TO SC RATER 400 ARRS 2 YERTtCAL SOS TO SE RATES SCO AMAS- ALL SOS ROAR TO SE SLLRER ALA TER / SO/TASLY BAAC-EO TO W/THSTARO A MAX*MUR OR S0,000 RMS AMPERES SHORT C/RQOLT CURRENT. 8- /MCOM/MO LtRE CABLES M/LL SE TOP PCS W/TWO 204 ACM CABLES AER ARASE. J- OUTGO/AG CABLES PROM STARTERS, ETC . W/LL L.EAYE TRE CONTROL. CENTERS PROR THE TOP. AO- AMTS* CAL ARRANGEMENTS OP STARTERS ARB BREA HERS ARE TO BE AS SHOWN OH THESE BRAW/OOS, STARTERS SHALL BE OP THE C/RCiAT BREAHER COMBLRAT/OM TYPE. // OVERLOAD S/HE TALL tC. RELAYS (EXTERNAL HARO REST TYRE AMS/ENT COMPENSATES) ARE TORE PROMOEO /R ALL THREE PRASES. HEATER ELEMEHTS ARE TO BE PURCHASER &/HSTALLEO BY OWNER AT LATER OA7E. 2-ONE EXTRA NORMALLY OPEN AUX/L/AR/ CONTACT /S TO SE PROY/BEU YY/EACM MOTOR STARTER CONTACTORB-LAMACO/D NAMEPLATES . LETTER NE/GNT OP CLRCOLT NUMBER TO BE-jr*. LETTER HE/CRT OPC/RCU/T BESCA/PT/ON TO BE** LETTER RE/CHT OP BUS NUMBER TO BE LETTERS TO SE WH/TE OH BLACH BACHOROOAO- M- TENDONS NAMEPLATE TO BE LOCATEO TOP AMO CENTER OP MOTOR CONTROL CENTERS W/A LARACOtD NAMEPLATE SHOW/RO THE SOS NUMBER BJRECTLY BELOW. i/S/MST/UL LAMACOiO NAMERL A TES PES/&NAT/MG /AtCOM /NO PEEPER SPACES f ALL CUOiCLE 0<V3ej, Hr MOL DED CASE SPEAREPS POR PEEOER USE ORLY ARE SO.OOO AMP. /NTERROAT/HG (/0& A. PRAMS A R 7 REP - 22 S A- PRARE ARE TYPE TRPR). BREAMEPS USES /R COMB/RAT/ON MOTOR B TASTERS SHALL BE AS,000 ASEM ARPS /R TERRUP T/M & (/CO A PRAHE ARE TTPSE TPP - 22 S AMP RRAME ARE T/PE TP<7~). DATA BELOW FOB DETAILED /NFdRrtAT/ON 1---------- >0 YW AST mtod wmtrsa V0k A^e.. c 790/ 2 ee i tz El f so a*v *** tor iwam ySS&SSm cowm LBA& /OOA +6 o EXBG&prnoMj PUMP NO P'S MOTOR RC M-3 1 2x*ACurr 4 twos aer /UtMT FL47I *JOaOSt*A(F a? toD0 CRT- * TEO/ REACTOR REC/RC POMP *2 o, 7902 2 3 tr*TS ^trea ZOO A 40 BS COMPRESSOR AC. Jt MOTOR HO M-jt o s TRAY, /-$ "C.t%.. 4*4 /J*/2 CRT. m 7302 EC REP UN/T COMP. HO- 2 7903 / 2 CAT. * 73OS SPARE STARTER c 7904 / c TEflf A 7?1/ Z* / / A ce iaC 7 78Q ce ireC7 7tf? . ZOA 20 A E s r ;*rt J75<1 /OO S.S' R 4tS PUMP NO. P'4 MOTOR HO. M'4 PUMP MO. R-0 MOTOR NO. M'C POMP MO. P /L X 7-StAfj /-C., Y<- TRAY, /"C-> fL */2 TKA Y, 3`C., % 3'f. i/"* T*.ay. He.. -K/2 CAT. 10 7904 PR/M STR/PRER PEES PUMP ~/ CAT. ~7*eS RES ST/LL PEEO PUMP 00/ CAT **790& COOL/NO TOWER PUMP *2 P 7907 -k - 3CA to /O kLVA TOAi, 4/C, 3 *tiOi i *4- CAT +7307 EC sro/ZFKk cs Aaex> uci/tr/NCj c 7709 / c 7909 / Y 79/0 / T 77// / 2 ceiisc st g fi> ce >rs> / C &.S.7A ce i2a/ c-V 7 A / ce ci?.r % E 79/2 / C 79/S t t ce <2ic a6A. C 79/4 / ce i2a2 c zi.t-n o 79*4 >k SEAim '.uxcom So A AS 20A S' /2 3~ tSA fA 3oa /2SA >* v O T O /SA J 2.2 BOA *s TWO /sSt4 so /2 JO PUMP HO- P-13 PLHP NO. P-2 MOTOR NO- M'P PUMP NO P-24 MOTOR NO- M -22 YENT COMPRESSOR T+ MOTOR NO- M 2J T/r/ir, ,4-** J*V2 T/?M, -C.,7e *'2 <a 2 T/TAf, ft ~/2 1 !</c, y,_ F&ia'iz Z- iV56//v PUMP NO P -/O 4 * r/PAr, /"c., -/ toAB/TATOR MO, A'/ e MOTOR MO. MSC r/?Ar, ji'e., TRARSPERS ft AIT SUflf t ORE OSS OP/WToHnct. TKAY . fit"C y.Z `/c t CRT ~ TSOP EC PRAMSPER PUMP CAT. "* 7209 RYE JT/LL PEPL OX PUMP **/ CAT *79/0 OLAM0 PLUSH PUMP */ CAT. * 72// *STRG- TENT COMPRESSOR CA 7. - 72/2 WELO/HO EC 2 RC L. AREA CAT. ~T2/3 CRT. *72/4 PL AS HER BOPP A G/TA TOR CAT. *T2AS EMERG. POWER T/PAMSPER PANEL 79/4 -k o c 79/7 / / ce i2lc i a e> 4oA /o C PUTURE SPACE ONLY POMP RO. P-/4 MOTOR NO M-Pf Oo 77TAK !&.% P'P i 3 'It if CAT- *T9/L PUTUME CAT. *TB/7 EC REWORM PUMP ~/? t2l27 V8PYZV PHES/Xt? 'wy K/o, saw Vo. 6H&. TOW* mPAMSSL4rCvOsHtfSU tOAB SGTUAL itnr 20<ool^C4B. oeswrr ^ W/TR PLANT *T /OG*X PRO0UCT/OR) T0794L. PA**4ETPTLATm -innr /^jAA^A=v-*Tm OEsefl^r/ov 1 ooupesr / *sar skz*- AMPLE MEATS J& ASOB4PAS 1 PCi/A P/.pe 2t7. S3 305 93 2*5.93 40 27 ^ ^er 333 so ftnrs x jtwtfciv *twr/.*r COHriBSNTlAL* Subject to Protective Ord r Lit 14th Judicial District Court no. S1-1H3 SL 008943 CwhacSMfeVMiM ""-Sojiu nfg. PITTSBURGH PLATE CLASS COMPANY LAKE CHARLES* LOUISIANA. EC PLANT QsiT LhnHC QMfflgAK ROOMPT" LMYtOUT^ ALAS E*^e5E 0'*- V<~- t.-v-v.-S8 "'r -s-V^-V p*?- : }Zk REVISIONS T 1 ;? BUS 7900 ! FUTURE TIME CLOOC LIGHTING tUW/^/O iKJK. 79/S J2S A. SFAFE 71/6 FUTURE 79/7 4-80 V! SW, &WL N/Hi 300, z Pols. &es. FUTURE (2 SPEED \ \ STARTER) FUTURE 7901 71/0 7904 ! 790S /AKZOFUUO, FESOSPS purups. / 7101 77// t FUTURE 7706 79/2 7107 7102 / 2 77/3 SPA (3.S. 79/9 FUTURE / 710S / 7903 2 r \ *4 3 / S4 igangirxgygrfy^Q^g# /MOTOR CONTROL CENTO* SHALL BE FABRICATED PER GENERAL ELECTRO'S SPECIF/CAT/OHS POP 7700 LINE MOTOR CONTROL CENTERS. VERTICAL SEC TiONS ARE TO BE 70* NtGNt20" WIDE / S3" GEER EGA Rt UG AM S TAR TEAS ON ONE StOE ONLY. 2~ WIRING tS TO BE NEMA CLASS /, TYPE B. 3 - ENCLOSURE TO BE MEMA TYPE /. 4 - POWER SUPPL Y : 490 YOL T. J PRASE.CO C YCL E. S-CONTROL POWER ; /20 YOLT, SO CYCLE, USE A SEPARATE CONTROL TRANSFORMER FOR EACH STARTER. A - PROVIDE A LOO AMP GROUND BUS W/BtGHT %?DtA. MOLES FOR EACH VERTICAL SECT/ON OF MOTOR CONTROL CENTER. 7- MAIN HORIZONTAL BUS TO BE RATED LOG AMPS 4 YERT/CAL BUS TO BE RATED 300 AMPS. ALL BUS NORM TO BE SILVER PLATED 0 SUITABLY BRACED TO W/TRSTAAP* A MATINOR OF 20,000 RMS AMPERES SNORT CIRCUIT CURRENT. 1- INCOMING LINE CABLES WILL BE TOP FED W/TWO JOO NCR CABLES PER PRASE. 9- OUT GOING CABLES FROM STARTERS. ETC. NHL LEAVE THE CONTROL CENTERS FROM THE TOP. /O-YWYS/CAL ARRANGEMENTS OF STARTERS AND BREAKERS ARE TO BE AS SHOWN OR THESE DRAWINGS. STARTERS SHALL BE OF TNE CIRCUIT BREAKER COMBINATION TYPE. # OVERLOAD BIMETALLIC RELAYS (EXTERNAL HAND REST TYPE AMR/ERr COMPENSATED) ARE TO BE PROVIDED IN ALL THREE PRASES. NEATER ELEMENTS ARE TO BE PURCHASED* /MSTALLEO BY OWNER AT LATER DATE. a- ONE EXTRA NORMALLY OATH AUXILIARY CONTACT /S 70 BE PROVIDED Y&EACtt MOTOR STARTER/CONTACTOR. D- LANACO/O NAMEPLATES r LETTER HEIGHT OF CIRCUIT NUMBER TO 3C-A*. LETTER HEIGHT OF BUS NUMBEN TO SEE*. LETTER HEIGHT OF CIRCUIT DESCRIPTION TO BE LETTERS TO BE WHITE ON BLACK BACKGROUND. H- VENDORS NAHEKtATE TO BE LOCATED TOPAND CEHTEA OF MOTOR CONTROL CENTERS R/A LAMA CDID NAMEPLATE SNOWING THE BUS NUMBER DIRECTLY BELOW. <f`SWSTALL L AMAC0/O NAMEPLATES DESIGNATING INCOMING FEEDER^SFACEJ^^ ALL CtlO/CLB OOORA MOLDED CASE BREAKERS FOR FEEDER USE ONLY ARE JO.OCD AMR INTERRUPTING (MO A. PRAPS ARETNEF - BAER AFRM-AFSMEINA-T-R--E-E--R---R--T--U-Y--P-P---ET- INrGM' 1/00 A FRAME ARVESETOYPIEN TCOOPHO2IIZYSA TA/OMNP NFRTAOM/E^ A*?RTE**TTYfP*EA TFjr]**L as AStOOO ASYM cFoVmNRb, SaTcAbRT4ER ft t S CO&- to *ao k eir-w^ ato. z. f&ex omo. &*a - nee) -J-J`c.,1 -fi. soo/te.* r ^ I X FYNR STARTER I BSo vf A/o. T9QD LGT CONTACTOR --C SSL) & P420 y. ^mincHpiHEL m MCC FOR At GOO LIGHTING. 6304 _ -*7G - tZG/240 v. u i* LIGHTING FNL *SM RIGHT LIGHTING - TIME CLOCK CONTROLLED SEE DATA BELOW FOR DETA/LED /A/EORMAT/Oft ta1tr | L/--\flC^ N>OD. *T0O SMCCkACTC*Hft/L* ll*'4T EMMk HODEO CCHft, oil. BSTURW SOL, VALVe, i/U/LL A* 8/H 2.2,7 > 7701 Jg 77CX Z A 7703 Z)i 7707 t 7710 7tlf dmnuiztui/VE SWT PAP LOW /X%42 W* OOAjCtBr 4 MOB i ?MP kvrttMMIMttf \B*S> mas 56A fS /OOA 70 ce C. S.CTA CR I1S> C&JS7A 204 204 SOA COMPRESSOR NO. YtS 14 MOTOR NO- M-3G ytkAYe fimc+ % b9c4b*i2. CKT* 770/ CONTROL BLOG. A/c UHlT - PUMP NO. P-2 MOTOR NO- M"2 YTTMYjli'C. %t7*4 /E+SZ CKT. N 7702 REACTOR NECIRC. POMP */ PUMP /VO. P'/S AtOTOR MO. M-JS TRAY, 3JC.i% 3w% 1*4| TRAY, Vc- W.*2 CRT. P 7703 COOL HYG TOWER PUMP *! PUMP NO. P S MOTOR NO- MS yRAY, rc.t 9L ~sz CKT. * 7704 PR/M. STR/PPER PUMP *2 PUMP NO. F-T MOTOR NOi M-7 ITRAY, PC., Jt */Z CKT. * 770S NYS STILL FEED PUMP*2 PUMP NO F-/2 MOTOR NO. M-tZ Y**** /4*c.,%,t4*G/sle\ CKT. * 7700 EC TRANSFER PUMP */ FUTURE SPACE ONLY 7707 FUTURE 77*7 /oc A m. COMPRESSOR NOTE MOTOR NO. MZ7 TRAY. i%-C.. ifC. 4*7 4s**t CRT. *7709 4 3/C **&. EC REFRIG. UNIT COMPRESSOR*/ cb >ne 5,264 204 cRiaftCC.17S cr asC B.U9 * *< fS4 ISA 204 suri-P+Lfe aw*a c* 3b PUMP NO. P-7 MOTOR NO. M-7 PUMP NO. P-N MOTOR NO. R-tt FUTURE SPACE ONLY HOOD FAN NO. L'3 .MOTOR* No/ N-ZGdRTt SPA&&. AGITATOR AID. A 2 MOTOR NO. MS! TRAY, lmC., 5t *12 TRAY, S"C.,ft*/2 f*C.. % */L TRAY, i"C., & *12 FUTURE SPACE ONLY FAR NO. L -/ MOTOR NO. I TAAy. We* % 4*4tStL TRAY./'C-.K *12___________ CRT. m 7707 NYS STILL REFLUX PUMP *2 CKT. 77/0 PRODUCT PUMP *2 CKT. *77/1 FUTURE CKT m 7712 LAB MOOD EXHAUST# INTAKE PARS CKT *7713 SPARS BtZG. i GTPDTBA. CKT m79t4 BOTTS DOPP AGITATOR. MGTU4L G9HPWLMWBO LO*C> /StHSEMOi ^ JY/TN PLANT AT NOR PRODUCTION) CKT. Tf/S SPARE I2SA.AC9 TOTWX CKT. * 77/G FUTURE ESXfAkUIHUXB A AOtARpyLLTM CKT * 77IT COOL/MG TONER */ FAN conrwtmihu Subject to Protect!* Ofdec of Hth Judicial District Court -----------------------no., ---------------------------------------------------- ; CXXUCXNT4 AMsr GYZXE KAGAME FOLATE EKJ90DFNU9 LAN! APT HUHBEA C1.9L0OCAKHACCA4IMTKYCZLLHEMOKmJrDJOAAYKP ssmtfflrfWi'------------ --------------------- ft. 4MO.iL > MOK 3oA. A*xes. r***, i *t .) 2 Ht. * CKT * 77/7 *'a#J L&!i/4M,-7kc CLC ACWA. 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