Document 0gNENnma2xmMxypeXN7evQg3m

& L-jaj-^tai^-,--:;-. j i C-1530\ DISTILLATION\ MODULE\ DO 014110 OONFTDFNTTAl '-'rF? **- CAN D200 SEQUENCE (22) C-1 530 AK<22)=221 DM(22) r AK(22)224 DM(22) AK(22)=221 DM(22) AK(22)=220 DM(22) STEP(221) PROCESS WAIT AIC<22)=222 DM(22) 1f i kAK(22)~221 DM(22) STEP(222) COLUMN HEATUP AK(22)=223 DM(22) i lAK(22)-222 DM(22) AK(22)=224 DM(22) 1aIC(22)=223 DM(22) STEP(224) CONTROLLED SHUTDOWN AK(22)=225 DM(22) JSTEP(225)y DO 014111 CONFTDFNTT ____ _______________________Q^P______________ --- V/ sj \s \f V -j ~000^~pJj~~ C-HM L, *rr ( : ,,Np ***^-- -- TM0-- ^ M <Ht *CC,, ,,v -V M MX a/ I-- tutl [><5 0*3*1 0*3*3 n -S -im @ - (^1 0 --JfQQj -OD^~ - -Q'ffJ EC-1520 REVERSE LOGIC 2**&in msmr S0*2C12 W m!? 0*271 Mw32,*3 0S*2H74 Hoor*a EC-ISSO ^0 0- rOfe^k___ i---ffe><6- c-iaao N h "*kK us ---,----- <S dv 0*1*1 H7Q-i ^ Mm a 0 - U^QJ t0*i2f7f1 S0*3T74 0t*i2f7f7 t0*i2f7f1 t0*i3f7f4 m0*2 B0*23*1 t0i*f3f*4 t0i*3f*f7 t0i*1ff*1 -(><?] E-1530 D 1-mm |.-^ ICi--mHHH-^k C|t--1AM. |n4 ILTi-l* otntihaamtet i 'mXjtj xb^2H'nxttii x<mt xjooM< xmiTOxWi MM MM MM oistillation status tM OOW MASTER GIST SCO STEPS to Id iQ Q T-- V i DO 0141 Ip OONFTOFNTTAL 0 ^0 0 l-U prao-r-1-1323 REV LOGIC m Mil mMV* 0*d1t*c1i " Lvajjaa wmm - rjfil'.fo.i, ~i iS-.-i. v.t rt;r* -w:<,v.^..>i^; CHLORINATED METHANES GENERAL RESOURCE INFORMATION s_________________________________________________________________________ \ Department: CMP Job Title: C-1530 MOD V General Information Scope: To provide the operator with the necessary information needed to assist them in the training and operations of the C-1540 column. C-1530 is an M2 finishing column which will be controlled by the Mod V controller. The control system has a total of 6 steps (220-225) . STEP 220 is the "MAINTENANCE WAIT" step . There are no control activities taking place in this step. Anytime any work is to be done on this column which requires the column to be down the MOD should be placed in this step and tagged out properly. STEP 221 is the "PROCESS WAIT" step. There are no control activities taking place in this step. The MOD will be in this step just prior to starting up C-1530. The system should be lined up and valves stroked in this step. C-1520 reflux drum, D-1521, will be level controlling to T-1500, via the level control valve AO(212), at approx 35X, AK(218), We are operating at a lower then normal level to allow for extra space during the feed swap over to C-1530. Operator intervention to terminate STEP 222 is the "ESTABLISH C-1530 LEVEL AND HEAT UP" step. When the MOD is placed in this step, and, if a C-1520 reflux pump is running, indicated by DI(229) or DI(239) being "FALSE", C-1530 feed AOV, DO(222), will open. D<j(260) will become "TRUE", changing AO(212)'s slave controller ramp setpoint, AC(907), to a value of (0) for 1 second. This will cause the feed control valve, A0(212), to C-1530 to close, cutting the feed to C-1530 momentarily. One second later, the slave controller ramp setpoint, AC(907), will begin slowly ramping up until it reaches the value that it had, AC(960), prior to opening the feed AOV, DO(222). Once reached AO(212) will assume a new level setpoint for D-1521, AK(205). This will allow for a much smoother transition, keeping us from over feeding C-1530 during its initial start up. DO 014113 CONFTDFNTTA! C-1530 MOD V General Information page 2 ^ If the bottoms level, AC(906), is already greater than the minimum level setpoint, AP(1219), or when it reaches it, and if the pumps, D0(208) and D0(218), are in automatic, the (A) pumps will energize. If for some reason the (A) pump fails to energise within a given time frame the (B) pump will. Energizing the pumps will enable the'bottoms control valve AO(223) and energize the bottoms AOV, D0(204), open. Once enabled, AO(223) will begin controlling C-1530 bottoms level AC(906) back to E-150Q at AK(201) setpoint. If there isn't sufficient level, the valve will remained closed and the pumps will be on total circulation via the ARC valves. This valve can be placed on flow control by giving AK(204) a value. Also, when one of the bottom pumps energize, and if the bottoms level, AC(9Q6) is greater than the minimum setpoint to begin steam, AP(1924), ALARM 271 will activate. When the board operator is ready to begin a steam flow, make DM(267) "TRUE", clearing the alarm and energizing the steam AOV, DO(225). When the steam AOV, DO(225) is confirmed open, indicated by DI(225) being "FALSE", the steam control valve, A0(213), will become enabled. Once enabled, if the bottoms temperature, AI(237) is less than AP(1921 ) value, AO(213) will begin controlling a steam flow, AI(216), based on AK(276) setpoint, which will be set between 2000-5000# hr. This will allow the column to be slowly heated up. Once the bottoms temper ature becomes greater than AP(1921), or, if the MOD automatically terminates to step 223, the master controller, DC(935), will become enabled and begin controlling the bottoms temperature AI(227) at AK(211) setpoint by automatically adjusting the steam to feed ratio, or, if you choose, go on straight ratio control by giving AK(233) a value between .01 thru 1. Example. AK(233) has a value of .3 AK(233) * C-1530 feed flow = steam flow .3 * 15000# feed flow = 4500 # hr steam flow The overhead pressure control valve AO(204) will attempt to control the selected overhead pressure AC(903) at AK(227) setpoint. When the column pressure, AC(903), becomes 10# higher, AP(990), than E-1700 pressure, AC(1780) the vent control valve AO(233) will become enabled and begin controlling a vent flow, AI(206), based on Ak(252) setpoint. If while running, ALARM(267) activates, indicating a high column pressure, and, if the pressure control valve, A0(204) is greater than approx 70-80% open, AP(1908), the ramp setpoint, AC(283), will automatically be increased, increasing the vent flow. However, at this time, once the alarm clears, the vent flow goes back to controlling AK(252) setpoint. DO 014114 r-0NFT 0FNTTAl -t-sS-Vy K, C-1530 MOD V General Information page 3 ( The MOD wi11 automatically terminate this step when C-1530 bottoms level AC(906) becomes greater than AP(986) and' the feed flow AI(225) is greater than AP(987) and the bottoms temperature AI(237) is greater than AP(1925) and the bottoms pumps are running. STEP 223 is the " RUN C-1530" step. When the mod terminates to this step, if the master controller, DC(935), for the steam control valve, AO(212), hasn't yet become enabled, it will, (see steam valve in step 222 for control) The bottoms AOV, 00(204), to E-1500 will be opened. However; the board operator can sample C-1530 bottoms and if good, go forward to T-804's by making DK(72) "TRUE". This will open the AOV, D0(224), to T-804 and close D0(204) to E-1500. DK(72) will be autozeroed if the mod moves to step 225, shutdown, due to alarms (265),(273) or (281 ). STEP 224 is the " C-1530 CONTROLLED SHUTDOWN " step. There is no control shutdown at this time, however code is left in so that in the event one is needed it is already there. If you attempt to move to step 224, it will move right back to 223. STEP 225 is the " C-1530 SHUTDOWN " step. The MOD will AUTOMATICALLY MOVE to this step if SHDN ALARM 265 (high pressure),273 (high level) or 281 (operator initiated) is activated. When entering this step the MOD will CLOSE the feed, control AOV, the steam control valve and AOV, level control valve, vent control valve and shut the bottoms pumps. The pressure control valve A0(204) will remain active. GR 9/92 C1530M0D.RES no 014115 00NFT0FNTI A! C-1530 IPT MODULE PROCESS FAMILIARIZATION ( TANKS AND VESSELS X PURPOSE: To familiarize you with the purpose, design, and operation of major tanks and vessels in your area. Including internal and external components (flanges, taps, baffles, etc) and explain their functions. f RESOURCES: P&ID'S, Experienced Personnel, Pressure Vessel Data Sheets REQUIRED LEVEL OF PERFORMANCE: 100** Correct OBJECTIVES: 1. Locate the following tanks and vessels in your area and explain their purpose. Include all inlet and outlet service flows (feed,btms,vent lines), destinations & product content (shell & tube). A. C-1530 (column) B. RE-1520 (reboiler) C. E-1530 (btms exchanger) D. EC-1530 (Intergral overhead exchanger) * 2. State where C-1530 vents to. * 3. List all the places where C-1530 btms can be routed to and physically locate each line. * 4. State where C-1530 gets its feed from. * 5. State what coolant is used in EC-1530. * 6. State what type steam is used on RE-1520. * 7. Draw a simplified diagram of the equipment listed above and label the parts in their appropriate location. DO 0141 1 A C0NFTDFNTTAI C-1530 IPT MODULE PROCESS FAMILIARIZATION VALVE OPERATION PURPOSE: To familiarize purpose of all operation will section. you with the location, type, operation and valves used in your area, control valve be covered in "CONTROL AND SENSING SCHEMES" RESOURCES: Plant flow sheets, experienced personnel, pics display REQUIRED LEVEL OF PERFORMANCE: 10096 correct* OBJECTIVES: * 1. Physically locate, and operate (where applicable) the following valves. A. AO(213) (steam to reboiler) B. A0(204) (Cooling tower water to EC-1530) C. A0(223) (C-1530 btms out) D. A0(233) (C-1530 vent) E. D0(222/232) (C-1530 feed AOV) F. D0(204/214) (C-1530 btms to E-1500 AOV) G. D0(224/234) (C-1530 btms to T-804's AOV) H D0(225/235) (Steam to reboiler AOV) I . Manual block valve on steam at header, J . Manual block valve on steam to reboilers at reboilers K. Manual block valve on steam trap. * 2. Given any valve, state if opened or closed. DO 014117 CONFIDE NT TAl C-1530 IPT MODULE PROCESS FAMILIARIZATION MECHANICAL EQUIPMENT PURPOSE: To familiarize you with the function, location, and maintenance of the mechanical equipment in your area. RESOURCES: Experienced Personnel, Equipment Manuals, Data Sheets REQUIRED LEVEL OF PERFORMANCE: 100* Correct OBJECTIVES: * 1. Physically locate and explain the operation and function of the following: A. P-1530 A/B * 2. Physically locate the following for the above listed items. A. Field switch B. Main switch gear C. Shroud temperature transmitters. D. Suction valve E. Discharge valve F. Recirculation valve G. Bleed H. Seal Purge (if applicable) * 3. Explain how and if the above pumps are controlled by the mod. 4. Explain the importance of monitoring the shroud temperature and what you should do if it is high. * 5. List the safety devices for C-1530 and their setpoints. (psv) ( no oi4iia CONFIDENTIAL Xsafcfeiai C-1530 IPT MODULE PROCESS FAMILIARIZATION CONTROL AND SENSING SCHEMES i PURPOSE: To give you a good understanding of the control and sensing schemes in the C-1530 area, including location and purpose of key instrumentation. RESOURCES: P&ID'S, Experienced Personnel REQUIRED LEVEL OF PERFORMANCE: 100X Correct OBJECTIVES: * Explain the function of the following controllers and how they operate. A. A0( 213) B. A0( 204) C. A0( 223) D. A0( 233) E. D0( 222/232) (steam to reboiler) (Cooling tower water to EC-1530) (C-1530 btms out) (C-1530 vent) (C-1530 feed AOV) * 2 Explain the function of the following AOV's and how they operate. A. D0(204/214) B. D0(224/234 ) C DO(225/235) (C-1530 btms to E-1500 AOV) (C-1530 btms to T-804's AOV) (Steam to reboiler AOV) * 3. Physically locate the following instrumentation and explain their function. A. AI(203/213) B. AI(224/234) C. AI(216 ) D. AI(206 ) G. AI(226 ) I . AI(239) K. AI(237 ) L. AI(263) M. AI(264) (C-1530 level trans) (top pressure trans) (steam flow) (vent flow) (C-1530 to T-1500/T-804 ) (C-1530 diff press trans) (btms temp) (C-1530 ovhd temp trans) (E-1530 outlet temp trans) * 3 Draw a detailed diagram of the system,including all controllers and instrumentation in items #1 and #2 , 014119 00NFrDFK/TXA| C-1530 IPT MODULE / CONTROL AND SENSING SCHEMES i MOD V OPERATIONS PURPOSE: To give you a good understanding of the control and sensing schemes of the MOD V controller. RESOURCES: P&ID'S, Experienced Personnel REQUIRED LEVEL OF PERFORMANCE: 100* Correct OBJECTIVE: 1. Demonstrate starting up C-1530 and be able to explain what is taking place in each step. 2. Acknowledge and explain any given alarm. 3. Explain the conditions in which the MOD will automatically rerout C-1530 btms to T-1500. 4. Demonstrate changing any given setpoint and also explain what effect this change will have on the column. 5. Explain the conditions in which the MOD will automatically begin ramping down the rates and place the column on recycle. 6. State which valves and transmitters have abort code written and what are the conditions of the abort. DO 0141PO CONFTDFIMTTA! -*j^. . l'.^:-_-^' rilif-fh'-f^ C-1530 IPT MODULE PROCESS FAMILIARIZATION AREA HAZARDS & PROTECTIVE MEASURES PURPOSE: To familiarize you with the hazards and protective measures to reduce those hazards in your area. RESOURCES: S&LP, Experienced Personnel, Safety Procedures REQUIRED LEVEL OF PERFORMANCE: 100X Correct* * OBJECTIVES: * 1. State the chemical hazards of C-1530 * 2. State the electrical hazards of C-1530. * 3. State environmental problems and actions to be taken in event of the following spills: A. Leak on C-1530 btms line * 4. State the protective equipment requirements for maintenance on the following: A. C-1530 B. RE-1530 (reboiler) C. EC-1530 (fin fans) * 5. List the safety devices and their setpoints for the following pieces of equipment: A. C-1530 DO 014121 C0NFTDFNTTA1 C-1530 IPT MODULE PROCESS FAMILIARIZATION ( OPERATING DISCIPLINE PURPOSE: To give you a good understanding of operating parameters of the major equipment in your area. The problems associated with the process being out of operating parameters. r RESOURCES: Experienced Personnel, Operating Manuals, REQUIRED LEVEL OF PERFORMANCE: 10056 Correct OBJECTIVES: 1. State the normal operating parameters of the following. A. C-1530 top pressure B. C-1530 btms level C. C-1530 control temperature D. C-1530 differential pressure E. C-1530 btms temperature F. C-1530 Vent flow G. C-1530 overhead temperture H. HCL in C-1530 bottoms 2. State the results of high or low parameters and the results if it remains high or low. 3. Demonstrate using the MOD V what should be done to bring these problems back to within their normal operating parameters, include all the instrumentation that you should monitor. DO 0141 70 CONFTDFNTTAl C-1530 IPT MODULE ( SPECIAL SKILLS PURPOSE: To allow you to demonstrate your ability to perform tasks in a logical and safe sequence, using established job procedures. RESOURCES: Procedures, Experienced'Personnel REQUIRED LEVEL OF PERFORMANCE: 100** Correct OBJECTIVES: * 1. Demonstrate/simulate in the field completing each task in a logical safe manner, (use yellow tags for simulation) A. Line up C-1530 for start up. B. Heat up the steam line to RE-1530. C. Shut down C-1530 and isolate D. Draining C-1530 E. Pad/Depadding * 2. List the steps (in sequence) necessary to make the following equipment ready for maintenance: A. C-1530 B. P-1530 A/B C. RE-1530 D. PSV-C1530 A/B * DO 014123 OONFTDFNTTAl C-1530 IPT MODULE ( OPERATIONS ROUTINE CHECKLISTS PURPOSE: To familiarize and allow you to demonstrate completing routine checklists in your area. RESOURCES: Experienced Personnel, R ound Sheets, Operating Manuals REQUIRED LEVEL OF PERFORMANCE: 100% Correct* OBJECTIVES: * i. Demonstrate making a round explaining each item and its importance. DO 014T04 oonftdfnttai C-1530 IPT MODULE V OPERATIONS EMERGENCY PROCEDURES PURPOSE: To familiarize you with emergency conditions and procedures in this area. RESOURCES: Emergency Startup & Shutdown Procedures, Plant Personnel REQUIRED LEVEL OF PERFORMANCE: 100# Correct OBJECTIVES: 1. Given an emergency situation and shutdown procedure in this area, simulate (in sequence) shutting the area down, explain what is occurring in each step, include precautionary measures such as washing out and purging equipment, you will be tested on the following: * A. Leak on C-1530. * B. Fire * 2. Your area has just experienced a power failure, explain your actions, (power is still off), your answer should be step-by-step. Do n i 41 -> c, DONFinFNTTAI ,. "'-l *-#-* r; *< * " .. :,, -1 -'>, '"-. - . i' - r? --?'' - C-1530 IPT MODULE PROBLEM ANALYSIS "V PURPOSE: To allow you to demonstrate your ability to handle abnormal situations (upsets) when they occur in your area. RESOURCES: Procedures, Experienced Personnel, Operating Manuals REQUIRED LEVEL OF PERFORMANCE: 100* Correct OBJECTIVES: 1. List the sequence of steps you would take if the following condition were to occur. * A. HCL is high in the bottoms B. DP across the column is increasing C. Steam valve wound up D. High/low level in C-1530 E. M3 in the bottoms is high * F. C-1520 pressure is high and still increasing. * G. Loss of steam flow. * H. Pressure control valve wound up. * AN OS QUESTION. GR 5/91 Cl 530MOD.IPT DO 0141?6 CONFIDENT T A! CHLORINATED METHANES { GENERAL RESOURCE INFORMATION Department: CMP Job Title: C-1530/P-1530 General Information Scope: To Provide The Operator With The Necessary Information Needed For The Current IPT Training Program. The function of C-1530 is to finish "METHYLENE CHLORIDE". The feed from C-1520 reflux drum D-1521 is level controlled (AO 212) via (P-1521) to C-1530. The feed consist of "METHYLENE CHLORIDE" and "LIGHTS", which are "METHYL CHLORIDE" and "HCL". As the feed enters the column via AOV DO(222). The level in the bottoms of the column will start to increase. When a sufficient level has been established 30# Steam will be started through C-1530 reboiler RE-1530. As the steam begins heating up the bottoms product, the lighter components (lower boiling points) are vaporized and driven upward through the column. They pass through the integral overhead exchanger EC-1530 where the he viest of these components (methylene chloride) are condensed by a cross exchange with cold cooling tower water (pressure controller). The condensed product begins flowing back down through the column as reflux, condensing the heaviest of the components on each tray. The components that were not condensed (Ml & HCL) are vented back (flow controlled) to the vent recovery system E-1700. The cooling tower water control valve A0(204) on EC-1530 is the pressure control valve for C-1530. As the pressure on the column increase, the pressure transmitters (AI 224/234) located on the overhead line sends a signal to the MOD V controller, which in turn sends a signal to the control valve to open. Thfs will increase the water flow through EC-1530 and condense more of the gas in the overhead, thus lowering the pressure. During start up, the bottoms of the column will be level controlled to T-1500. Once the column has'been lined out and sample results are within our product specs, the board operator can being going forward into T-804 A or B. Once the product has been started forward, cyclohexane is added into the stream. Cyclohexane is used as an inhibitor to keep the product from breaking down to HCL, causing discoloration. We try to maintain approx. 200 to 400 ppm cyclohexane concentration in the T-804's. continued: DO 014177 CONFTDFNTTAl ( C-1530 GENERAL INFORMATION page 2 To help board operator determine how much load the column can handle, it is equipped with a differential pressure transmitter AI(239) which will indicate a differential pressure across the column. This will help us determine when the column has reached maximum capacity and also if flooding condition exist. The normal differential pressure is approx. 6 psig. the normal concentrations of the bottoms product is 10-15 ppm water and 1-3 ppm hcl. the normal operating temperatures on the bottom of the column is 85-87 deg c. SAFETY Required safety gear when catching samples on this column is Hard Hat, Scott-O-Vista, Rubber Gloves, Multi-bit Respirator and Monogoggles. Monogoggles and Multi-bit Respirator just have to be on operational personnel. Required safety gear when opening lines are Hard Hat, Monogoggles, Gloves & Multi-Bit respirator. Monogoggles to be worn when breaking into lines. Prior to any line opening the line must be drained, purged & properly tagged. Also, If contract workers are doing the break in, it is required that the line be initialed by DOW supervision or their designee and the contract foreman. Also a safe work permit has to be issued to the contract personnel and the redtag master accepted, (see line opening procedure). Anytime work is performed in the piperack a safety harness is also required along with the minimum block standards. Anytime PSV's have to be taken out of service, Monogoggles, Hard Hat, Gloves Have to be worn. Nfu'lti-Bit Respirator has to be on you person. HAZARDS The HAZARDS of this system is "CHEMICAL EXPOSURE", ROTATING EQUIPMENT, and FALLS. CHEMICAL EXPOSURE Exposure to Methylene Chloride could occur when preforming normal job duties such as sampling or line opening. Proper safety gear must be worn. oo Co NF 0i41P8 tofNTtai C-1530/P-1530 General Information page 3 l ROTATING EQUIPMENT C-1530 has 2 pumps which are taken out of service for repair. The proper safety gear must be worn when performing this operation. The Coupling Guard should be on these pumps at all time to protect personnel while working around the pumps, except when the pumps has been properly tagged and prepared-for maintenance. FALLS C-1530 is equipped with ladders on the side of the column, giving access to the upper decks on the column. The ladder have a guard rail/cage around the ladder. Caution should be taken when climbing. Finger Rings are not allowed when climbing is involved. The line to C-1530 run through the main pipe racks. Occasionally it becomes necessary to climb in the rack. A Safety Harness is required when entering the pipe rack. ENVIRONMENTAL To protect the column in the event the column overpressures the column is equipped with several safety devices such as safety valves which are set to relieve at 75 psig. There are numerous alarms on the MOD V control panel which will inform us of any potential problem. If a release should occur, Methylene Chloride will be emitted to the atmosphere. OPERATING PARAMETERS Top Pressure Btms Pressure Control Temp. Differential press Btms Temperature C-1530 Vent flow HCL in C-1530 btms DESIGN 48# 5 OX 50 deg C 5.5# 70 deg C 50# <5 ppm * r"> Dimensions T rays Design Pressure Design Temperature 2'6" ID x 60' Tan to Tan 33 valve trays Tray 1-21 Chrome steel Tray 22-33 Monel 75 psig 400 deg F RE-1530 Design Pressure Shel1/Tube Mat. of Construct Shell/Tube 250/100 psi Carbon Steel/ 70/30 cu/ni EC-1530 Design Pres 75 psig C-1530 GENERAL INFORMATION page 4 ( \ P-1530's are C-1530 bottoms pumps. One of these pumps will energize when the MOD V controller is placed in step 222 and there is sufficient level in C-1530. If both pumps are in the AUTOMATIC position in the field, the (A) pump will be the primary pump. When a sufficient level is reached the (A) pump will energize. If the (A) pumps doesn't energize within approx 4-6 seconds the (B) pump will. If while running the low flow alarm for this pump activates the spare pump will automatically energize. the operator can energize the spare pump from the MOD by initiating a DM function, DM(135). These pumps will automatically shutdown if we have a low level. P-1530 is a sealless magnetic drive pump, (magdrive) Speed Flow volts Phase Hertz Mat of construction -- = = = = = 3500 rrpm 50 460 3 60 Casing Cast Steel Impeller - Ductile Iron GR/TN 1/92 revised GR 8/92 Cl530GEN.RES DO r-ONF 014100 fnFNTT Al CHLORINATED METHANES ( GENERAL RESOURCE INFORMATION Department: CMP Job Title: E-1530 General Resource Information Scope: To provide the operator with the necessary information needed for the current IPT program E-1530 is C-1530 bottoms fin fan cooler. It shares the same fans as C-1540 and C-1550 bottoms. Its purpose is to decrease C-1530 bottoms product temperature from approx 88 deg C to 39 Deg C. prior to entering the t-804's. This will keep the T-804s from venting as much to the psa system. The exchanger utilizes two fans which pull air up through the fans shroud across the outside of the tubes, cooling the product flowing through the tubes. This will keep the tanks that the product is being stored in from excessive venting. The fans utilized in this system also supply air circulation for all the distillation bottoms coolers. OPERATION/DESIGN TUBES Rows Size Material of constr. Design Pressure Design Temperature 4 1" x 20' 90/10 CU/N1 150 psig -20-500 deg F FANS Motor Diameter 10 hp 8 ft TN 2/92 revised GR 8/92 El530GEN.RES DO 014131 C0NFTDFNTTAI V` ' . *-r_v- - v-.. . CHLORINATED METHANES SAFE JOB PROCEDURE Department: CMP Job Title: C-1530 Drain Procedure Scope: To Assist The Operator In Draining C-1530 When It Is Being Prepared For Maintenance. Major Hazard(s): Chemical Exposure, Hot Lines. . Safety Equipment Required: Minimum Block Standards. 1. Ensure that the associated block valves are manually Dlocked in. With the exception of the bottoms level control valve AO(223). 2. Ensure that all AOV's that are used for isolation purposes and that are "FAILED CLOSED" valves, have the "AIR" to them shut off. With the exception of D0(204) 3. Connect a N2 hose to the top head of the reboiler if there's not sufficient pressure already on C-1530 and pressure the column up to approx 25# above T-1500 pressure. (BE SURE YOU USE THE CORRECT N2 HOSE INSTALLATION PROCEDURE). C-1530 SAFETY'S ARE SET AT 75# 4. Ensure that the bottoms AOV's to T-804'S are closed. 5. Open C-1530 bottoms AOV D0(204) to T-1500 . 6. Place the bottoms level control valve AO(223) in manual and open. 7 . Place the bottoms pump in manual on the mod and give it a value of (1) this will energize the pump. Pump as much product as possilbe to T-1500. 8. When the board operator feels that the column is about to go empty station an operator by the pump. *When the pump begins to gas out, immediately shut it down. 9 . Place the bottoms level control valve and AOV back in automatic and ensure that it did close. 10. Hook up a N2 hose to the suction of the pumps. Block in the suction valve and discharge valve and blow N2 through the ARC valve. This will clear the lines of liquid. 1 1 . Low point the following lines. A. Suction line on pumps. B. Reboiler 12. Hang the necessary tags needed for the job. 13. See Pad/depad procedure (where applicable). TKI 9 /9 Cl530DRN.PRO v- j --^-i---^~^-j-^- CHLORINATED METHANES SAFE JOB PROCEDURE Department: CMP Job Title: C-1530 Pad/Depad Procedure f Scope: To Assist The Operator In Pad And Depading C-1530 When It Is Being Prepared For Maintenance. Major Hazard(s): Chemical Exposure, Inert Atmosphere. Safety Equipment Required: Minimum Block Standards. 1. Ensure that C-1530 is completely drained of liquid. 2. Ensure that all the lines into and out of C-1530 are drained of liquid and all valves are manually blocked in. 3. Ensure that all AOV's that are used for isolation purposes and that are "FAILED CLOSED" valves, have the "AIR" to them shut off. 4. Run tubing on the downstream side of the vent control valve to to a throx tie point to the dry header. 5. Block in the downstream block valve on the vent control valve and using the vent control valve, depressure C1530. 6. Connect a N2 hose to the top head of the reboiler and pressure the column up to approx 50#. (BE SURE YOU USE THE CORRECT N2 HOSE INSTALLATION PROCEDURE). 7. Using the vent control valve, begin depressuring the column to the throx. Monitor the throx while doing this. 8. Pad and depad until the system is clear. 9. Check with supervision and see if't.hey want to leave a N2 purge on the system. If not, disconnect the N2 hose. 10. Hang the necessary tags. TN 2/92 Cl530PAD.PRO no 014133 CONFTDFNTTAl CHLORINATED METHANES SAFE JOB PROCEDURE Department: CMP Job Title: C-1530 Controlled Shutdown Procedure Scope: To Assist The Operator With the Safe & Controlled Shutdown Of C-1530. Major Hazard(s): M2.HCL, Hot Lines, Hot Steam/Condensate. Safety Equipment Required: Minimum Block Standards NOTE: WE SHOULD BE ABLE TO PUT D-1521 BACK TO T-1500 FOR ABOUT 4 HRS BEFORE IT PRESENTS ANY PROBLEMS, WHEN SHUTTING C-1530 DOWN. (DEPENDING ON THE LEVEL IN T-1500) 1. Place C-1530 in the control shutdown step (224). This will close the feed AOV (DO(222) and open the AOV from D-1521 to T-1500 D0(202). Ensure that this took place. 2. Monitor T-1500 level and flow to E-1420. AO(132) T-1500 level control valve will be attempting to control the level at AK(802) setpoint. The increase in the feed rate and the M2 concentration in T-1500 to D-1450 will change the composition of the feed to distillation. Monitor C-1510/1520 operations when doing this. If you think the change in composition is going to drastically effect distillation, you can go on flow control with AO(132) by setting AK(839) at a value greater than (0). Take the level raise in T-1500. 3. Slowly decrease R-1300 rates using AK(111). This will decrease the amount of M2 that is being made in R-1300 and slow down the level raise ir1T)-1450 from T-1500. 4. Place C-1530 in step 225 (SHUTDOWN STEP). * Ensure that control valves become disabled and closed. 5. When the levels in T-1500/D-1450 get to high we may have to shutdown R-1300 and place the rest of distillation on total recycle. (SEE R-1300 SHUTDOWN PROCEDURE) TN 2/92 Cl530SD.PRO DO 014134 OONFTDFNTTA! C-1530 SYSTEM CHLORINATED METHANES START UP CHECK SHEET 1 DEPARTMENT: METHANES JOB TITLE: INITIAL LINE UP AND START UP C-1530 (MOD V) MAJOR HAZARDS: HCL, M2, HOT LINES SAFETY EQUIPMENT REQUIRED: HARD HAT, MONOGOGGLES,RESPIRATOR,SAFETY GLASSES AND HEARING PROTECTION. SPECIAL PROVISIONS: THE FOLLOWING ITEMS MUST BE CHECKED (YES) AND INITIALED PRIOR TO C-1530 BEING STARTED UP. NOTE: MAKE SURE ALL CONTROL VALVES ARE IN THEIR PROPER POSITION BEFORE LINING CONTROL VALVES UP.(MOD V)(BOARDMAN) CHECK A. HAVE ALL RED TAG MASTERS BEEN CLEARED AND TAGS PULLED. (OUTSIDE OS/SOS) B. IS C-1520 RUNNING C. IS D-1521 LEVEL GREATER THAN 35X D. IS THE FLOW FROM D-1521 TO T-1500 BETWEEN (5000 - 10000# HR) E. MAKE SURE THAT THE STEAM TRACING ON F. HAS THE STEAM LINE TO C-1530 BEEN HEATED UP (USE THE 1" LINE AROUND THE AOV) G. HAVE ALL QUICK OPENING VALVE BEEN BLOCK & BLINDED OR BULL PLUGGED. *^ H. MAKE SURE THE FOLLOWING MANUAL VALVES ARE LINED UP 1. FEED VALVE AT COLUMN 2. BTMS OUT VALVE UPSTREAM OF PUMPS 3. CONDENSATE TRAP FOR RE-1530 4. STEAM VALVE AT HEADER INITIAL I on 14135 OoNf r0^T7A/ C-1530 SYSTEM START UP CHECK SHEET I. MAKE SURE THE FOLLOWING CONTROL VALVES ARE LINED UP AND THE AIR TO EACH CONTROLLER IS OPEN. 1. A0(233) VENT CONTROL VALVE 2. A0(213) STEAM CONTROL VALVE 3. A0(223) BTMS CONTROL VALVE 4. A0(204) COOLING WATER VALVE J. MAKE SURE THE FOLLOWING INSTRUMENTATION ARE LINED UP. 1. AI(216) STEAM FLOW TRANSMITTER 2. AI(206) VENT FLOW TRANSMITTER 3. AI(234) & AI(224) PRESSURE TRANSMITTER 4. AI(239) DIFFERNTIAL PRESSURE TRANSMITTER 5. AI(203) & AI(213) C-1530 BTM LEVEL TRANSMITTER 6. AI(226) C-1530 BTMS FLOW TRANSMITTER K. ARE THE PUMPS LINED UP AND FIELD SWITCHES IN AUTO (THIS INCLUDE SUCTION,DISCHARGE,ARC VALVE & BLEEDS CLOSED AND BLINDED) L. MAKE SURE THE FLOW THROUGH SAMPLE POINT ON THE PUMPS ARE LINED UP. M. HAS THE ENTIRE SYSTEM BEEN WALKED OUT AND LINED UP AND ARE ALL BLEED VALVES CLOSED AND BLINDED.(OUTSIDE OS/SOS). PAGE 2 DATE/TIME: APPROVED BY: (SUPERVISOR) AND/OR (BOARDMAN) I DO 014136 OONFTDFNTTAl nrtfwiiiMfM n n hVnVi t J.'n'iWn . C-1530 SYSTEM MOD V CHECK SHEET THE FOLLOWING ITEMS MUST BE CHECKED AND INITIALED PRIOR TO START UP. CHECK INITIAL A. IS THE GPI SYSTEM WORKING PROPERLY B. ARE ALL THE MANAUL DISCONNECT SWITCH IN THEIR CORRECT POSITION C. ARE ALL THE LAMP BULBS ON THE MOD V WORKING PROPERLY D. ARE THERE ANY (DS) ALARMS ON (IF SO CHECK OUT AND CALL HARDWARE PERSONNEL) E. ARE BOTH MOD V COMPUTERS RUNNING F. IS THE MOD V PRINTER WORKING PROPERLY G. HAVE ALL ALARMS BEEN CLEARED. (ALARMS ) H. HAVE MANUAL SHUTDOWN SWITCHES BEEN RESET TO THEIR PROPER POSITION.(IF APPLICABLE) I. HAVE THE ABORT KEY IN ITS PROPER POSITION J. HAVE ALL THE PERMISSIVES FOR STEP (222) BEEN MET K. MAKE SURE ALL CONTROL VALVES AND INSTRUMENTA TION ARE IN THE AUTOMATIC POSITION ON THE MOD L. IS THE MOD IN STEP 221 (PROCESS WAIT) M. MAKE SURE THAT THE FOLLOWING*(AK'S) AND (AP'S) HAVE THE CORRECT SETPOINTS. 1. AK(227) = ( 2. AK(252 ) 3. AK(233 ) 4. AK( ) ) DEGC BTMS TEMP VENT FLOW STM/FEED RAT PRESS WHEN THE ENTIRE CHECK SHEET HAS BEEN FILLED OUT AND ALL ITEM ARE OK, THEN YOU CAN TERMINATE FROM STEP (221) TO STEP (222) AND LET THE MOD V START UP C-1530. ! \ DO fl 1 4 | 3 ^ donftdfn/ttai . "-i-H - CHLORINATED METHANES SAFE JOB PROCEDURE Department: CMP Job Title: C-1530 START UP PROCEDURE Scope: To Assist The Operator With The Safe Start Up of C-1530 Major Hazard(s): M2, HCL, Hot lines, Falls Safety Equipment Required: Minimum Block Standards Except When Climbing Which Required a Safety Harness 1. Complete the C-1530 Start Up Check Sheet & Mod Check Sheet 2. Terminate step 221 3. Monitor level,temp,pressure & valve response during start up . (if problems occur during start up don't hesitate to move to step 225 and shut C-1530 down). 4. Verify the pumps energize when the level in the column becomes greater than AP(270) value. 5. When the MOD terminates to step 223 and the temps/pressure looks good, catch a C-1530 bottoms sample and analyze. If good, put the product forward into T-804'S by making DK(72) "TRUE". TN/GR 12/91 Cl530SU.PRO DO 014130 OONF T DFK/T T A! I'fl <! CHLORINATED METHANES ( GENERAL RESOURCE INFORMATION Department: CMP Job Title: C-1530 TROUBLE SHOOTING INFORMATION r Scope: To provide the operator with the necessary information needed to assist them in trouble shooting the plant. IF ANY OF THE FOLLOWING CONDITIONS OCCUR CHECK SOME OF THE FOLLOWING: A. High HCL concentration in the bottoms samples. *. Increase the steam flow/temp setpoint *. Increase the vent flow it may be insufficient *. Recheck sample. *. Check D-1521 sample for HCL. *. Make necessary adjustments on C-1520. #. Ensure we are operating at normal operating pressures. #. Check the feed flow it may be excessive. Also check D-1521 level control valve and make sure it is functioning properly. B. D/P ACROSS THE COLUMN IS RISING *. Check the vent flow, may need to increase to help decrease the amount of reflux *. Cut steam, may be driving column to hard *. Check the feed rate. May be above max feed flow *. Check the BOTTOMS out of THE COLUMN make sure we have an adequate flow. *. Using guages verify the transmitter is^functioning properly. *. Check the bottoms level transmitters and ensure they are functioning properly. C. STEAM VALVE WINDING UP NOTE: You should get an alarm if this condition occurs. *. Check the condensate trap may not be working. *. Check the reboiler shell side pressure. The reboiler may be dirty, (unlikely though) *. Check the temp setpoint and ensure it is set to the normal operating parameter. *. Check the 30# steam system and ensure we are running at the normal operating parameters. I ntinued: 00 014139 AM* / C-1530 TROUBLE SHOOTING INFORMATION i _____________________________________________________________________________ page 2 D. HIGH PRESS. ON COLUMN *. Check pressure control valve and ensure that it is functioning properly. *. Check the steam control -valve and ensure it hasn't come wide open due to some malfunction. *. Increase the vent flow setpoint. We may be taking an insufficient vent flow and building up with HC. Also check the vent recovery system pressure. #. Check the vent control valve and ensure that it is functioning properly. *. Check the cooling tower water pressure. Due to outside temperature and cooling tower sump temperatures w may be using a lot of water and the pressure may be low. *. Check the cooling tower sump temperature and low r if possible. This will increase the efficiency of all the exchangers in the plant that use cooling tower water. *. If the cooling tower water pressure is low check the cooling tower pumps and ensure that at least two pumps are on-line. Also, ensure that we have an adequate level in the sump. #. Ensure that we don't have a build up of MUD in the sump. *. Open the bypass around the pressure control valve. E. LOSE BTMS FLOW *. Check bottoms pump and ensure one of them is on-line. *. Check bottoms control valve make sure it is open *. Check the bottom AOV make sure it is working and open. *. Check the bottoms flow transmitter and ensure it is funtioning properly. F. HIGH OR LOW LEVEL IN C-1530 *. Check level transmitter to ensure it is functioning properly also verify.^one level trans against the other. *. Run a trend chart on both level transmitter and see if there may be a problem *. Check the bottoms pumps and ensure they are running *. Check the bottoms control valve and ensure it is open and properly lined up. *. Check the bottoms out AOV and ensure it is open and hasn't failed (also check for DI/DO MISTMATCH). *. Ensure that we haven't lost steam flow, (cond trap) or steam valve closed or steam AOV has failed closed. *. Ensure that we are at the correct operating pressure. t ntinued: 00 01AlAO CONFTDFNTIAI dM. C-1530 TROUBLE SHOOTING INFORMATION page 3 LOW LEVEL: *. Check flow through sample point around btm c/v nsure that is was not left open. *. Check btms C/V may not be working properly. *. Check level transmitter to ensure it is functioning properly also verify one level trans against the other. *. Ensure that the steam valve is working properly and that we are not boiling everthing up the column. *. Ensure that we are at the correct operating pressure. NOTE: CHECK ALL ALARMS J. LOW PRESS. ON C-1530 *. Using guages, ensure that the transmitters are correct. *. Check the pressure c/v and ensure it is functioning properly and that the valve is closed. *. Ensure that there is no bypass water around the control valve. *. Decrease the vent flow, it may be excessive. *. Check the steam flow and control valve. Also check the steam trap, (see steam valve wound up) L. PRESSURE CONTROL VALVE IS WINDING UP. *. Check the cooling tower water pressure. Due to outside temperature and cooling tower sump temperatures we may be using a lot of water and the pressure may be low. *. Check the cooling tower sump temperature and lower if possible. This will increase the efficiency of all the exchangers in the plant that use cooling tower water. If the temperature in the sump is high check the fans. *. If the cooling tower water pressure is low check the cooling tower pumps and ensure that at least two pumps are on-line. Also, ensure that we have an adequate level in the sump. *. Ensure that we don't^fiave a build up of MUD in the sump. *. Open the bypass around the pressure control valve. *. Backwash overhead exchanger *. Check the vent c/v may need to vent more to the vent recovery system. M. M3 IN THE BOTTOMS SAMPLE IS HIGH. *. If out of spec, put back to T-1500. *. Check C-1520 reflux drum for M3. *. Check C-1520 temperature and adjust. *. Increase the reflux flow on C-1520. *. Reduce R-1300 rates if the columns are unstable and we are going back with M2 product for a lengthy period of time. TN/GR 1/92 C1530TBL.SHT DO 014141 OONFTDFNT I At.. -f CHLORINATED METHANES ^ EMERGENCY PROCEDURES Department: CMP Job Title: Fire in The Distillation Area. Scope: To Assist The Operator When An Emergency Situation Occurs. Safety Equipment: Scott-Air-Pack O.S Response 1. Start deluge guns . 2. Communicate your findings to the board operator or supervison. Tell the SOS to start the sprinkler system or if possible manually trip the system. 3. Make sure the area is clear of all NON-ESSENTIAL personnel. 4. Attempt to determine what's on fire. 5. Determine the area in which the fire is occuring. * If the fire is on a section of line that can be isolat d then do so immediatly. * If the pumps are on fire, hit them with the deluge gun, putting the fire out, then isolate, (the motors are shielded and should not be affected by the water) * If the fire is underneath a tank or column, extreme caution must be used. The excessive heat can cause a pressure build up and the safety's will release causing a large spill with the potential for ignition. * If the safety valve beginsrreleasing, get out of the area. S.O.S Response 1. Turn the sprikler system on in the area of the fire 2. Hit the SPILL ALARM ( DO 014142 CONFTDFNTTAl EMERGENCY PROCEDURES FIRE IN THE DISTILLATION AREA. PAGE 2 ^CONTINUATION: 3. Announce over the PA system that we have an Fire and Possible spill and that all HOT WORK should be stopped. 4. Check the wind direction before announcing the evacuation point of all NON-ESSENTIAL personnel. 5. Call in the emergency to the front gate . * Dial 333 and wait until everyone picks up * Give them your name and location * Tell them we have a fire and possible spill * Tell them the level spill (If Applicable) Catagory 1 = In Block Catagory 2 = Out of Block Catagory 3 = Out of Division * Have someone available to meet security 6. Depending on the severity of the fire, weather you will have to shut down the plant and evacuate. (SEE SHUTDOWN PROCEDURE) Supervisors Response 1. Asses the severity of the situation. 2. If a fire has the potential of cuasing an explosion concider the following. A. Shut the plant down and evacuate. NOTE: NOT ONLY OUR PLANT MAY HAVE TO BE EVACUATED BUT THE REST OF THE PLANTS IN THE DIVISION OR CLOSE PROXIMITY. GR 12/91 DISTFIRE.EMR f DO 014140 OONFTDFNTTAI department: CMP CHLORINATED METHANES EMERGENCY PROCEDURES Job Title: Spill In The Distillation Area. Scope: To Assist The Operator When An Emergency Situation Occurs. O.S Response 1. Observe the spill from an area upwind or from a safe distance, Determine the area in which the spill is occuring. Determine if a SCOTT-AIR-PACK is needed. 2. Communicate your findings to the board operator or supervison. 3. Clear the area of all craftsman and NON-ESSENTIAL personnel. 4. Determine the corrective action you are going to take. * If the leak is on a section of line that can be isolated, and the line is identified, get the O.K. from the boardman or supervisor then block in the line. * If the pump has blown a seal, swap pumps and shut the leaking pump down and isolate. S.O.S Response 1. Hit the SPILL ALARM 2. Announce over the PA system that we have an Spill in the distillation area (state which area it is in) and" and that all HOT WORK should be stopped. 3. Check the wind direction before announcing the evacuation point of all NON-ESSENTIAL personnel. 4. Call in a Spill to the front gate . * Dial 333 and wait until everyone picks up * Give them your name and location * Tell them the type of Product being released * Tell them the level spill Catagory i = small Catagory 2 = medium Catagory 3 = large CONTINUED: t 014144 OONFTOFNT TAI JL ( EMERGENCY PROCEDURES SPILL IN THE DISTILLATION AREA. PAGE 2 Type Spill column overheads bottoms C-1550 C-1510 C-1520 C-1530 C-1540 C-1550 T-1500 D-1525 HCL/M1 Ml/M2/M3/M4/HCL M1/M2/HCL M2/M3/M4/HCL M2/HCL M3/M4 HCL M2 M3/CL2 M4 CL2 M3 M1/M2/M3/M4/HCL M3/M4/CL2 * Have someone available to meet security 5. Communicate with the supervisor/SOS/OS as to what systems may have to be shut down, or what bottoms/overhead line from a distil lation columns may have to be rerouted, or if the leak is in a section of line that can be isolated without effecting the main operations of the plant. 6. If a distillation column has to be shutdown, SEE EACH COLUMNS INDIVIDUAL SHUTDOWN PROCEDURE. 7. Discuss with the supervisor the severity of the spill and wheather you will have to shut the entire plant down and evacuate. Supervisors Response 1. Asses the severity of the situation. 2. If a leak on the column or tank should occur, concider the following. A. Rope of the area, have fire fighting equipment availabe on the site. B. Attempt to plug the leak if it is a small area. C. Have the board operator shutdown/reroute equipment/product. NOTE: IF THE COLUMN OR FEED TANK HAS THE POTENTIAL FOR A CATASTROPHIC FAILURE, SHUT THE PLANT DOWN AND EVACUATE. CATASTROPHIC FAILURE: I.E. = IF THE VESSEL HAS LARGE CRACK IN THE WELD TO WERE THE ENTIRE VESSEL COULD RUPTURE WIDE OPEN. GR 1/92 DISTSPIL.EMR 00 01414c; CONFTDFNTTA!. CHLORINATED METHANES SAFE JOB PROCEDURE Department: CMP Job Title: EMERGENCY PROCEDURE IN THE EVENT OF A MOTHER BOARD FAILURE Scope: General information on possible ways to determine which mother board has failed and corrective measures WAYS TO DETERMINE WHICH MOTHER BOARD FAILED 1. DS light #7 indicates which computer is driving the graphics display and alarm scan. This DS light is lit all the time when the left computer is driving the graphic display and when the light is off the right computer is driving the graphic display. They will automatically swap this job backwards and forwards on a time basis. Another check that can be done is open the door on the MODV can and on the inside you will see rows of do cards with lights on them. In each row of cards the left row is for the left computer and the right row is for the right computer. All the lights should be on (may be dimly lit) if any of the lights are off or blinking then that computer is probably having problems. By understanding the above information. If the system is acting up when the DS #7 light is on then it is likely the left computer (mother board) is the problem or if the system has problems with DS #7 light off it is likely the right computer is the problem. 2. If you can the determine which computer is giving problems then that computer can be haulted by using the switch below the computer and the other computer will contiue to run the process. In the event the wrong computer was haulted just turn the switch back on and hault the other one. NOTE: If system is acting strange the system can be shutdown and problems with the computer cap be repaired and system restarted. NOTE: If you haulted a computer always contact the area engineer as soon as possible so he/she can notified the proper people to have it reparied or contact the mod 5 hardware group directly, the mod hardware group is on call on a 24 hour basis. NOTE: MOD 5 hardware group PHONE #6248 AFTER HOURS 295-6770 DG/7/18/91 M0DM0THER.PRO 014146 CONFTDFNTTAI CHLORINATED METHANES SAFE JOB PROCEDURE department: CMP Job Title: Starting and swapping MOD V operated pumps. Scope: To provide the operator with the necessary information needed to properly start,swap and restart a MOD V operated pump. Major Hazard(s): Not filling the pump bowl with liquid prior to starting can damage the pump when energized. Safety Equipment Required: Minimum block standards for swapping. Scott -o- vista and rubber gloves to drain pumps. Environmental Hazards. A chemical release due to a malfunctioning seal NOTE: IF THIS PUMP IS A MAG DRIVE PUMP, MONITOR AMP AND PRESSURE. IF AMPS AND PRESSURE ARE SWINGING, THE PUMP MAY BE CAVITATING. TO PREVENT DAMAGE TO THE PUMP, SWAP PUMPS AND SHUT DOWN. IF THE AMPS ARE LOW AND THE PRESSURE HIGH, THE PUMP MAY BE DEAD HEADED. I, Lining up a MOD V operated pump 1. Close and blind any bleed valves on the pump. 2. Line up the suction, discharge and recirculation. (check for leaks) 3. Bump the starter (on then back to off). This will fill the bowl up with liquid and help eliminate damage to the pumps (MAG DRIVE'S) 4. If both pumps are available for operation place the (A) pump field switch in the "AUTO" position first, then the (B) pump field switch. (When the switches has been placed in the auto position it will indicate to the MOD and the BOARD OPERATOR that everything is O.K.) The MOD will start up the following pumps automatically, when the right conditions exist and the: field switches are -in "AUTO". A.. P-1250 A/B B.. P-1260 A/B C,, P-1320 A/B D.. P-1450 A/B E., P-1500 A/B F. P-1511 A/B G. P-1520 A/B H. P-1521 A/B I . P-1525 A/B J. P-1530 A/B K. P- 1540 A/B L. P- 1541 A/B M. P- 1550 A/B N. P- 1710 A/B The following pumps wi 11 have to be started by the board initiating a (DK) function. A. P-1750 = DK(150) B. P-1760 = DK(100) C. P-1770 = DK(102) The condensate pot pumps will have to be started by the outside operator. 00 014147 conftdfnttai r-- mV STARTING AND SWAPPING MOD V OPERATED PUMPS. pag 2 ^ I. SWAPPING MOD V OPERATED PUMPS AND PREPARING PUMP FOR MAINTENANCE. In the event the pump that is presently on-line needs to be swapped, it will be necessary for the board operator to initiate a (DM) function to energize the off-line pump. The off-line pump must have the field switch in the "AUTO" position and already be lined up in the field.(NOTE: THEIR ARE A EW PUMPS WHICH WILL HAVE TO BE PLACED IN MANUAL TO SWAP, USUALLY ON THE TANKS) The following is a list of the pumps that will AUTO START when their (DM) values are set: A. P-1250 A/B B. P-1260 A/B C. P-1320 A/B D. P-1450 A/B E. P-1500 A/B F. P-1511 A/B G. P-1520 A/B H. P-1521 A/B I . P-1525 A/B J . P-1530 A/B K. P-1540 A/B L. P-1541 A/B M. P-1550 A/B N. P-1710 A/B " DM (210) = DM ( 214) = DM(136) = DM(134) = DM(IOO) = DM(107) = DM(130) = DM(133) DM(131) DM(135) DM(150) = DM(153) = DM(155) = DM(216 ) 1. Energize the pump by initiating the proper (DM) function 2. Once the board operator feels he has good control then shut down the other pump in the field by placing the field switch in the "OFF" position. NOTE: If you are making a weekly or monthly pump swap, then set the pump up in the back up mode. If the pump is in need of repair move to item # 3 3. Block in the suction, discharge and recirculation valves. 4. Bleed down using both bleed valves (suction and discharge bleed valves after the ARC valve). BE SURE TO ROD OUT THE BLEED VALVES TO MAKE SURE THEY ARE NOT PLUGGED. If the CONTENTS are CHLORINATED HYDROCARBONS, you need to depressure the pump to the throx unit through the collection header.(DO NOT DEPRESSURE D-1525 OR C-1540 REFLUX PUMPS TO THE COLLECTION HEADER BECAUSE OF CHLORINE CONTENT) 5. Tag out the pump and check the field switch. (THE FIELD SWITCH WILL BE CHECKED BY THE OPERATOR WHO WILL ISSUE THE SAFE WORK PERMIT AND THE MAINTENANCE PERSONNEL WHO WILL BE WORKING ON THE PUMP. 6. Once the pump has been the line up procedure. GR 9/91 Updated:8/92 repaired, pressure it up and then follow _________________ Do 014149 MODVPUMP.PRC C0NFTDFNTTA1 CHLORINATED METHANES SAFE JOB PROCEDURE apartment: CMP Job Title: STEAM LINE HEAT UP PROCEDURE Scope: General information on ways to properly heat up line. 1. To heat the steam line the 1" line around the steam aov will have to be manually open. 2. Then a small bleed on the upstream side of the steam control valve can be taken until all condensate is bled out. This will have to done slowly to keep the line from hammering. 3. Once the line is free of condensate and is hot, then the jumper line between the steam header and condensate can be lined up to keep the steam line hot. 4. Then the bleed to atomsphere can be block at this time. 5. The steam control loop can be line up as needed. DG/CB 09/24/91 revised GR 6/92 STEAMHEAT.PRO r DO 014149 CONFTDFNTTAI