Document 0gae2623b26ojdzGZrvGZ6GM

^INDUSTRIES INDUSTRIAL CHEMICAL DIVISION .'!$:ON LAKE CHARLES, LOUISIANA i CENTRAL STEA,,My* STRIPPER ^ - "OPLRAT^?^4ANUAL xrCi. J COtTFtDECTIM&S Subject, to Pror-ot:. Of 14th J r . : V . ^-r;`~r *'4 Ci- X "" 1^ ** OCTOBER, 1980 MANUAL NO. Z-_____ ASSIGNED TO: CONFIDENTIAL CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 SL 000001 Memorandum To: Billy Jr. From: Michael Tritico Date: 12/18/97 Dear Billy, After we. hung up the phone awhile ago I began to recall some things and decided to search my old reports in this computer for "vinyl." Here are the ones that turned up that seem to most clearly apply to what you were asking me about: SL 007887 08/04/85 refers to end of EPA authority, takeover by DEQ, and "we no longer have the 40 minutes grace period to restore vents after a trip." SL 047743-744 11/17/84 upset released 3.2 lbs. VC SL. 047759-60 10/05/83 18 lbs. SI,047761-62 04/07/83 3.9 lbs. SL 047785 10/11/79 new EPA spill reporting guidelines, if over 600 gallons of VC. spill, must report SL 026385-91 03/05/86 5 incinerator bypasses in 1 month -140 lbs. 3 in another month -1,637 lbs. 30 seconds single event -1,615 lbs. SL 026533-536 09/14/92 pipeline leak - 2,800 lbs. SL 026583-86 06/14/91 1,140 lbs. And statement that "false alarms are not uncommon in warm weather." And a 15 second event released greater than 1,000 lbs. SL 07319 06/13/80 WTU scrubber stack normally releases 3.6 pounds per day vinyl chloride. SL 088773-74 05/29/81 event -1,750 lbs. SL 104326 07/10/ 87 3 lbs. Plant B leak SL 104960-961 1975 memos about worker overexposure to VC SL 104985-992 1987 legal dispute between LA AG and PPG lawyer over numerous vinyl chloride releases SL 104993-105020 1987 more documents about that situation SL 105465-67 ? loading operation large fugitive emission release South Terminal VEV 492752-759 1987 releasing 8,521 lbs. DEQ/Vista settlement $12,000 for 24 events VEV 493093-96 emissions 03/30/79 Conoco objects to spending $ to control VC I don't know il this is stuff you already remembered or not, but I figured that I'd better send it by tax tonight in case you might need it in the morning. (Sorry my memory is damaged and it took me awhile to remember that we might have some of this. Thank goodness for computer memories.) Mike 12/18/97 8:45 P.M. CENTRAL OHC STEAM STRIPPER AREA INTRODUCTION This operations manual has been prepared to fulfill the following objectives: (1). To serve as a training guide for supervisors and operators involved with the Central OHC Steam Stripper Operation. (2). To serve as a ready reference for operations personnel. (3). To provide a standard procedural approach for area operations to insure the continuity of operating procedures. (4). To serve as a source of current data, information, procedures, etc, relating to the Central OHC Steam Stripper area. This manual is designed to provide a logical approach to start-up and initial operation of the Central OHC Steam Stripper, As experience dictates, operational changes may need to be made in this manual at some later date. A record of such additions and deletions, should be kept on the page provided for this purpose. (See next page) Information in this manual is considered confidential. This manual is the property of PPG and as such may be recalled at any time. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-114-5 SL 000002 Date Change No. CENTRAL OHC STEAM STRIPPER OPERATING MANUAL RECORD OF CHANGES Description Originator SL 000003 CONFIDENTIAL? Subject to Protective Order of 14th Judicial District Court No. 91-1145 NOTES ON PAGE-NUMBERING SYSTEM The pages in this manual are numbered using a system of two numbers; the first being the section number, while the second represents a page number, illustration, or table in that section. Thus, page 1-2 represents page 2 in Section I; Figure 3.4 represents Figure 4 in Section: III, and so on. This system should facilitate easy revision of this manual as required. \ SL 000004 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 TABLE OF CONTENTS Page I. GENERAL PROCESS DESCRIPTION A. Function of the Central OHC Steam Stripper Area B. Steam Stripper Area Overview - Its Role inPlant "B" C. Process Description D. Process and Mechanical Flowsheets 1-1 1-1 1-1 1-4 II. SAFETY FOR THE CENTRAL OHC STEAM STRIPPER AREA A. General Safety Rules B. Responsibility for Safety C. Emergency Procedures and Warning Signals D. Respiratory Protection E. Clearing Procedures F. Tagging; Safety Permits G. Miscellaneous Safety Practices 1. Electrical Equipment 2. Relamping and Receptacles 3. Grounding H. Safety Showers I. Control Building J. Lab and Lab Hood Fan K. Definitions 2-1 2-4 2-7 2-8 2-9 2-12 2-14 2-14 2-15 2-15 2-15 2-16 2-16 2-16 III. CHEMICALS IN THE CENTRAL OHC STEAM STRIPPER AREA A. Ch mical Descriptions 3-1 SL 000005 CONFIDENTIAL: S^!Ct ^ Protective of i4th Judicial Distric No. 91-1145 Order t Court ' -- -- - - 1. Calcium Chloride 2. Carbon Tetrachloride 3. Cell Liquor 4. Chlorine 5. Chloroform 6. cis - Dichloroethylene 7. Cuprous Chloride 8. Dichloro Acetylene 9. Dowtherm A 10. Ethyl Chloride 11. Ethylene 12. Ethylene Dichloride 13. Ferric Chloride 14. Hydrogen Chloride 15. Methane 16. Methyl Chloroform 17. Nitrogen 18. Oxygen 19. Pentachloroethane 20. Sodium Carbonate 21. Sodium Formate 22. Sulfuric Acid 23. Tetrachloroethane (sym- and unsym-) 24. trans - Dichloroethylene 25. 1/ 1/ 2 - Trichloroethane 26. Trichloro Ethylene 27. Vinyl Chloride 28. Vinylidene Chloride B. Special Safety Hazards - VDC 3-1 3-2 3-5 3-7 3-8 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-19 3-21 3-22 3-23 3-24 3-25 3-26 3-27 3-28 3-29 3-31 3--36 3-37 < 3-38 3-39 3-41 3-43 IV. EQUIPMENT IN THE CENTRAL OHC STEAM STRIPPER AREA A. Process ID No. and Sac No. Index 4-1 SL 000006 CONFIDENTIAL: of S14tuh CJt utdoicPiarlotDecistivtreicOt rCdeorurt B. Equipm nt Descriptions 1. Steam Stripper Feed Pumps 2. Steam Stripper Feed Tanks 3. Steam Stripper Economizers 4. Sodium Formate Transfer Pumps 5. Sump Pump 6. Organic Transfer Pumps 7. Air-Cooled Condensers 8. Steam Strippers 4-2 4-2 4-2 4-3 4-5 4-5 4-6 4-6 4-8 V. DETAILED PROCESS DESCRIPTION A. Steam Stripper Feed System 1. Sources of Steam Stripper Feed 2. Feed Tanks/Fhase Separators B. Steam Stripper Economizers C. Steam Strippers D. Air-Cooled Condensers E. Process Sump F. Rupture Disc Schedule 5-1 5-1 5-2 5-4 5-5 5-7 5-7 5-8 VI. CENTRAL OHC STEAM STRIPPER OPERATION A. Utilities 1. Well Water 2. Steam 3. Instrument Air 4. Nitrogen B. Start-Up Procedure C. Start-Up Checklist 6-1 6-1 6-1 6-1 6-1 6-3 6-6 SL 000007 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 D. Shut-Down Procedure E. Special Procedures 1. Switching Feed Tanks whileStripper is Operating 2. Switching Stripperswhile Operating F. Emergency Shutdowns 1. Loss of Electrical Power 2. Loss of Steam 3. Instrument Air Loss G. Operational Charts, Graphs, Tables VII. PROCESS CONTROL AND INSTRUMENTATION A. General Discussion of Control 1. SteamFlow Control 2. Feed Tank LevelControl 3. SteamStripperLevel Control B. Implementation of Control C. Color Graphics Display (CRT) D. Keyboard Functions/User Instruction Set - 1. Tank 2. Plot 3. Time 4. Logg 5. Dayr 6. Valu 7. Cert 8. Insr 9. Otsr 10. Alrv 11. Ltim SL 000008 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 6-9 6-13 6-13 6-14 6-15 6-15 6-16 6-17 6-19 7-1 7-1 7-2 7-2 7-3 7-4 7-5 7-6 7-7 7-7 7-8 7-9 7-10 7-10 7-10 7-10 7-11 7-11 APPENDICES A. Sample Log Printout B. Sample Daily Report Printout C. Sample Alarm Review Printout D. Process Variable - Point Number Correspondence Index E. High/Low Alarms and Alarm Conditions F. Central OHC Steam Stripper Area Line List G. CAL-VAC Rupture Discs H. Safety Permit Procedures SL 000009 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 LIST OF FIGURES Pag FIGURE 1.1 Central OHC Steam Stripper Process Flowsheet (Dwg. 57D-10002.0) 1 -4 FIGURE 1.2 Central OHC Steam Stripper Mechanical Flowsheets 1-5 (Dwgs. 57D-10003.2, 10004.1) FIGURE 6.1 - Central OHC Steam Stripper Area Utilities 6-2 FIGURE 6.2 Central OHC Steam Stripper Recirculation Configuration 6-2A FIGURE 6.3 Operations Graph: Steam Rate vs. Stripper Feed Rate 6-20 FIGURE 7.1 Central OHC Steam Stripper CRT Display (SK-10102) 7-4A FIGURE 7.2 - Central OHC Steam Stripper CRT Display Point Index (SK-10103) 7-4B SL 000010 CONFIDENTIAL: Subject to Protective Order qf l$tft Judicial District Court No. 91-1145 1-1 GENERAL PROCESS DESCRIPTION; A. FUNCTION OF THE CENTRAL OHC STEAM STRIPPER AREA: The Central OHC Steam Stripper area functions to remove and recover soluble chlorinated hydrocarbons from aqueous effluent streams produced in the OHC-I, OHC-II and OHC--111 (Vinyl) areas. The desired degree of removal of chlorinated organics results in a final steam stripper effluent, containing no more than l-5ppm organics. This low level of chlorinated organics allows PPG to ultimately dispose of the stream via the process sewer. B. STEAM STRIPPER AREA- OVERVIEW - ITS-ROLE IN PLANT "B": In the chloral treatment units chloral is treated with cell liquor (caustic) to produce sodium formate and chloroform. This mixture in the aqueous effluent streams from OHC-I, OHC-II, and OHC-I 11 (Vinyl) is routed to the steam stripper area. The sodium formate is water soluble and is carried out with stripper bottoms. The chloroform (and other organics in effluent streams) is stripped overhead in the steam stripper and is recovered. Stripper ! bottoms are sent to the formate destruction unit where the dissolved sodium formate is treated with HCI and sodium hypochlorite to form salt (NaCI) and CO2 .(both free and dissolved carbon dioxide). >' C. PROCESS DESCRIPTION: The central OHC Steam Stripper Area consists of two steam strippers, two air-cooled condensers, four economizers, two feed tanks, a process sump and various pumps, motors and valves. SL 000011 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 1-2 Aqueous effluent streams from the OHC-I, OHC-II and OHC-III (Vinyl) are collected in a common header and routed to the steam stripper from: (1). reactor phase separator overflows/ (2). DH still reflux drum overflows, (3). chloral treatment overflows, (4). Bicarb surge tank purges. The collected effluent streams to the processed by the central OHC Steam Stripper area are pH-adjusted with cell liquor at the individual areas producing * . ---- them prior to their combination in the steel header to the central steam stripper feed tanks. The incoming effluent is monitored for pH before it enters the feed tanks to insure maintenance of pH 10 in the tank since no provision for pH adjustment (cell liquor addition) at the steam stripper feed tanks is made; pH control is the responsibility of the individual areas producing the aqueous effluent. The steam stripper feed tanks act as phase separators/surge drums by accumulating organics and phasing them out to the lower sections of the tanks. Each feed tank contains four (4) phases: (I). aqueous phase - steam stripper feed, (2). indeter minate phase - emulsion between aqueous and organic phases containing catalyst from OHC reactor carry-over, (3). organic phase - steam stripper overhead and phased-out organics, and (4). sludge phase - catalyst solid* and tarry residue from organic phase. Feed tank aqueous and organic phase levels determine stripper feed rates as the aqueous phase is fed to the top of the steam stripper after passing through economizers to be preheated by steam stripper bottoms. SL 000012 e.-v* ,C0NFIDENT1AL: Order No. Ois tri< t Court 91-1145 1-3 The steam stripper serves to steam distill and so separate soluble organics from the aqueous feed. All organics are removed overhead when 3% by volume of the feed is driven overhead. The driving force is provided by live steam injected into the base of the stripper column. Steam rising through the column removes organics from the aqueous stream moving down the column, contacting though a packed bed in the column. Vaporized organics driven overhead are routed through air-cooled condensers and returned to the feed tanks as condensate. As they accumulate in the feed tank, phase organics are pumped to the intermediate crude storage tanks at OHC-I. Steam stripper bottoms (now free of chlorinated organics) are pumped through the economizers to preheat the aqueous phase fed.to the steam stripper. The cooled bottoms are normally routed to the formate destruction unit, although they may be routed back into the feed tanks during start-up or upsets*. Auxiliary nozzles located on the feed; tank allow for the removal of indeterminate phase and sludge phase by vacuum truck, The process sump collects all pad run-off, seal leaks, spills, etc. from the steam stripper area and routes them back into the steam stripper feed tanks. All rupture disk vent pipes on process vessels are routed to the process pad and drain to the process sump. SL 000013 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No 91-1145 ill!. INDUSTRIAL CHEMICAL DIVISION ghTOr'flg5TPM*TMPgft KBiWtfET TtZJ(*.** -7f DWG ~m TTfc|a>___ MUi l -f ] I I 1 I r ! I I 1 I ! 1 i A i II SAFETY FOR THE CENTRAL OHC STEAM STRIPPER AREA This section is designed to cover the safety rules and precautions which must be adhered to while working in the Central OHC Steam Stripper area. The development of a safely operating plant and a safety - conscious work force is based entirely on the attitudes of the people involved. A positiv attitude toward the safe completion of all jobs Is essential, as well as an awareness of the hazards inherent in all jobs. Individual regard for safety should be a continuous activity, carrying with it the responsibility to strive to improve the safety conditions for all jobs through observation and action. Each person involved must actively take part in the overall safety program to insure that it functions properly to make this a safer place to work for all concerned. A. GENERAL SAFETY RULES The following list of general safety rules applies to the Central OHC Steam Stripper area. It is intended to supplement the Employee's Safety Manual. The Central OHC Steam Stripper area has been included in Zone No. 17 of the present zoning system. The Directional Center will be locat d inside the west door of the Per/Tri maintenance shop. Rules; (1) Personnel entering the Organics Area will deposit lighters, matches, regular flashlights, etc. at the main gate to this area. (2) Smoking is permitted in the control room only. Permanent light rs SL 000017 will be provided at this location. Subj of I4t; t Protective Or a*** ewe* (3) The usual safety equipment will b r quired in the Organics Area -- that is:' a. Hard hats b. Chemical goggles (safety glasses under goggles are optional) c. Respirators d. Plastic-coated gloves (4) Established plant tagging procedures will apply in the Organics Area. (5) Company vehicles only will be allowed to travel the road to the Control Building without a permit. (6) A vehicle permit signed by the operating supervisor or lead operator will be required for any vehicle to travel norfh of the main piperack in this area. Never cross a barricade with a vehicle/ regardless of whether it is up or down, without a vehicle pass. (7) An equipment permit signed by the operating supervisor will b required before the following equipment can be carried into the Organics Ar a: a. Welding machine b. Cutting torch c. Electrically driven drills d. Any electrical equipment except explosion - proof flashlights (8) Only explosion-proof flashlights will be allowed in the Organics Area. (9) Regular plastic utility hoses are not to be used for handling organics; use Teflon-lined hoses equipped with proper quick-connect fittings and bleed-off valves. (10) All light circuits outside the control building are to be off and tagged out b fore relamping of the ar a is atter"*,"4 SL 000018 ctjive Orde i s 1 y. i c fc Co (11) The grounding system for electrical equipm nt is inside the feed r conduit. This ground must be connected before the connection cover is installed. (12) Do not dump flammable organics into trapped sewers or openings wh re harmful vapors could be evolved, 03) Open samples or containers of organics are not to be left sitting around to give off vapors. (14) Full-face masks or Scott Air-Paks will be used for protection against organic vapors. (15) Liquid chlorine is not to be trapped in vaporizers, surge drums, or any isolated section of piping. (16) Clothing that has been wetted with organics should be removed immedi ately and the body thoroughly washed with soap and water. These clothes should be properly laundered before they are worn again. (17) Air should not be allowed to enter any process vessel that contains organics. (18) In case of emergency warnings, all vehicles and equipment in the area on permits will be shut off immediately. Vehicles should be parked on the roadside out of the way and evacuated. New vehicle passes will be issued to remove the vehicles, (19) All steam-out nozzles, hoses, and purge equipment must be properly grounded to prevent the possibility of an arc from an accumulated static charge. (20) Chlorine should never be h ated above 450F due to the possibility of a reaction between th chlorine and any metal it contacts. < CONFIDENTIAL: SL 000019 of 14th to Protective Judicial Distric Order No m ~ 7 - - t Court (21) No smoking or open flam $ will b allowed In the control laboratory* (22) The laboratory hood fan Is to operate continuously. Do not attempt to run analyses unless the fan Is In service. (23) Always put liquid organics Into tanks through standlegs or bottom nozzles. Falling liquids can generate static electricity. (24) The control room and electrical starter rooms are pressurized for safety; therefore, they are to be utilized by authorized personn I only. All doors and windows must be kept closed at all times. B. RESPONSIBILITY FOR SAFETY SUPERVISOR'S RESPONSIBILITY IN ACCIDENT PREVENTION A supervisor of any work force is in a key position to train his people to abide by the plant safety rules and regulations; he also must Instruct his people to constantly comply with these safety rules and regulations. The results of this training and compliance keeps all plant personnel thinking and working in unison which is both important and necessary to accomplish safe working conditions within the plant. Listed below are some of the responsibilities of a supervisor in accident prevention. 1. To train employees to do all jobs safely. 2. To issue Job Safety Instructions when required. 00002 3. To enforce safety rules and regulations. 4. To recognize and correct unsafe acts and conditions. 5. To investigate all accid nts and fill out th Supervisor's Accident Report. SubjectC^FnDBNTlAL: ` Uth 6. To mv stigat all near-miss accidents and correct the condition or act. 7. To require workers to report for first aid when injured. 8. To conduct formal safety meetings. 9. To observe safety rules and safety practices. EMPLOYEE'S RESPONSIBILITY IN ACCIDENT PREVENTION Each employee has a personal responsibility in accident prevention. He has a responsibility to his family, to his fellow workers, and to his employer by whom he is paid to work safely. In the performance of his duties, he will be expected to observe safe practice rules as well as instructions r latlng to the efficient handling of his work. (1) Each employee will be issued a copy of the Plant Safety Manual. (2) Each employee will carefully study and observe all the rules in the Safety Manual, especially those applying to his particular duties. These rules will be strictly enforced and ignorance thereof will not be accepted as an excuse for their violation. (3) If a difference of opinion arises concerning the meaning or application of these rules or the steps necessary to carry them out, the decision of the supervisor in charge of the work will prevail. (4) Every employee will consider it a part of his or her duties to take an active part in promoting safety. (5) Employees will be careful always to place themselves in a safe and secure position. The care exercised by others must not be relied upon for protection. (6) When walking down th roadways, employ^g^haM^kee^ on the I ft bqLi 0U0U0U0U2Z1 oof f144fth J7 udicPiarlotDecistivtreicOt rCdeorurt No. 91-1145 z-c side in order to face approaching vehici s. (7) Do not run in the plant or on the parking lots. (8) Salt tablets or substitutes should be taken when sweating freely. (9) Never take unnecessary risks or short cuts. (10) Conduct that may be termed "fooling" or "horseplay" is strictly forbidden and is subject to disciplinary action. (11) All employees shall consider it part of their duties to: (a) Report unsafe conditions. (b) Correct unsafe acts. (c) Know disciplinary action for violation of safety tules. (d) Report ALL injuries and near-miss accidents to supervision im mediately. (e) Know the proper procedure in reporting emergencies. (f) Refrain from taking chances. (g) Ask a supervisor for help whenever needed. (h) Refrain from tampering with anything of which you have no knowledge. SL 000022 (i) Attend safety meetings. (j) Know the location and use of gas masks, fire fighting equipment, safety showers, etc. in your work area. (12) Employees shall be fully dressed when on the job. Shirt tails should be tucked in. (13) Do not work in clothing that is saturated with oil or chemicals. (14) Do not ent r rop d off or barricaded areas unless authorized to do do. Barricades shall be removed as soonCOa\sNJ pF^rIDaMcEtNic-Ta_Il_Aa_Lf:ter jVob is completed. Subject to Protective Order 14th Judicial District Court No. 91-1145 05) Nev r jump from platforms, scaffolds, loading docks or other high places, 06) Always use handrails when walking up or down stairways. 07) Avoid walking on piperacks, structural steel, etc. Use provided ladders or walkways. 08) Beards are not allowed in the plant. 09) Long sideburns which could interfere with the use of a full fac mask are prohibited. (20) Employees required to work around moving or rotating machinery and welding and burning operations must not wear hair longer than collar length and such that ?t extends out beyond the ears. (21) Knowing and following correct operating procedures is necessary to th safe operation of this plant. (22) Do not loiter or wander through operating units. Use the roadways or walkways connecting adjacent units. (23) No employee shall sleep on the job. (24) Do not stand on chairs, boxes, or other make-shift supports. & 0 0 0t C. EMERGENCY PROCEDURES AND WARNING SIGNALS The Central OHC Steam Stripper area is included in the Plant "B" evacu ation area. The Plant "B" evacuation horn is the regular plant horn blown in short blasts. It may be activated from any Plant "B" control room or the guard house. The OHC-1 control room switch is located on the north wall. The sounding of this hom will shut down all non-process equipment in Plant "B" and will cause all non-essential personnel to leave the ar a. Plant "B" includes all th Organics Area - ast of Columbia Southern Road CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court *qn . 1 - ] 1 5 and south of Parish Road. The Plant "B" evacuation horn should b sounded in case of a major br ak or if there is some reason to expect a major break. Whenever the evacuation horn is sounded, the guard should be notifi d of the nature of the emergency If at all possible. If it is desirable to vacuat the whole plant, the guards will have to be notified arid they will s und the plant evacuation alarm. The guards are the only people able to sound the all-clear signal, signified by two long blasts of the horn. D. RESPIRATORY PROTECTION In order to prevent personnel exposure to harmful chlorine and organic vapors, proper respiratory protection must be worn at the appropriate times. Three types of respiratory protection equipment are provided for personnel in the Central OHC Steam Stripper area; filter-type respirators, self-contained breathing equipment, and air-supplied masks. The self-contained equipment consists of 30-minute Scott Air Paks and 6- minute MSA escape units. The escape unit mask can also be connected to the control room breathing air systems such that a person may continue to operate equipment inside the control room without using up the 6-minute air supply bottle or having to strap on a 30-minute air pak. Besides the standard pocket respirator, a twin cartridge full-face mask filter respirator is provided. The dual cartridge respirator is a light concentration work mask which can be used in situations where self-contained equipment is not' necessary and the pocket respirator is insufficient. Good for environ ments containing combinations of chlorine and organic vapors not exc ed- ing 2% by volume, the use of the dual cartridg^jjp[|^E^^rgs at least _, SL 000023 Subject to Protective Order of 14th Judicial District Court No. 91-1145 2-9 19.5% oxygen In the atmosphere. The mask com s with interchangeable cartridges for different types of gases. After these masks have been used, they should be exchanged for new ones at the safety department. There are 30-minute air paks, 6 minute escape units and twin cartridge full face mask located in the control room for easy access. It should be pointed out here that methane and ethylene are not filtered out by any of the filter type respirators in the plant and therefore present special problems for respirator protection. However, since neither methane nor ethylene is. toxic, the area exposed to these can be evacuated before sufficient concentration is reached to suffocate any personnel. If it is necessary to enter an area where quantities of methane or ethylene are present, self-contained breathing equipment should be worn. E. CLEARING PROCEDURES One of the most important aspects of an operator's fob and especially th lead operator's job is the proper clearing of equipment for maintenance work. Many accidents and infuries are the result of poor and improper clearing and tagging procedures. For complex clearing operations, such as a distillation column or reactor, the area supervisor will generally leave general clearing Instructions. It is up the operating crew to execute the instructions and follow up on some of the details of clearing that are obvious, but may have not been specifically mentioned, such as opening low point bleeds, etc. For smaller, routine fobs such as filters or pumps, the operators are xp cted to be able to cl ar th se without specific instructions, SL 000024 CONFIDENTIALr Subject to Protective Order of 14th Judicial District Court No. 91-1145 The lead operator has the same r sponsibility in tagging as a supervisor does when the supervisor issues a welding or vessel entry permit. He is saying in writing (hanging a signed tag) that the equipment is then safe for mainte nance mechanics to work on. On extensive piping systems, all piping should be traced out carefully to find all tagging locations. Do not depend on memory of all branches and block valve locations. It is advisable to get someone else (another operator, lead operator, or supervisor) to double check the tagging of a complex piping system. In recent years, clearing jobs have become more complex. No longer is it acceptable to dump organics to the sewer (even the segregated sewer). When ever possible nitrogen should be used to push liquid from a piece of equipment back into the process (remember to only use N2 where process pressure is less . than the N2 pressure). In other cases, 55 gallon drums and organic box s will have to be used to drain process equipment. Now it is not only important to have equipment drained and depressurized, but it should also be nitrogen purged before maintenance work is performed on it. This is done to prevent exposure of maintenance personnel to even the smallest levels of organic vapors. The lock and tag procedure is the cornerstone of PPG's policy for safe maintenance work. Basically, all valves required to isolate the particular section of line or vessel to be worked on must be closed. The isolated section must be depressurized and purged as necessary. A lead operator's "DO NOT OPERATE" tag must be hung on each isolation valve. Any SL 000025 CONFIDENTIAL* ctive Order istrict Court electrical equipment must be tagged and locked out. The maintenanc foreman will also tag each valve. Finally, the mechanics will hang their personal tags on each valve. All persons are supposed to pull their tags when jobs are completed. Valves with tags on them should never be operated. If maintenance tags are found on valves that need to be operated, the area foreman or shift engineer should be contacted so that they can arrang for the appropriate maintenance personnel to pull the tags. The detailed procedure for clearing equipment is: 1. Isolate the tank, vessel or line. 2. Drain all liquid out of the vessel. Be alert to open all low point bleeds, orifice manifolds, etc. 3. Purge the equipment with nitrogen to remove organic fumes and evaporate residual liquid. 4. Tag each isolation valve with lead operator tags. In effect, this indicates the equipment is ready for maintenance to work on. Do not tag any valves unless the equipment is completely ready. 5. Where welding or vessel entry is required, each line connection to the vessel must be blinded off. The equipment should be purged with air. 6. Before any welding or vessel entry is done, the atmosphere should b checked out with an explosimeter by the Operations foreman. W Iding and entry permits must be filled out by the Operations and Maintenanc foremen before welding or entry may proceed. SL 000026 of order CourM Clal Dlstri-Ct No. 9 j- 7iak 2-12 to act as a manway watch. Airline masks and bottles must be avail able for the person inside to use immediately if the oxygen in th vessel suddenly becomes deficient. 7. When work is through and tags are removed, equipment should b nitrogen purged to remove oxygen. As this is done, the vessels should be pressurized so that each flange or connection that was opened can be leak-checked. New welds and packings on new valves should also be leak-checked. F. TAGGING, SAFETY PERMITS See the section in the safety manual entitled "Tags and Tagging Procedure". There are essentially four tags used Tn Area B. Types of Togs; (1) "DO NOT OPERATE" This is a plastic tag that should be placed on faulty equipment, or equipment requiring maintenance, by leadmen and foreman for both maintenance and operations. The tag should be signed, dated, and the reason given for tagging in pencil. "DO NOT OPERATE" tags may b pulled by employees of the same fob classification if the situation is fully known. When tagging a piece of equipment, all control points should be closed and tagged by operations first. (2) "PERSONAL TAG" This is a white plastic tag with name, man number, and "DO NOT OPERATE" inscribed on th tag. This tag can be used by maint nance CONFIDENTIAL: , workers who are working on procesc^^entd^n^fft^teiW (PPder SL 000027 of 14th Judicial District Court No. 91-1145 i, " I w endangered. Only the named person can use and pull his personal tags. (3) "INSTRUMENT SHUT-OFF TAG" This is a white cardboard tag used to indicate when an instrument is out-of-service for repairs or calibration. (4) "SUPERVISOR'S TAG" This is a laminated red paper tag with the supervisor's name inscribed on it. Supervisor's use their tag like a "PERSONAL TAG". Types of Permits See the section called "Safe Work Permits" in the safety manual for more details on permits. Also see Appendix H of this manual. 0). "WELDING, BURNING, OR OPEN FLAME PERMIT" A Welding, Burning, or Open Flame Permit (WBOF) must be issued prior to beginning "hot work" anywhere in Plant B. A paper copy is posted in the Operations Control Room and a cardboard copy is posted conspicuously on the job site. A WBOF Permit is not valid unless signed by both an Operations Supervisor and a Maintenance or Construction Field Foreman. The maximum duration of a WBOF Permit is four (4) hours and it may not be revalidated after that time. (2). "STRUCTURAL CHANGE, DRILLING, AND EXCAVATION PERMIT" This yellow cardboard permit is required when maintenance or construction must change structures, do drilling, or do excavation work. Engineering or th area maintenance general foreman sign thiCpNfhlflENTIAL: Subject to Protective Order SL 000028 of 14th Judicial District Court No. 91-1145 4-14 (3) "TANK ENTRY PERMIT" This is an orange cardboard permit issued to maintenance for entry into vessels/ tanks, manholes, pipes, and sumps. Both operations and maintenance supervisors will sign this permit. The tank must be tested for flammable organics content and oxygen content. A second man should be available to pull the man inside the tank out with the safety harness rope. Air bottles and masks should be provid d for both men. All lines going into the vessel must be blinded. Se clearing procedure. (4) "VEHICLE ENTRY PERMIT" This is a green cardboard permit issued by operating leadmen or the foreman for vehicles or spark producing equipment in process or barricaded areas.for 30 minutes or less. (5) "IGNITION SOURCE PERMIT" The Ignition Source Permit (ISP) is similar to the WBOF Permit and is designed to control the use of tools and devices having the potential to provide a jpark or source of ignition in areas of the plant where this is a concern. The ISP has a maximum duration of eight (8) hours and must be signed by an Operations Supervisor in the affected area. The paper copy is posted in the Operations Control Room and the cardboard copy Is posted in a conspicuous place on the job site. (G) MISCELLANEOUS SAFETY PRACTICES (1) Electrical Equipment SL 000029 , CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Z- I D PPG's Electrical Engineering (and Loss Prevention) Department(s) have evaluat d the Central OHC Steam Stripper area as a Class I, Group D, Division 2 installation, as is most of Plant 6 with a few exceptions in specific areas. The PPG Electrical Area Classification Drawings should be consulted prior to any electrical modifications. With this classification, lighting is vapor-tight, motors are TEFC (Totally Enclosed Fan Cooled), and all arcing devices are explosion-proof with seal-offs used. (2) Re lamping and Receptacles Vapor-tight fixtures are used in the process area. The relamping proc dure will be to first determine the lamps which need changing by turning on all lights. Then, turn off all fights and relamp. To simplify this procedure, circuit breakers for lights in the process area and control laboratory have been grouped in the lighting panels. Globes and guards must be replaced after re lamping. (3) Grounding Grounding in the Central OHC Steam Stripper area has been given sp cial attention due to problems peculiar to the handling of hydrocarbons. Grouncb for motors and other electrical devices are contained in the conduit supply ing the device and connected to the device frame internally. Motor changeouts should be checked to see that the ground has been replaced. It ie nnwirtiielv This should be kept in mind when performing maintenance work on any equipment in this area. H. SAFETY SHOWERS CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1143 The Central OHC Steam Stripp r area contains six (6) safety showers supplied SL 000030 2-16 by the well wat r system In the ar a. Saf fy showers are to b used without hesitation by all personnel in the event that they are doused by chemical spills. Safety showers are well identified by highly visible fluorescent orange and white striped signposts and all personnel should become thoroughly familiar with their location. Any time saved in reaching the nearest safety shower could be critical in minimizing possible injury resulting from chemical contact. The safety showers in the area are listed below with this location: SAFETY SHOWER NO.LOCATION 1 On top of feed tank ^T-1. 2 At the auxiliary 6" nozzles on Tank ^T-l (ground level) near level transmitter LT-208. 3 At foot of stairs on Tank ^T-2, 4 On 1st level next to the ^2 steam stripp r feed economizer. 5 On 2nd level at flow control valve ^219 on stripper feed, between the stripp rs. 6 On 3rd level next to ^2 air-cooled con denser; next to the ^2 steam stripp r. CONFIDENTIAL: I. CONTROL BUILDING Subject to Protective Order of 14th Judicial District Court No. 91-1145 The control building is pressurized to prevent accumulation of any vapors inside. Since it is a pressurized building, non-explosion proof lectrical equipment is used and smoking is p rmitted inside. The positiv pressure SL 000031 k/ 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 contaminants; 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 bags are in the suction of the air conditioner. For any problems with the air condition r, notify the supervisor. Both the control room and switchgear room are equipped with emergency lanterns which will come on if normal lighting power Is lost. J. LAB AND LAB HOOD FAN The laboratory has several nitrogen outlets. If this nitrogen were open d up and allowed to purge into the room, any person in the lab could be asphyxi ated. Protection against this is given by the lab hood fan. This special hood has two fans, one discharging info the hood and one pulling out of the hood to the outside. The fan pulling out has a larger capacity, thus there is a net flow of air out of the lab, preventing concentration of fumes or nitrogen'. K. DEFINITIONS CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-.il 4 5 Some of the terms used in the following discussion are defined below: (1) Flash Point - The flash point of a solvent is the lowest temperatur at which a vapor is given off in sufficient quantities so that the vapor- air mixture above the surface of the solvent will propagate a flame away from the source of ignition. It is the temperature below which a solvent may be used or stor d in open containers without formation SL 000032 2-\t> of an explosiv vapor-air mixture. (2) Explosive Limits - When combustible vapor is mixed with air in the proper proportions, ignition will produce an explosion. The vaporair mixture which will form this proper proportion is called the ex plosive range. The explosive range includes all concentrations of a mixture of flammable vapor or gas in air in which a flash will occur or a flame will travel if the mixture is ignited. The lowest percentage at which this occurs is the lower explosive limit and the highest per centage is the upper explosive limit. Explosive limits are express d in percent by volume of vapor in air. (3) Maximum Allowable Concentration (MAC) - The maximum allowable concentration for a material is the maximum concentration of that material that can be tolerated by personnel for a continuous 8-hour exposure period with no ill effects, given as MAC numbers. SL 000033 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Ill. CHEMICALS IN THE OHC CENTRAL STEAM STRIPPER AREA NAME FORMULA Calcium Chloride Carbon Tetrachloride C II Liquor Chlorine Chi roform cis-Dichoroethylene Cuprous Chloride Dichloroacetylene Dowtherm A Ethyl Chloride Ethylene Ethylene Dichloride Ferric Chloride Hydrogen Chloride Methane M thyl Chloroform Nitrogen Oxygen P ntachloroethane Sodium Carbonate Sodium Formate Sulfuric Acid T trachloroethane (sym- and unsym-) CaCI2 CCI4 NaOH/H20 Cl2 CHCI3 c2h2ci2 Cu2CI2 C2CI2 c2h5ci c2h4 c2h4c,2 FeCI3 HCI CH4 C2H3CI3 N2 02 c2hci5 Na2C03 NaCOOH h2so4 c2h2ci4 trans-Di ch 1 oroethy lene 1,1,2-Trichloroethane Trichloroethylene Vinyl Chloride Vinylidene Chloride c2h2ci2 c2h3ci3 c2hci3 C2H3CI C2H2Cl2 ABBREVIATION Causti c Cis- DCA EC EDC hydrochloric acid natural gas MC PENTA Soda Ash s-TeCE, u-TeCE sym- , unsym- transTCE TR1 VC, chloroethylene VDC SL 000034 SubjectCtoFpD1TrIAL: of i4u,cLucLTectlve Order No. 91 ^strict Court 114 5 3-1 NAME: Calcium Chloride FORMULA: CaCI2 MOLECULAR WEIGHT: 110.99 BOILING POINT: 2912F (1600C) MELTING POINT: 1422F (772.22Q SOLUBILITY IN WATER: 59.5 parts CaCl2/100 parts H20 at 16.2F 347 parts CaCI2/100 parts H20 at 680 F DENSITY: 156.8 lbs. per Ft3, @ 77F (2.512 gram/cc@ 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 kcal/mole) to form the hexahydrate. Thus, care should be taken if water washing any CaCI2 solid from process equipment or pads as it may splash into the operator's eyes, TREATMENT: Wash exposed area with water. Flush eyes for 15 minutes, then report to First Aid. SL 000035 CONFIDENTIAL: Subject to Protective.Order of 14th Judicial District Court No. 91-1145 3-2 NAME: Carbon Tetrachloride FORMULA: CCI4 MOLECULAR WEIGHT: 154 BOILING POINT: 170.2<>F (76.78C) FREEZING POINT: -9F (-22.78C) VAPOR PRESSURE: 90.9 mm Hg. @ 68F VAPOR DENSITY: 5.32 (air *1.0) LIQUID DENSITY: 98.9 lbs. per Ft3@ 77F FLASH POINT: None EXPLOSIVE LIMITS: Nonflammable and non-explosive in air at ordinary temperatures and pressures. MAXIMUM ALLOWABLE CONCENTRATION: 10 ppm for 8 hrs. DETECTION ODOR CONCENTRATION: Carbon tetrachloride has a distinctive odor but, unfortunately, can be detected only in concentrations exceeding the maximum allow able concentration. HAZARDOUS PROPERTIES: The principal hazard in the industrial use of this chemical is from inhalation of the vapor. The effects of excessive exposure of carbon tetrachloride may be both immediate and delayed. The immediate effects may include headache, symptoms resembling inebriation or drowsiness and abdominal discomfort. The delayed effects may include severe damage to the heart, liver and kidneys which may not be evident until 1-10 days after the exposure. Skin contact with the liquid leads to dryness through the removal of natural oils from the skin. Repeated or prolonged exposure may cause dermatitis, cracking of the skin and danger of secondary infections . SL 000036 CONFIDENTIALt Subject to Protective Order of 14th Judicial District Court No. 91-1145 3-3 Eye contamination by liquid carbon tetrachlorid causes burning, intense irritation and other symptoms of inflammation. Subacute or chronic carbon tetrachloride poisoning may result from prolonged or repeated xposure to the vapors or the liquid. A threshold limit value of 10 ppm by volume in air has been set by some agencies as a maximum safe concentration for a daily 8 hour exposure. TREATMENT: In extensive skin contact the patient should get under the shower immediately, if such is available. Clothing and shoes should be removed under the shower. --' - If liquid carbon tetrachloride has entered the eyes, irrigate immediately with water. This can be done with an eye bath, if available, a gentle stream of water from a hose, or by pouring water from a clean container. The eyelids should be held apart during the irrigation to insure contact of water with all the tissues of the surface of the eye and lids. If pain is still present, it is permissible as a first aid measure to instill 2 or 3 drops of 0.5 perc nt pontocaine solution or an equally effective aqueous topical anesthetic. No oils or oily ointments should be instilled unless ordered by a physician. If carbon tetrachloride has been swallowed, call a physician immediately. Vomiting should be induced by having the patient stick his finger down his throat or by giving large quantities of warm salt water (2 tablespoons to a glass of water). If vomiting occurs, give more water in order to attempt to wash out the stomach. Remove patient to an uncontaminated area. If breathing has stopped an effective means of artificial respiration should be started immediately. If oxygen inhalation apparatus is avail able, oxygen should be administered, but only by a person authorized for such duty by a SL 000037 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No . Q ? - 1 Ki s 3-4 physician. The patient should be kept warm, but not hot. CAUTION: Persons exposed to carbon tetrachloride should not be given alcohol, oils, fats or epinephrine. NEVER give anything by mouth to an unconscious patient. SL 000038 CONFIDENTIAL: Subject to Protective Order \ of 14th Judicial District Court No. 91-1145. 3-5 NAME: Cell Liquor (Caustic Soda, Sodium Hydroxide) FORMULA: NaOH MOLECULAR WEIGHT: 40.00 BOILING POINT: 253.4F (123C) MELTING POINT: 605.1F (318.39C) VAPOR PRESSURE: @1362F, 1mm. Hg LIQUID DENSITY: Normally a solid. Cell liquor is approximately 10% NaOH in a salt solution. (100 Ib/gal; 1.1 gram/ml @ 77F) SOLUBILITY: 42 grams/100 grams H2O @ 0C; 347 grams/100 grams H2O @ 100C. FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 1.2 ppm by volume HAZARDOUS PROPERTIES: This material, both solid and solution, has markedly corrosive action upon all body tissue. Caustic solution is detectable by the slippery feeling of soapy wat r. Its corrosive action on tissue causes burns and frequently deep ulceration, with ultimate scarring. Prolonged contact with dilute solutions has a destructive effect upon tissue. Mists, vapors, and dusts of this compound cause small burns, and contact with the ey s, either in the solid or solution form, rapidly causes severe damage. Ingestion either in th solid or solution form causes very serious damage to the mucous membranes or other tissu s with which contact is made. It can cause perforation and scarring. Thus effects of inhalation, vary from mild irritation of the mucous membranes to a severe pneumonitis. It can cause an irritant dermatitis. Caustic soda will react with water or steam to produce heat and will at tack organic tissue. S|_ 000039 CONFIDENTIAL: of A4t" tD Protective Order Judicial District Court No. 91-1145 3-6 TREATMENT: Where larg quantities are handled the ar a should be well ventilated and face masks should be worn. Speed in removing caustic from contact with the skin is important. Remove all contaminated clothing at once, then flush the skin with water thoroughly. The use of small portions of water, such as by sponging, may cause more serious injury due to heat liberated on dilution. After flushing with water, use liberal quantities of a neutral izing solution such as a 0.5% solution of boric acid, citric acid, or ammonium chloride. If any caustic soda contacts the eyes, they should be irrigated immediately with an abun dant amount of water for at least 15 minutes. The eyelids should be held apart during ir rigation. The eye should then be washed with a mild saline solution if available. Wash the eye with water for an additional 15 minutes. A physician should be seen immediately after the eye is thoroghly washed. SL 000040 CONFIDENTIALr Subject ta Protective Order of 14th Judicial District Court No. 91-1145 3-7 NAME: Chlorin FORMULA: Cl2 MOLECULAR WEIGHT: 70.91 BOILING POINT: -30F (-34.44C) VAPOR PRESSURE @ 75F: 92 psig FREEZING POINT: -148F (-100C) LIQUID DENSITY@ 77F; 11.6 pounds/gallon RELATIVE VAPOR DENSITY: 2.45 (Air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 0.35 to 1 ppm DETECTABLE ODOR CONCENTRATION: 3.5 ppm HAZARDOUS PROPERTIES: Liquid chlorine as well as chlorine gas is very dangerous to th yes. High concentrations of chlorine gas can cause pneumonitis and edema of the lungs. Upon inhalation 15 ppm is very irritating to the throat and 1000 ppm is fatal. Lung ir ritation is one of the most serious effects of chlorine; once in lungs, chlorine combin s with moisture to form 02 and HCI. Cl2 is about 2^r times as heavy as air, therefore, it has a tendency to collect in the low spots or stay near the ground. Chlorine can react to cause fire or explosion with temperature, ether, NHg, hydrocarbons, hydrogen, pow dered metals, polypropylene, rubber or alcohols. TREATMENT: Remove patient from toxic area and loosen all constrictive clothing about th neck. Oxygen should be administered in all cases to prevent cyanosis and relieve the pain of deep respiratory effort. Notify a physician. SL 000041 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 3-8 NAME: Chloroform FORMULA: CHCI3 MOLECULAR WEIGHT: 119.5 BOILING POINT: 143F (61.67C) FREEZING POINT: -82F (-63.33C) VAPOR PRESSURE: 160 mm Hg@ 68F VAPOR DENSITY: 4.13 (air = 1.0) LIQUID DENSITY; 93 lbs. per Ff3 @ 68F FLASH POINT: None EXPLOSIVE LIMITS: Will not burn in air MAXIMUM ALLOWABLE CONCENTRATION: 50 ppm for 8 hrs. DETECTION ODOR CONCENTRATION: 200 ppm (NOTE THAT THIS IS HIGHER THAN THE MAXIMUM ALLOWABLE CONCENTRATION) HAZARDOUS PROPERTIES: The most important hazard of chloroform arises from the fact that r peated exposure to low atmospheric concentrations may result in damage to the liver and kidneys. In high concentrations it has narcotic properties and is an effective surgical anesthetic. Contact with skin and mucous membranes may produce irritation. In the presence of excess water or at very high temperatures, such as occur in open flam s, chloroform decomposes to give phosgene, hydrogen chloride, and other products. In the presence of a strong alkalis and water, chloroform may become violently explosive. On exposure to air and sunlight, chloroform slowly oxidizes to phosgene. SL 000042 CONFIDENTIAL: to Protective Order I4tli Judicial District Court No. 91-1145 3-9 TREATMENT: If substantial quantities are spilled upon a person, the contaminat d clothing should be removed promptly and the affected skin area should be flushed with plenty of water. The contaminated clothing should not be worn until free of the material. If the eyes are contaminated, they should be flushed with plenty of flowing water. Medical attention should be obtained if any irritation persists. If chloroform has been swallowed, vomiting should be induced as soon as possible by tickling the throat with a finger or by giving an emetic, such as two tablespoonfuls of common salt in a glass of warm water. CALL A PHYSICIAN. Anyone showing signs of ill effects from breathing the vapor of chloroform should be r moved to fresh air, kept warm and quiet and be made to rest. If breathing stops, artificial resuscitation should be given. Get medical attention promptly. SL 000043 CONFIDENTIAL: Subject to Protective* Of 14th Judi cial Distri^i- No. 9I-.114 5 ,,"t 3-10 NAME: cis-Dichloroethylene (Cis) FORMULA: ClHC = CHCI MOLECULAR WEIGHT: 96.55 BOILING POINT: 140.36F (60.20C) VAPOR PRESSURE: 3.33 psia@ 70F 400 mm@ 41.0C FREEZING POINT: -112.9F (-80.5C) SPECIFIC GRAVITY: 1.2756 @ 25F VAPOR DENSITY: 3.34 FLASHPOINT: 43F(6.11C) EXPLOSIVE LIMITS: UEL 12.8% (% by volume) LEL 9.7% MAXIMUM ALLOWABLE CONCENTRATION (MAC): TVL 200 ppm DETECTABLE ODOR CONCENTRATION: Pleasant odor HAZARDOUS PROPERTIES: Dangerous fire hazard. Moderate explosive hazard. Dangerous disaster control. When heated to decomposition, it emits highly toxic fumes of chlorides; can react vigorously with oxidizing materials. In case of fire, use ^O, foam, CO2 or dry chemicals. TREATMENT: In case of contact exposure, remove contaminated clothing and wash skin thoroughly with water. Flush eyes with water. If taken internally, report to First Aid immediately. For exposure by inhalation, remove patient from contaminated area - give artificial res piration and O2 if necessary. Report to First. Aid. SL 000044 CONFIDENTIAL* Subject to Protective Order of 14th Judicial District No. 91-1345 NAME: Cuprous Chloride FORMULA: Cu2 Cl2 MOLECULAR WEIGHT: 223.4 BOILING POINT: 2490.8F (1366C) MELTING POINT: 791,6F (422C) VAPOR PRESSURE: N/A FLASH POINT: N/A EXPLOSIVE LIMITS: N/A MAXIMUM ALLOWABLE CONCENTRATION: N/A DETECTABLE ODOR CONCENTRATION: N/A HAZARDOUS PROPERTIES: Cuprous chloride is toxic and a strong irritant. Handlers should wear dust masks, safety goggles, and rubber gloves. SL 000045 CONFIDENTIAL: oorfS1?4?thcJt uNtdooi.cPia9r1lte1DUci.ts5ivtreictOrCdeorurt 3-12 NAME: Dichloroacetylene (DCA) FORMULA: CIC = CCI MOLECULAR WEIGHT: 94.94 BOILING POINT; 89.6F (32C) VAPOR PRESSURE: FREEZING POINT: -85F (-65C) LIQUID DENSITY: FLASH POINT: EXPLOSIVE LIMITS: MAXIMUM ALLOWABLE CONCENTRATION (MAC):' TC (human) 0.5 ppm DETECTABLE ODOR CONCENTRATION: HAZARDOUS PROPERTIES: Dichloroacetylene is a gas with a disagreeable sweetish odor, narcotic and poisonous causing nerve and eye dysfunction at trace concentrations. S vere xplosion hazard w/shocked, heated, in air. Dichoroacetylene is explosive and spon taneously flammable in air, burning with release of phosgene. Explosion can occur when shocked (electrical) or heated. When heated to decomposition or in contact w/acid or acid fumes, it emits highly toxic fumes of chloride. Reacts vigorously with oxidizing material. TREATMENT: Remove exposed individual from area immediately and call or report to First Aid. SL 000046 COnjriDOAT'Ai,: to P! fi i.< ' ' 1 ' Of f'H.h Ji r i d ] ' ' .1 <. 3-13 NAME: Dowtherm A FORMULA: 26.5% diphenyl, 73.5% diphenyl oxide BOILING POINT: 500F@ 1 atmosphere FREEZING POINT: 53F (11.67C) FLASH POINT: 255F (123.89C) Dowtherm A is heavier than air. Dowtherm A is used in our process as a liquid and is a mixture of two chemicals. It is not normally toxic or otherwise hazardous, except that at the temperatures we will use it, safeguards must be provided. It has a very distinctive odor. -- * <-- HEALTH HAZARDS: Unless the fumes are so strong as to cause oxygen deficiency, there is no hazard. The odor is irritating to intolerable below the safe toxic limit. Skin irritation is of minor consequence, however, contact should be avoided. FIRE HAZARD: The temperatures of use are above the flash point so precautions must be taken as if it were highly flammable. Inert gas (N2) purge and "no burning and welding" pro cedures must be used. The best fire extinguisher is water, because its vapor concentration is very low at water temperatures. SL 000047 CONFIDENTIAL: ,ct to Protective Order 1- r.' - 1 n' ct-rl t court of 3-14 NAME: Ethyl Chlorid (EC) FORMULA: CIH2C-CH3 MOLECULAR WEIGHT: 64.52 BOILING POINT: 54.09F (12.27C) VAPOR PRESSURE: @25C/ 1199 mm Hg FREEZING POINT: -218.2F (-139C) RELATIVE VAPOR DENSITY: 2.22 (Air = 1.00) VAPOR PRESSURE: 1000 mm @20 FLASH POINT: -58F closed cup; -45F open cup. EXPLOSIVE UMITS: UEL 15.4% LEL 3.8% AUTOIGNITION TEMPERATURE: 966F (518.9C) MAXIMUM ALLOWABLE CONCENTRATION (MAC): 1000 ppm/8 hours DETECTABLE ODOR CONCENTRATION; HAZARDOUS PROPERTIES: Liquid irritates eyes; harmful. Vapor irritates eyes, skin/ mucous membranes. High fire hazard - heat, flame, oxidizers. S vere explosion hazard - flame. EC forms phosgene on combustion; use C02 extinguishers for fires. TREATMENT: Remove patient from exposure, use artificial respiration if needed. Call a physician. SL 000048 CONFIDENTIAL: dicial District Court No. 91-1X45 3-15 NAME: Ethylene FORMULA: C2H4 MOLECULAR WEIGHT: 28.05 RELATIVE VAPOR DENSITY: 0.97 (air = 1.0) BOILING POINT: -219F (-139.44C) FREEZING POINT: -273F (-169.44C) EXPLOSIVE LIMITS: 2.75 to 28.60% by volume with air DETECTABLE ODOR CONCENTRATION: Sweet AUTOIGNITION TEMPERATURE: 10I0F in air (543.33C) HAZARDOUS PROPERTIES: A simple asphyxiant. Ethylene is a flammable gas and a dangerous xplosion hazard upon exposure to heat or flame. It can react vigorously with oxidizing materials. Ethylene is moderately toxic, but its slight toxic effects disappear when the patient is removed from exposure. Ethylene will displace oxygen in the air causing the victim to suffocate. Use only C02 or dry chemical extinguishers to combat ethylene fires. TREATMENT: Remove patient from exposure and perform artificial respiration if breathing has stopped. Report to First Aid. SL 000049 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 d-IO NAME: Ethylene Dichloride (EDC) (1,2-dichloroethane) FORMULA: CH2CICH2CI MOLECULAR WEIGHT: 98.966 BOILING POINT: 182.3F (83.5C) MELTING POINT: -31,9F (-35.5C) VAPOR PRESSURE: @84.9F, 100 mm. Hg. LIQUID DENSITY: @68F, 78.47 lbs per Ft3 RELATIVE VAPOR DENSITY: 3.35 (air 1) FLASH POINT: 64.9F open cup, 55,4F, closed cup EXPLOSIVE LIMITS: 6.2 to 15.9% by vol. MAXIMUM ALLOWABLE CONCENTRATION: 50 ppm., 200 mg./m.3 DETECTABLE ODOR CONCENTRATION: Much less than maximum allowable AUTOIGNITION TEMPERATURE: 840F (448.9C) HAZARDOUS PROPERTIES: Ethylene dichloride has a distinctive odor and strong local irritating effects, which give warning of its presence in relatively safe concentrations. There is ir ritation of the eyes and upper respiratory passages. Ethylene dichloride has a specific ef fect on the cornea. Exposure to the vapor, or, in animals, injection under the skin, pro duces a clouding which may progress to endothelial necrosis and infiltration of the corn a by lumphocytes and connective tissue cells. The narcotic action of the compound is strong, probably of the same order as chloroform. Its toxic effect upon the liver and kidneys are less than that of carbon tetrachloride, but animal experiments indicate that these organs may show congestion and fatty degeneration. Edema of the lungs has also been reported in animals. D rmatitis in man has been observed. SL 000050 CONFIDENTIAL: Subject to Protective Order of 14til Judicial District Court No. 91-114 5 >vAjAff n SaEffisHSIRff T 3-17 In short xposures to high concentrations, the picture is one of irritation of the yes, nose and throat, followed by dizziness, nausea, vomiting, increasing stupor, cyanosis, rapid pulse, and loss of consiousness. Chronic poisoning, where exposure has occurred over a period of several months, may cause loss of appetite, nausea and vomiting, epigastric distress, tremors, nystagmus, leucocytosis, low blood sugar levels, and possible dermatitis if there has been skin contact. Employees exposed regularly to ethylene dichloride should be examined at least semi annually, by a physician acquainted with the occupational hazards involved. Physical xaminations should be required also when any symptoms of poisoning occur. Employees who may be subjected to severe exposures of ethylene dichloride vapor as in tank cleaning and repairs in intermittent operations where general ventilation is not practical, in cases of failure of piping or equipment, and in cleaning up spills, should be provided when indicated with proper eye and respiratory protection as follows: (a) Suitable gas-tight chemical safety goggles. (b) Rescue harness and life line for those entering a tank or enclosed storage space. An outside attendant should maintain constant observation. (c) Positive pressure hose masks with hose inlet in a vapor-free atmosphere. Air-line masks with reducing valve and filter suitable for use only where conditions will permit safe escape in case of failure of the compressed air supply, or self-contained breath ing apparatus with stor d oxygen or air, which allows greater mobility but usually requir s SL 000051 fSUthCj v Prot^tiv, 14th Judicial Distr- Order No . q 7 _ 1 1 ,1 t Court 0* NORMALLY OPEN C -NORMALLY CLOSED </ -SWITCH (C -BREAKER VC ZW-TWOUREF: DRAWINGS: SK- 53*9 CIA-71001.9 ii: tNOusntits INDUSTRIAL CHEMICAL DIVISION LAKE CHARLES LOUISIANA title Sewer Segregation Stripper Feed Circuits DRAWN it DATE K.M.MELLWO *0/4/7* CHECKED RT PATE APPROVED BT OATR SCALE NONE CHANCE P-377 BILL OP HA1EBIAL DnWo.GS.-K., -7802_ LSHEET 1 OF____ 3-18 more highly trained men. in tank work small manholes may make this apparatus unsuitable because of its bulk, although the type known as self-generating is specially designed for entrance and egress through small openings. Masks and breathing apparatus should be approved by the United States Bureau of Min s and should be equipped with full face pieces. (d) Industrial gas masks, approved by the United States of Mines with canisters approved for use in ethylene dichloride vapor should be used only when it is certain that the concentration of vapor is less than 2 per cent by volume (20,000 parts per million) and the atmospheric oxygen is not lower than 16 per cent, and then only for exposur s not exceeding one-half hour. TREATMENT: All contaminated clothing should be removed at once. Clothing, including sho s, soaked in ethylene dichloride should be removed and not worn again until thoroughly dry. All affected areas should be washed thoroughly with warm water and soap. After this an intment containing lanolin should be applied in order to replace the natural skin oils. For serious or persistent cases of skin trouble and for signs and symptoms of generalized poison ing, a physician should be consulted. If liquid ethylene dichloride has entered the eyes, they should be washed promptly with copious quantities of water for at least 15 minutes. It is advisable to irrigate the ey s gently with water at room temperature in order to minimize additional pain or discomfort. Ethylene dichloride vapor can produce injury to the eyes if the exposure is intense or in the same manner as for the liquid. Medical attention should be obtained in all these con tacts with the eyes. SL 000052 , Aw A J. \ J(j | or 14th Protective Order Judicial District Court No. 91-1145 SAC LIST SEWER SEGREGATION PUNT Revised 10-31-79 Vessels Existing Stripper Unit Preheater T-l Phase Separator T-2 Steam Stripper C-l Vent Scrubber C-2 Economizers E-1 Condenser E-2 New Stripper Unit Phase Separator ^ 2 Steam Stripper ^2 Economizers Stripper ^2 Condenser WTU Preheater WTU Steam Desuperheater Pumps API Separator S. Heavy Layer Transfer N. Heavy Layer Transfer Old Stripper Unit S. Stripper Feed Pump N. Stripper Feed Pump W. Stripper Product Pump E. Stripper Product Pump W. Stripper Bottoms Pump E. Stripper Bottoms Pumps New Stripper Unit Stripper Feed Pump ^3 Stripper Feed Pump ^ 4 Stripper Bottoms Pumps * 3 Stripper Bottoms Pump ^ 4 SAC * 60-1421 60-1422 67-114 67-115 71-1655 71-1656 60-1889 67-171 71-2100,71-2101 71-2102 71-2103 71-2104 71-2105 55-2419 55-2418 CD O O O in N 55-2560 55-2561 55-2280 55-2281 55-2562 55-2563 55-2933 55-2934 55-2931 55-2932 0 tn ft. O' (i- t-i. zr 0> Li Orf Cn a O* <"! O O. nH* o n 'OH ^ t~- O r~J | fi- HHH01 'f<f"5l' `-"si in rnr " p* fu rs ft* no- CfE" C w' <I*f!f 3-19 NAME: Ferric Chloride FORMULA: FeCI3 MOLECULAR WEIGHT: 162.2 BOILING POINT: 590F (310C) VAPOR PRESSURE @ 75F: nil SUBLIMATION POINT: 572F (300C) SPECIFIC GRAVITY: 2.8 (1.00 for air) RELATIVE VAPOR DENSITY:. Normally a black solid FLASH POINT: None EXPLOSIVE LIMITS: None HAZARDOUS PROPERTIES: Ferric chloride presents no particular problem in handling. How ver, in the anhydrous form, it may be injurious to clothing, and all contamination of both skin and clothing should be washed off immediately. F rric chloride will seriously stain clothing and skin when it is contacted, so it is advisabl to wear gloves and aprons when handling it. Ferric chloride is extremely hygroscopic (absorbs water), and when this takes place, h at release occurs. When taking material from a drum*, remove the desired quantity as quickly as possible and immediately seal the drum to prevent it from absorbing moisture from the air. The fumes from this reaction are toxic. FeCI3 also emits HCI fumes when decomposed by heat. > TREATMENT: In the case of eye contact, flush immediately and thoroughly with water and then rinse with a weak solution of sodium bicarbonate or boric acid. A physician should always SL 000053 Subject' of 14th Judicial Djnf Order No. 91-1145tIict Court SAC LIST (continued) Lift Station Pumps W. Lift Station No. 1 Pump E. Lift Station No. 1 Pump W. Lift Station No. 2 Pump E. Lift Station No. 2 Pump W, Lift Station No. 3 Pump E. Lift Station No. 3 Pump S. Lift Station No. 4 Pump N. Lift Station No. 4 Pump S. Lift Station No. 5 Pump N. Lift Station No. 5 Pump W. Lift Station No. 6 Pump E. Lift Station No. 6 Pump W. Lift Station No. 7 Pump E. Lift Station No. 7 Pump Lift Station No. 8 Pump rol Valves Old Stripper Unit Valve ^ Stripper Bottoms Stripper Feed Steam to Preheater Steam to Stripper Stripper Product Desuperheater New Stripper Unit 175 to 50 psi steam Reducing Station Desuperheater Steam to Preheater Steam to Stripper Stripper Feed Stripper Bottoms LCV 1015 FCV 1002 TCV 1010 FCV 1016 LCV 1024 TCV PCV 1103 TCV 1104 TV 1109 FV 1129 FV 1141 LV 1130 Revised 10-31-79 55-2296 55-2297 55-2564 55-2565 55-2295 55-2294 55-2642 55-2701 55-2702 55-2704 55-2703 55-2705 55-2286 55-2287 55-2733 SAC * 80-13201 80-13202 80-13203 80-13204 80-13205 80-15166 80-18429 80-18430 80-18401 80-18402 80-18403 80-18404 SL 00053 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court Ho. 91-1145 be consulted in such cases. * Remove the drum lid carefully to relieve any pressure that may be built up inside. 3-20 SL 000054 CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court No. 91-1145 RUPTURE DISC SCHEDULE Vessel Preheater (T-l) Steam Stripper (C-l) Phase Separator (T-2) Jm. Graphite/Insert Size 4" Graphite/Insert 4" Graphite/Insert 2" Rating 15#/225F 15#/225F 15#/225F Order No./Loc. 23-851-0085 1-11-05-0? 23-851-0085 1-11-05-05 NOTE: Safety heads required with 150# FL6 SL OOOSA' COWr 1 bbN'il- ijj " Subject to Protective Order of 14th Judicial District Cour No. 91-1145 d-^ NAME: Hydrogen Chloride FORMULA: HCI MOLECULAR WEIGHT: 36.47 BOILING POINT: -122.6F (-85.89C) MELTING POINT: -173.7F (-114.28C) VAPOR PRESSURE: @ 64F, 3040 mm. Hg. LIQUID DENSITY: Normally a gas RELATIVE VAPOR DENSITY: 1.268 (air = 1) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 5 ppm for 10-hour working day DETECTABLE ODOR CONCENTRATION: 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 bums. 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 es sential that all affected body surfaces be washed with copious 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 000055 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 COLLECTION POINT LIST Collection Point Number Description 1 VCM Heavy Still Stack Seal 2 VCM/EC Lab Drain 3 HC1 Scrubber at VCM 4 EC Trench 5 HC1 Header Drain 6 Trl-Ethane AIBN Pad Drain 7 VDCM Pump Pad Drain 8 Pump Pad Drain 9 HC1 Surge Drum Drain 10 MC Plant Trench 11 Catalyst Pot Drain 12 MC Section Scrubber Drain 13 VDCM Dryer Reactivation Drain 14 VDC Phase Separator Drain 15 TCE Storage Tank Scrubber Drain 16 VDC Reactor Drain 17 T/E Scrubber Stack Drain 18 19 20 21 22 23 24 25 * NC - Not Continuous VDCM DH Still Reflux Drum Drain VDC Pad Drain T/E Scrubber Drain w tn c fa. 0" ft >_!- No. 1 EDC Scrubber No. 1 EDC Plant Trench P/T Pump Pad Drain No. 2 EDC Plant Trench O C*. rT cO E a r+ O 0* H- o 0 E ^ h>- TJ M VC CJ b> u Mm0 M 1 rt i~> a a KJ M H- 0 M Cn rt ui rr h- h GC Pot h- a 0 rf C na 0 0) CH Flow* 20 gpm 1 gpm Max 200 gpm NC NC NC NC NC NC 1 gpm NC 5 gpm NC NC 5 gpm Max 200 gpm NC 1 gpm NC 47 gpm Max 50 gpm NC NC NC 1 gpm 3-22 NAME; Methane (Marsh gas) (Natural Gas) FORMULA: CH4 MOLECULAR WEIGHT: 16.04 BOILING POINT: -258.7F (-161.5C) FREEZING POINT: -297.8F (-183.22C) VAPOR PRESSURE: @-115.8F, 34,900 mm. Hg. LIQUID DENSITY: @-263.2F, 25.91 lbs. per Ft3 RELATIVE VAPOR DENSITY: 0.555 (air -1.0) FLASHPOINT: -306F (-187.7C) EXPLOSIVE LIMITS: 5.3% to 14.0% by volume in air MAXIMUM ALLOWABLE CONCENTRATION: 1% by volume DETECTABLE ODOR CONCENTRATION: Odorless in pure state. PPG uses with mercaptans which give slightly sweet odor to the gas. AUTOIGNITION TEMPERATURE: 1004F (540C) HAZARDOUS PROPERTIES: A simple asphyxiant. A dangerous fire and explosion hazard. Its low density allows it to accumulate in high concentration in poorly ventilated areas. Com bat fires with CO2 or dry.chemical extinguishers only. TREATMENT: Patients should be removed from exposure and artificial respiration applied if n cessary. Report to First Aid. SL 000056 CONFIDENTIAL: Subject to Protective Order of I4th Judicial District Court No. 91-1145 Collection Point Number 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 *NC- Not Continuous Description Flow* No. 2 EDC Plant Scrubber Max 50 gpm GC Pot 1 gpm Heavy Still Pad Drain 5 gpm Pad Drain 25 gpm NC VDC Retention Tank Pump Drain 2 gpm Pad Drain 10 gpm Pad Drain 10 gpm Sump Pump Discharge 5 gpm Utility Drain 15 gpm Reboiler Drain 15 gpm VDCM HQMME Tank 5 gpm VDCM Reactor Heater Pad Drain 10 gpm Condensate Pump Pad Drain 1 gpm P/T Entrainment Separator Drain NC Loading Rack Drain NC Per-Tri Reactor Trench Recycle Scrubber 15 gpm from scrubber Auxiliary Still Line Scrubber 5 gpm Trench Around DH Still Feed Tanks Per-Tri Reactor Scrubber Trench Per-Tri Bottoms Tank Scrubber NC 60 gpm 10 gpm 0Ml rn CONFIDENTIAL: Subject to P ro te c tiv e 14th J u d ic ia l D is tri< No. 91-1145 Tank Drain NC Tank Drain NC Heavy Still Feed Filter Drain NC Still Line Scrubber Drain 20 gpm Per-Tri Still Feed Filter Drain NC SL 00 054) uCf oiri oa OC flJ H 3-23 NAME: Methyl Chloroform (MC) (1,1,1-trichloroethane) FORMULA: CI3C-CH3 MOLECULAR WEIGHT: 133.41 BOILING POINT: 165.38F (74.1C) VAPOR PRESSURE: 125 mm Hg @ 77F (25C) FREEZING POINT: -22.7F (-30.39C) LIQUID DENSITY: 11.1 Ib/gal (1.3314 gm/cc) @ 77F RELATIVE VAPOR DENSITY: 4.60 (air= 1.00) FLASH POINT: none EXPLOSIVE LIMITS: UEL - None ' LEL -None MAXIMUM ALLOWABLE CONCENTRATION (MAC): 500 ppm for 8 hours continuous DETECTABLE ODOR CONCENTRATION: 20-100 ppm HAZARDOUS PROPERTIES: Methyl chloroform is not as toxic as other chlorinated hydrocarbons such as CCI4; however, it can still cause damage to the body upon continuous or prolonged exposure to large quantities of vapors or liquid. Moderate exposure is unlikely to produce * injury. MC is readily absorbed through the lungs. In acute exposure, a functional d pression of central nervous system leading ultimately to respiratory failure can result. Der matitis may result from repeated skin contact, but MC is only poorly absorbed through the skin. Eye contact results in painful discomfort, but no permanent damage to vision is likely, TREATMENT: Remove victim to uncontaminated environment and apply artificial respiration if breathing has stopped Remove wet clothing and do not wear again until thoroughly dry. If eyes were contaminated, flush with copious amounts of water. Report to First Aid, SL 000057 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court' No. 91-1145 Collection Point Number 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 Description Tank Drain No. 1 Per Phase Separator Overflow No. 2 Per Wash Column Overflow No. 1 Per Wash Column Overflow No. 1 Per Dryer Drain No. 2 Per Dryer Drain Trl Product Dryers Drain No. 2 Per Phase Separator Overflow Trl Neutralizer Overflow Scrubber Drain Trl Neutralizer Bottom Pump Pad Drain Tetra Compressor Pad Drain Pump Pad Drain Tetra Plant Trench Tetra Emergency Scrubber TCE Storage Tank Scrubber Pump Pad Drain Chloral Drain DH Still Feed Tank Sight Glass Drain Intermediate Crude Tank Sight Glass Drain Pump Pad Drain Intermediate Crude Tank Sight Glass Drain Absorber Acid Pump Suction Drain Bottoms Scrubber Drain Bottoms Trench Drain Incinerator Pump Pad Drain Flow* NC NC NC NC NC NC NC NC 5 gpm NC NC NC NC Max 2S 5 gpm NC 1 gpm NC NC NC NC NC 5 gpm NC NC S ubject to P ro te c tiv e O rder 14th J u d ic ia l E fistricfc C ourt No. 91-1145 NC - Not Continuous SL 00051 3-24 NAME: Nitrogen FORMULA: N2 MOLECULAR WEIGHT: 28.02 SPECIFIC GRAVITY: 1.0 (air is 79% N2) DETECTABLE ODOR CONCENTRATION: None HAZARDOUS PROPERTIES: Even though nitrogen is a very safe, inactive gas, it has some inherent dangers since it is fed so universally throughout the plant. Its prime use is for padding of our equipment. 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, every vessel that is entered not only must first be checked for flammability, etc., it must also be checked for sufficient oxygen. All nitrogen lines, as well as other toxic lines, must be isolated from the vessel before entry and a clean air sweep must be provided. The apparatus for testing for sufficient oxygen is an analyzing device. Become familiar with its use. TREATMENT: Inhalation - Remove the person from the oxygen deficient area. Administer artificial respiration if necessary. SL 000058 CONFIDENTIAL: Subject to Protective Order Of 14th J udicial District Court No. 9I~li.45 Collection Point Number ____ 76 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 NC Not Continuous Incinerator Header Drain Acid Brick Pad Drain Dowtherm Pump Drain Aqueous Waste Pump Pad Drain Incinerator Pad Drain Acid Brick Pad Drain OHC-Tetra Lab Drain 0HC Trench Dryer Recovery Drain Per-Trl Distillation Trench Per-Trl Lab Drain Shipping Building Drain Shipping Building Drain Per Decolor!zer Per-Trl Dryer Filter MC Plant Trenches MC Plant Trenches MC Lab Drain Ash Liquor Tank Drain VCM Trench EC Vent Knockout Pot Tetra AIBN Tank Drain Acid Pit Overhead Drain Drain 0HhHsi1rcveO--no>' a s> r. ao ow*- o ?, H- Hi M VC SD ^ \'L 4 r+ VH&U-*i OHwH- fSrf*l-.*- r H*-> CD ' oH _oi-i noeH S' rf - Flow* NC NC NC NC NC NC 1 gpm NC 50 gpm 50 gpm 1 gpm NC NC NC NC NC NC 1 gpm NC NC 15 gpm NC 100 gpm NC NC SL ooo5e NAME: Oxygen FORMULA: 02 MOLECULAR WEIGHT: 32 COLOR: Colorless ODOR: None REACTIVITY: Very reactive HAZARDOUS PROPERTIES: Too High a percentage of 02 in the air we breathe will cause the person to pass out. Therefore, 02 lines on a vessel should be isolated before man entry. Pure 02 will cause many things to burn spontaneously at a much lower temperature lev I than air. Normal hydrocarbon oils and greases, for example, should never be exposed to O2. Never use a gasket or valve, etc. for 02 service unless you are sure it is acceptabl . At high temperatures, 02 will burn steel, stainless steel, or other alloy pipe and equip ment. Therefore, should a fire occur at or near an O2 line, apply water to the line to keep it cool. The normal "air" explosive ranges are considerably widened with hydrocarbon or chlorinated hydrocarbons in the presence of high 02. TREATMENT: If a pass-out should occur, remove the man from the area, apply artificial r spiration if necessary, and get First Aid help. S!_ 000059 CONFIDENTIAL; Subject to Protective Order Of 14th Judicial District Court No. 91-1145 3-2o NAME: Pentachloroethane (PCE, PENTA) FORMULA: CCI3CHCI2 MOLECULAR WEIGHT: 202.31 BOILING POINT: 321F (160.56C) VAPOR PRESSURE @ 75F: 4mm FREEZING POINT: -20F (-28.89C) LIQUID DENSITY 77C: 14.0#/gal., 1.681 gm/ml RELATIVE VAPOR DENSITY: 6.98 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: Below 121 ppm DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES: Pentachloroethane is a nonflammable and toxic liquid. It has a chloroform-Iike odor and can cause chronic intoxication. It is considered a stronger narc tic than chloroform and is about as poisonous as tetrachloroethane, which it resembl s in its action as a metabolic poison. It has a pronounced irritating effect upon the mucous m mbranes, causing an inflammation of the nose/ throat/ and respiratory passages. Chronic poisoning causes fatty degeneration of the liver/ inflammation of the kidneys, bronchitis, pronounced hyperemia of the lungs, and purulent pneumonia. TREATMENT: As described under tetrachloroethanes. Notify a physician. SL 000060 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 3-27 NAME: Sodium Carbonate (or Soda Ash) FORMULA: Na2C03 MOLECULAR WEIGHT: 106.0 MELTING POINT: 851 C (1563F) COLOR: (IN SOLUTION): Milky white; odorless small white crystals or white powder as solid with alkaline taste. DENSITY: 2.53 gram/ml FLASH POINT: None SOLUBILITY DATA: 7.1 grams/100 ml H20@ 0C; 45.5 grams/100 ml H20@ 100C EXPLOSIVE LIMITS: None HAZARDS: This is a weak to moderate caustic solution. It is not as corrosive or dangerous to the skin as sodium hydroxide solutions but any spill or splash should be washed off instantly. Contact with the eyes will cause permanent eye damage. Sodium carbonate should be treated with the same respect as sodium hydroxide. Sodium carbonate is nonflammable, but it can react violently with Al, P20^, H2SO4. A 1% aqueous solution of sodium carbonate has a pH ~-l 1.5. The solidanhydride(soda ash); mp 851C, d = 2.53, decomposes 400C to evolve C02 gas. It slowly absorbs H20 in air. It is insoluble in alcohol. The anydride is an irritant to eyes and the respiratory tract. Soda ulcers on hands can occur from contact. Nausea, vomiting, stomach ache, diarrhea all occur after ingestion. As a safety precaution, wear rubber gloves, safety glasses, coveralls when handling this material. TREATMENT: Flush eyes with water for 15 minutes. Wash skin with soap and water. Neutraliz spills with 6m HCI, dilute with H20 and route to process sump, SL 000061 CONFIDENTIAL; Subject to Protective Order of 14th Judicial District Court No. 91-1145 3-28 NAME: Sodium Formate FORMULA: HCOONa MOLECULAR WEIGHT: 68.02 MELTING POINT: 487.4F (253C) SPECIFIC GRAVITY: 1.92@20C (1.00 for air) PROPERTIES: A white deliquescent crystal with a formic acid-like odor, slightly hygroscopic, soluble in H2O, insoluble in ether which decomposes into sodium oxalate and H2 at high temperatures. It is a reducing agent. HAZARDS: Sodium Formate is highly toxic and strongly irritating to tissue. Wear rubber gloves, goggles, coveralls when handling this material as a solid. It is also a slight fire hazard. Dispose of solids by diluting with H2O, adding soda ash, neutralizing with 6m HCI, diluting with H2O and routing to process sump. TREATMENT: For eye contact, irrigate eyes for 15 minutes with water and report to First Aid. Wash spills from body with soap and water. If ingested, notify a physician and report to First Aid. SL 000062 CONFIDENTIAL: of SIu4bthjecJt uNtdooi.cPia9r1lo-t1De1c4ist5ivtreicOt rCdeorurt 3-29 NAME: Sulfuric Acid FORMULA: H2S04 MOLECULAR WEIGHT: 98.08 BOILING POINT: 626F (330C) MELTING POINT: 50.9F (10.5C) VAPOR PRESSURE: lmmHg@146C (294.8F) SOLID DENSITY: N/A VAPOR DENSITY: N/A AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 1 mg/m3 of Air DETECTABLE ODOR CONCENTRATION: 0.12 ppm (odorless) LIQUID DENSITY: @ 25C, 1.834 g/cc (Specific Gravity 60/60F) HAZARDOUS PROPERTIES: THIS IS ONE OF THE MOST TREACHEROUS CHEMICALS TO HUMAN FLESH. The greatest hazard of sulfuric acid is physical contact. Because of its affinity for water/ it dries tissue; creating heat, and resulting in a painful slow healing burn. Repeated skin contact with diluted sulfuric acid solution can cause dermatitis. It is a powerful oxidizer, and can ignite upon contact with combustibles. It emits highly toxic fumes when heated. Sulfuric acid reacts with water to produce heat. The acid should always be added to water upon dilution, never vice versa. It is a moderate fire hazard because of its high reactivity. TREATMENT: Skin - Immediately remove all contaminated clothing and equipment. Flush the exposed area with an abundance of water. After thorough irrigation with wat r, applications SL 000063 CONFIDENTIAL: 91-1245 3-30 of mild alkaline solutions may be used. Do not apply oils or ointments to burned area without instructions from a physician. Eyes - Flush with water for 15 minutes holding eyelids open. An eye anesthetic may b used for pain. Never use ointment. Call a specialist. Report to First Aid. Swallowing - If conscious, have patient wash mouth with water. Give at least 1 oz. f milk of magnesia or aluminum hydroxide gel well diluted in water. If these are not avail able, drink milk mixed with whites of eggs. Do not induce vomiting or pass a stomach tube. Call a physician. Report to First Aid, Inhalation - Remove patient from contaminated area. Give artificial respiration and oxygen if necessary. Report to First Aid. SL 000064 CONFIDENTIAL 1 or *>Hr i!rict 3-31 NAME: Symmetrical and Assymmetrical Tetrachloroethane (S. TeCE & A. TeCE) FORMULA: CHCI2CHCI2 and CC13CH2CI MOLECULAR WEIGHT: 167.86 BOILING POINT: S.TeCE 295F (146.1C); ATeCE 267F (130.5C) VAPOR PRESSURE @ 75F: S. TeCE 4mm; A. TeCE 13mm FREEZING POINT: S.TeCE -47F (-43.9C); A. TeCE -97F (-71.67C) LIQUID DENSITY @ 77F: S.TeCE 1.588 gm/ml; A. TeCE 1.533 gm/ml RELATIVE VAPOR DENSITY: 5.78 (Air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 5 ppm for 8 hour exposure DETECTABLE ODOR CONCENTRATION: Approximately HAZARDOUS PROPERTIES: The tetrachloroethanes are not flammable or explosive but are the most toxic of the chlorinated ethanes that will be handled in the Plant. The tetrachloroethanes are toxic by inhalation, by prolonged and repeated contact with skin or mucous membranes, or by oral intake. Although toxic, tetrachloroethanes may be handled safely if proper precautions are constantly observed. Prolonged or repeated ex posures to the product in any form are hazardous. The signs and symptoms of excessive absorption usually appear gradually and only after re peated exposures. In order of appearance they commonly are: unusual fatigue, loss of appetite and weight, sick stomach and vomiting, constipation, abdominal pain, jaundice, drowsiness, and in severe cases even unconsciousness and death. Some cases show mark d impairment of the nervous system inducing headache, numbness and tingling in fingers and SL 000065 'CONFIDENTIAL: of 14thC? Protective Order Of 14th Judicial District Court No. 9I-H45 3-JZ toes, trembling and twitching of muscles, and even paralysis of some muscles. The signs and symptoms of tetrachloroethane poisoning given above are due to systematic poisoning characterized by marked damage to the liver, kidneys, heart, blood cells and nervous system. The clinical picture varies with the type of exposure and the amount of the material which has been absorbed either at one time or at repeated times. The most serious effects are usually on the liver and the blood. The principal reute of absorption is by breathing the vapor, although it may also be absorbed by the skin. Tetrachloro ethane is currently considered the most toxic of the chlorinated hydrocarbon solvents in industrial use. Continued exposure to high concentrations of the tetrachloroethanes I ads to local irritation of the eyes and nose. There may be an upset stomach and vomiting, but since tetrachloroethane is less volatile than other hydrocarbon solvents, it does not often have an anesthetic effect. Subacute tetrachloroethane poisoning is the form usually encountered. This develops grad ually as a result of prolonged or repeated work in an atmosphere containing more than 5 parts of tetrachloroethane per million parts of air but under conditions where the amount absorbed causes no immediate reaction. Repeated exposure even to low concentrations s ems to increase sensitivity, and may lead to subacute poisoning. For some time, workers with subacute poisoning may show only such signs and symptoms as unusual fatigue, loss of appetite and weight, constipation and abdominal distress or pain. At any time they may develop more severe evidence of absorption such as vomiting, diz ziness, tenderness and pain over the liver, and jaundice. Even if removed from further exposure, the illness may persist and grow worse over a period of days, weeks or even months, and may finally even end in death. However, if after a few months ther has b n SL 000066 CONFIDENTIALl of lith'l v Protectl''e order of 14th Judicial District Court HO. *5 3-33 steady improvement/ complete recovery is the rul . Some conditions under which subacute poisoning may occur in employees are as follows: (a) Where the ventilation is inadequate/ resulting in high concentrations of more than 5 ppm of tetrachloroethane. (b) Where the vapor concentrations are high intermittently/ due to faulty handling of the liquid. (c) Failure of the individual to observe precautionary measures. 'i Tetrachloroethane is absorbed through the skin so that systemic poisoning can occur by this route with the same signs and symptoms as described above. Tetrachloroethane may cause dermatitis after repeated or prolonged contact with the skin, such as that which might occur in the handling of rags wet with the chemical product, dipping hands into the liquid, or wearing clothing saturated with it. Reddening, burning, and rarely, blisters may follow such exposure. In certain rare cases, the dermatitis may be caused by hypersensitivity to tetrachloroethane. The skin becomes rough, red, and dry due to the removal of skin oils. It cracks easily and is readily susceptible to infection. The skin has a chapped appearance. Tetrachloroethane may enter the eyes either as a vapor or as a liquid (spray or splash). The resultant irritation produces lacrimation, burning and other symptoms of inflammation. It can cause serious eye damage if immediate care is neglected. SL 000067 CONFIDENTIAL: Subject to Protective Order , of 14th Judicial District Court No. 91-1145 . d-M The first symptoms after toxic amount of tetrachloroethane are taken by mouth are those of irritation of stomach and bowels, such as sick stomach, vomiting, and diarrhea with bloody stools. It is absorbed very rapidly and even a small amount may go on to produce uncon sciousness and deep flushing of the skin. Death is apt to occur before such systemic changes as liver and kidney damage occur. TREATMENT: Most important in the case of any poisoning is quick removal from exposure. In the case of tetrachloroethane poisoning, this means first removing the patient from th con taminated atmosphere and, insofar as possible, removing the tetrachloroethane from the patient's skin, or gastrointestinal tract, if those areas are involved. The patient should be kept quiet and comfortably warm, but not hot. A physician should be called immediately. He should be told briefly and clearly what has happened and the exact location of th patient. A person showing symptoms of tetrachloroethane vapor poisoning should be removed promptly from the contaminated area. In case breathing has stopped, effective artificial respiration, such as that obtained by the prone pressure method or the Eve rocking method should be started immediately. If oxygen inhalation apparatus is available, oxygen should be admin istered, but only if one familiar with the operation of the apparatus is present to administer it. If the patient is conscious, hot tea or coffee may be given as a stimulant. A physician should be called at once. All contaminated clothing should be removed immediately. Clothing, including shoes, soaked in tetrachloroethone should be removed and not worn again until they are thoroughly free of tetrachloroethane. All affected areas should be washed thoroughly with warm water and soap. After this, an ointment containing lanolin should be applied in order to h Ip in replacing the natural skin oils. For serious or persistent cases of skin troubl , and for signs SL 000068 subjeotCtoPpDE,'M;'I'! f Uth er Wo. 9i~xi^5rict Court 3-35 and symptoms of generalized poisoning, a physician should be consult d. If liquid tetrachloroethane has entered the eyes, they should be washed promptly with copious quantities of water for at least 15 minutes. (It is advisable to irrigate the ey s gently with water at room temperature in order to minimize additional pain or discomfort.) Medical attention should be obtained in all cases involving contact with the eyes. If a person has swallowed tetrachloroethane, he should be made to vomit, if conscious, by having him drink a glassful or more of lukewarm water in which a teaspoonful of salt to the glassful has been dissolved. A similar amount of warm soapy water may be used. If necessary, the patient should be encouraged to stick his finger down his throat to induce vomiting. When possible, vomiting should be induced at least three times. Following this a tablespoonful of Epsom Salt dissolved in a glass of water should be given. A physi cian should be called at once. SL 000069 CONFIDENTIAL': Subject to Protective Order of 14th Judicial District Court No. 91-1145 3-36 NAME: trans-Dichloroethylen (TRANS) FORMULA: CIHC = CHCI MOLECULAR WEIGHT: 96.95 BOILING POINT: 119.10F (48.39C) VAPOR DENSITY: 3.34 FREEZING POINT: -58F (-50C) SPECIFIC GRAVITY: 1.246@25C (77F) VAPOR PRESSURE 5.205 psia@ 70F FLASH POINT: 36F (2.22C) EXPLOSIVE LIMITS: UEL 12.8%' LEL 9.7% MAXIMUM ALLOWABLE CONCENTRATION (MAC): 200 ppm (TLV) DETECTABLE ODOR CONCENTRATION: HAZARDOUS PROPERTIES: Moderate explosion hazard as vapor exposed to flame, Dang rous fire hazard with heat or flame. Exposure to high concentrations can cause nausea, vomiting, weakness, tremor and cramps. Can cause dermatitis from defatting action on skin. TREATMENT: Remove victim from source of exposure and flush with water. If eyes are expos d, irrigate with water. SL 000070 Subject to of 14tb Judic 3-37 NAME: 1,1/2 - Trichloroethane (TCE) FORMULA: CHCI2CH2CI MOLECULAR WEIGHT: 133.415 BOILING POINT: 236.8F (113.78C) VAPOR PRESSURE: @75F, 22mm. Hg. FREEZING POINT: -31F (-35C) LIQUID DENSITY: @77F/ 89.39 lbs. per Ft3; 11.93 Ibs/gal; 1.4319 grams/ml RELATIVE VAPOR DENSITY: 4.6 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 10 ppm DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES: Trichloroethane can cause burns of the eyes and has a seriously harmful effect upon the liver. It has a local irritating effect upon the mucous membranes, particularly of the eyes and nose. All contact with the eyes and skin should be avoided. This material should generally be handled with caution, because its toxicological prop rties have not as yet been adequately evaluated. TREATMENT: Remove patient from toxic area. Remove all contaminated clothing and wash all xposed skin surfaces thoroughly with soap and water. Flush eyes with copious quantiti s of water. Notify a physician; report to First Aid. SL 000071 CONFIDENTIAL! Subject to Protective Order of I4th Judicial District Court No. 91-1145 3-38 NAME: Trichloro thy I ne (Tri) FORMULA: Cl2C - CHCI MOLECULAR WEIGHT: 131.40 BOILING POINT: 188.60F (87C) VAPOR PRESSURE: 2.5 pslg at 100F FREEZING POINT: -99F (-72.78C) LIQUID DENSITY: 11.9 Ib/gal at 100F FLASH POINT: None EXPLOSIVE LIMITS: UEL 90% (Not flammable at normal room temperature; LEL 10.5% - 12.5% moderately flammable at higher temperatures) RELATIVE VAPOR DENSITY: 4.54 (air = 1.00) MAXIMUM ALLOWABLE CONCENTRATION (MAC): 100 PPm/8 hours DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES; Reacts with strong alkalies such as caustic soda to form highly flammable and toxic dichloroacetylene. Anesthetic effect at 400 ppm. Trichloroethylen may be harmful if inhaled, by prolonged or repeated contact with skin or mucous membrane, or if swallowed. It is a central nervous system depressent. TREATMENT: Wash skin area affected with soap and water. Eyes - wash 15 minutes for ey spills. Remove from contaminated skin. Remove from lungs or stomach -induce vomiting if necessary. Call a physician and report to First Aid. SL 000072 Subject of 14th 3 3-39 NAME: Vinyl Chloride (Chloroethylene, VCM, or VC) FORMULA: H2C:CHCI MOLECULAR WEIGHT: 62.501 BOILING POINT: 7.9F (-13.39C) MELTING POINT: N/A VAPOR PRESSURE: @ 77F - 2660 mm Hg (51.5 psia) FREEZING POINT: -224.7*F (-142.61C) SOLID DENSITY: N/A VAPOR DENSITY: 2.15 (Air=1.0) AUTOIGNITION: N/A FLASH POINT: -108.4F - open cup; -162F - closed cup EXPLOSIVE LIMITS: 4 to 22% by volume MAXIMUM ALLOWABLE CONCENTRATION: 1 ppm for 8 hrs./5 ppm for 15 min. ceiling DETECTABLE ODOR CONCENTRATION: Faintly sweet (like phenol when inhibited) LIQUID DENSITY: @ 77F7 61.92 lbs per ft3; @ 68F, 0.098 lbs per ft3 VISCOSITY: @ 77F/ 0.187 cp. 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 exposur s may cause some kidney deterioration. Inhalation of vapors greater than 500 ppm may produce a slight narcotic effect. At concentrations of 4% or greater, VC vapors may produce a deep or fatal anesthesia. The Department of Labor has declared Vinyl Chloride to be a carcinogenic (cancer-causing) compound. The main danger with VC is the extreme flammability of the vapors. VC when burning SL 000073 COWib^TIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 will form phosgene and HCI, so n ver approach a fir 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 ground. It will take very littl to explode the VC vapors - static electricity spark, friction spark, 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. All ex posed persons should be referred to the Medical Department. SL 000074 CONFIDENTIAL: Subject to Protective Order of I4th Judicial District Court No. 91-1145 0-*t i NAME: Vinylidene Chloride (VDC) FORMULA: CI2C = CH2 MOLECULAR WEIGHT: 96.95 BOILING POINT: 89F (31.67C) VAPOR PRESSURE @ 75F: 560 mm FREEZING POINT: -187.6F (-122C) LIQUID DENSITY@ 68F: 10.15 #/ga\., 1.218 gm/ml RELATIVE VAPOR DENSITY: 3.35 (air =1.0) FLASH POINT: 5F Open Cup, 0F Closed Cup EXPLOSIVE LIMITS: 7.3% to 16'.0% by volume in air MAXIMUM ALLOWABLE CONCENTRATION: 25 ppm, 5 ppm TLV DETECABLE ODOR CONCENTRATION: 500 to 1,000 ppm HAZARDOUS PROPERTIES: Vinylidene chloride is a flammable and toxic material. Vinyliden chloride is moderately irritating to the eyes and to the skin. The greatest danger from vinylidene chloride is inhalation. A single exposure for a few minutes to a high concentra tion of vinylidene chloride vapor rapidly produces a "drunkenness" which may progress to unconsciousness if exposure is continued. Even concentrations too low to cause an anes thetic effect, may produce organic injury to the liver and kidneys. A secondary danger from vinylidene chloride exists. Unstabilized vinylidene ehlorid in contact with air will decompose and form explosive peroxides. These peroxides are evident by the presence of a white solid. For this reason, all vinylidene chloride will be stabilized and all equipment will be passed with an inert gas such as nitrogen or methane. For fire fighting use dry chemical, foam, or C02 extinguishers. SL 000075 o)lh, CONFIDENTIAL: of 01 14ihCt Protective Judicial Order Wo. 91-U45ri0t CUrt 3-42 TREATMENT: When the skin is contacted by vinylidene chloride it should be throroghly washed with soap and water and all contaminated clothing removed and washed. If the eyes become contaminated, they should be flushed with water for 15 minutes or more. If a person is af fected or overcome from breathing vinylidene chloride vapors, he should be removed to fresh air at once. Medical attention should be obtained immediately. Artificial respiration should be administered if breathing stops. i SL 000076 CONFIDENTIAL:' Subject to Protective Order Of 14th Judicial District Court No. 91-1145 B. SPECIAL SAFETY HAZARDS There is one material handled in the Central OHC Steam Stripper area that presents safety hazards that require special consideration. While the majority of the materials handled in the plant are toxic or hazardous to various degrees and should each be handled with its due respect, VDC deserves separate discussion. VDC While VDC itself has certain toxic properties, the major hazard from this material is its tendency to form peroxides when it is unstabilized and contacts air. Two precautions are taken to avoid the peroxide formation in the plant. First, all vessels that contain VDC are padded with nitrogen to exclude the presence of air. In addition to this, all liquid VDC is stabilized with HQMME. The HQMME serves as an oxygen scavenger and prevents the peroxides from forming even when air is present. With this protectiv system, there should never be any peroxides in the plant; however, this material should be watched for and all precautions taken to avoid its forming. The peroxides are polymerization catalysts and cause VDC to polymerize when they are formed. If they are present, it will be indicated by a white solid in the VDC or th VDC system equipment. This solid is polymerized VDC and contains the peroxides. If these solids are isolated and dried, they will explode violently from either heat or mechanical shock. Other catalysts, such as light, water, or iron, will cause VDC to polymerize, so the presence of a white solid does not guarantee that peroxides have been formed; however, no chances should be taken if polymer is found. The most readily available peroxide destroyer is water, but the most effective material is caustic or cell liquor, which is also available in the plant. It is advisable to flush SL 000077 CONFIDENTIAL': Subject to Protective OrderT, Of 14th Judicial District Court 3-44 any equipment (that has contained VDC) with cell liquor, Follow d by a water wash, before any maintenance is done on if. This will insure against accumulated peroxides being trapped anywhere in the equipment or piping where they would be a maintenance hazard. SL 000078 f"Hr-urieetorcdocurr APPENDICES A. SAMPLE LOG PRINTOUT B. SAMPLE DAILY REPORT PRINTOUT C. SAMPLE ALARM REVIEW PRINTOUT D. PROCESS VARIABLE - POINT NUMBER CORRESPONDENCE INDEX E. HIGH/LOW ALARMS AND ALARM CONDITIONS F. CENTRAL OHC STEAM STRIPPER AREA LINE LIST G. CAL-VAC RUPTURE DISC H. SAFETY PERMIT PROCEDURES SL 000079 CONFIDENTIAL: Subject to Protective Ordef 14th Judicial District ocurt No. 91-1145 APPENDIX A SAMPLE LOG PRINTOUT i nnn....... :no9 OHC LOG 11/11/80 41 42 FAN / -- OFF~~~W"t"------------------ 41 42 ON HOURS i, 4.15 .00 41 LBVZFD/TK/BCiT.......................................... -------------- ------------------------------- #2 FD/TK/BOT 64.00000 . LEV% #1 FD/TK/TOP 64.00000 LEV* 00000fS-FD/T-K/TOP 64 . -----------------trEW------------------------------------- 1H STRIP 64 00000 LEU% *2 STRIP 64.00000 LE0% FEED TO tl 123.0000------------------ GFW------------------------------------------------ WFEED *2 160.0000 STEAM TO *1 1234.000 GPM 4/HR STEAM TQ-tB--tygrOOOO-------------- 4/HFf-------------------------------------------- STEAM FEED 54.40001 - PSIG #1 STRIP 6.400000 PSIG . 4.2-STRIP' 6.400000---------- RSXG--------------------------------------------------------- 41 FD/TK 32.00000 PSIG 42 FD/TK 32.00000 PSIG fl 42 STRIP LQ/PH 66.35491-----------'--DE-GF----------------------------- STRIP LG/PH 68.77612 DEGF 41 STRIP 0/H 78.28433 DEGF *2 STRIP 0/H 81,47688-------------- DEGF-------------------- ----------------- #1 FEED 70.03952 DEGF 42 FEED **70,54478 DEGF STEAM TO STRIP'S TEMP 298 ,-0000-----------------DEGF 41 STRIP FEED 10.40000 PH 42 STRIP FEED 10.40000 PH SL 000080 CONFIDENTIAL* Subject to Protective Qrdet of 14th Judicial District Court No. 91-1145 APPENDIX B SAMPLE DAILY REPORT PRINTOUT -BAYft---------------------------------------- ----------------- 1110 OHC DAY-RPT 11/10/80 11=1 *2 ON HOURS ---- 24.00---- . 00 ------------------------------ STEAM TO #1 1234.000 #/HR STEAM TO #2 192.0000 #/HR - -#4 STRIP FEE 11 10.00010------------ PH-- #2 STRIP FEED 10.40014 PH #1 STRIP 0/H 72.25672 DE6F #5 STRIP Q/H 0.000000-------- DEGF =#=1 FEED 71.94842 DEGF *2 FEED 0.000000 DEGF 4--STRIP LQ/PH 71.70858-------BE6F- *2 STRIP LQ/PH 0.000000 DEGF *1 FD/TK 32.00000 PSIG 42 FD/TK 32.00000----FS-.LG------------- FEED TO *3 173.0000 GPM FEED TO *2 0,000000 GPM SL 000081 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 APPENDIX C SAMPLE ALARM REVIEW PRINTOUT ALRV 1109*1 FEED LOW *70.12374 * ' 1 tO? *2 -FPHt W LOW- * 7062899 DEGF DEGF 1109 *1 STRIP 0/H LOW * 78.36838 1109 *2 STRIP 0/H LOW * 81.56086 DEGF DEGF 1109 *1 STRIP LQ/PH LOW * 68.43914 DEGF 1109 *2 STRIP LG/PH LOW *68.86036' DEGF 1109 *1.STRIP OPEN* 6.400000 PSIG --------1109 *2 "STRIf*OPEN-*- 6.400000--------- PfrfG---------------------------- 1109 *1 FD/TK OPEN* 32.00000 PSIG 1109 *2 F 1.1/7K OPEN* 32.00000 PSIG --------1109 STEAM F EED QPE-N* 54 40001--------- PS*G---------------------- 1109 FEED TO *1 OPEN* 123.0000 GPU 1109 FEED 10 *2 OPEN* 160.0000 GF'H --------1109 OTE-AM f-01 OPEN* 1234 * 000-------t9Hfi---------------------- 1109 STEAM TO *2 OPEN* 192.0000 */HR 1109 *1 FD/TK/TOP OPEN* 64.00000. LEW --------1109 *2 FD/TK/TOP -OP-EN* 64.00000--------LEW------------------- 1110 *1 FD/TK/BOT OPEN* 64.00000 LEW 1110 *2 FD/TK/BOT OPEN* 64.00000 LEW --------1110 *1--STRIP-OPEN* 6-Tr-OOOOO-------- LEW--------------------------- 1110 *2 STRIP OPEN* 64.00000 LEW 1110 *1 STRIP FEED OPEN* 10.40000 F'H --------1 i-10 -*2 OTRIF1 FEED OPEN* 10.4^0^0----------- PH------------------ 1110 FEED TO FEED TK'S OPEN* 10.40000 F'H 1110 SET F'H ED TO *1 OPEN* 24,92187 GPM ------- 1410 SE-T-LEUE-L-- TO *1 HIGH* 81.9062-4------- LEW-------------- 1110 SET LEVEL TO *2 HIGH* 92.40626 LEW 1110 OUT TO *2 STEAM VALVE LOW * 2.343750 7. ------- 1110 OUT TO *2 LEVEL UAL-VEQPE-N* 13.75000---------------& 1110 *1 FEED PUMP OFF * 0.000000 7, 1110 *2 FEED PUMP OFF ------- 1110 t2 STRIP PRESS HIGH-------------- :----- :----- -----------:---------------- 1110 *1 S02-F0RMATEPUMP OFF 1110 *2 S02-F0RMATE PUMP OFF ------- 1-110 1 STRIP PRESS HIGH----------------------------------------------------1110 *i AIR CONDENSER OFF 1110 *2 AIR CONDENSER OFF SL 000082 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 APPENDIX D PROCESS VARIABLE - POINT NUMBER CORRESPONDENCE INDEX STEAM STRIPPER *1 Point No . Process Variable 1 ^1 Feed Temperature 3 ^1 Overhead Temperature 5 Liquid Phase Temperature 7 Stripper Pressure 9 ^1 Feed Tank Pressure 12 ^1 Feed Rate 14 ^1 Steam Rate 16 ^1 Feed Tank Top Level 18 ^1 Feed Tank Bottom Level 20 ^1 Stripper Level 22 ^1 Feed pH 25 ^1 Feed Rate Setpoint 27 ^1 Steam Rate Setpoint 29 Level Setpoint 31 ^1 Feed Out Monitor 33 ^1 Steam Out Monitor 35 ^1 Stripper Level Out Monitor STEAM STRIPPER *2 Point No. Process Variable 2 ^2 Feed Temperature 4 ^2 Overhead Temperature 6 ^2 Liquid Phase Temperature 8 ^2 Stripper Pressure 10 #2 Feed Tank Pressure 13 #2 Feed Rate 15 ^2 Steam Rate 17 ^2 Feed Tank Top Level 19 ^2 Feed Tank Bottom Level 21 ^2 Stripper Level 23 #2 Feed pH 26 ^2 Feed Rate Setpoint 28 ^2 Steam Rate Setpoint 30 ^2 Level Setpoint 32 ^2 Feed Out Monitor 34 ^2 Steam Out Monitor 36 ^2 Stripper Level Out Monitor VARIABLES COMMON TO BOTH STRIPPER SYSTEMS Point No. 11 24 Process Variable Steam Pressure Feed Tank Feed Inlet pH o C) o *v . ^ X1 $7 O to $ `S'^ ' 37 38 39 PRV - Positive Reference Voltage RTD ZRV - Zero Ref renc Voltag <D O . O <J O ^. Cr .Vt"o, -O..' 40 SL 000083 Stripper St am Fe d Temperature Cq'V APPENDIX E HIGH/LOW ALARMS AND ALARM CONDITIONS: 1. Tank Feed Inlet pH-for tanks ^1 and ^22. pH on steam stripper feed to strippers " 1 and ^2 3. Steam stripper overhead temperature for strippers ^1 and ^2 4. Steam stripper bottoms temperature for strippers #1 and #2 5. Steam feed flow to strippers ^1 and ^2 6. Steam stripper bottoms level for strippers ^1 and ^2 7. Total feed tank level for tanks ^1 and ^2 8. Feed tank interface level for tanks and ^2 9. Steam stripper overpressure for strippers ^1 and ALARM POINTS HIGH LOW pH 13.0 pH 9.0 pH 13.0 pH 7.0 220F 200 F 230F 205 F + 20% deviation in steam feed rate. 80% 20% 80% 20% 80% 20% 15 psig SL 000084 Subject Ct!o'Pp ENTlU: Uth 0rcJer tio. 91 , , Lrict '1145 Court APPENDIX F CENTRAL OHC STEAM STRIPPER AREA LINE LIST / SL 000065 CONFIDENTIAL! Subject to Protective Order Of 14th Judicial District Court No. 91-1145 fr T7~ - T C iwtaa 9CCHO FROM r '' w w t r/ *Tf ~ *4 . ?t * z~- ~ -- -**-'w-- ^ esot 3- 4'-** j*1/ 9Sf / 'c ?( 4 rtees MW MO - '/M Mwisr '#9 r* -v>? ! --r~r- ^ ** r.j rt r ~3E~ 't r- x ;*z s' J' tot>+-P4-14Q TO ~ rMHW >>> <MO dMT nr T r*5 /O' MOSS - 'f-SS&S r-too*- M*** ti '- too*- ***** AW MW * wn.C3MVH MT IWJH FLOW =t VfctfTTC we ar jwwi 4 vovrf Ji o /O'? ZOO r tuta *9 cor srotMeesr c i Fr -' ?* 1 *> * c-i r .!,, l > r* MO ww lea* /CM sees so&e soar Ml 'V i ? il - mt- jrfO- A -F /*' /*' /?' ' /itrjw/ A3 /.t'.ftXS 3*39-MS ,'J*' /V t9-ss*s-M7 /*-JAW-A* /? JAS// Ofjfts-jxss-ms jw atuutt - 9*vrr S*MW */ iffH/ty fr/nw jwwr iww mi j - - *0,3 - - JO* - - **J smarv sttraav . , i*e*trs <a o _*ti wbaraO 1 ef 4. test UJ toe-* soos J/Ct-M its ,- /'too/-mo* /' (tif7tt s/*s JKJS3 /' /' 4663 - ,1*3 /* Og-STtS-SttZ M LTinrv sztr/c*j " - jvsn? favnm w/r 3/3 c sect soot goes SCO* V V %' V 3L.T9 ti-m3-3tQ3-K7* StffSTtS- JVOS-A T9 ftf- 3007 M 79 rif-ms-stcs-M?* emtsrr snersot* r-t r-9 tmurr ststr/ost toot* AM Mf 0009 #' A# fYttr-jjjtrt msec* o* a'^jtsftrt 4 ' 4-*cs*-jr-jn fSW* JlWiMHf C-/ 'x * e-f f* wnw f*r- "' * O^eaft-M /" t'tCOBXMM jvanr. arts* ntsctMQ Mtntoostt to jo'srtAst 9 LINE LIST wise EOLXV LEHOTM afuunrr CF- rot XFTO WSUUiTKMSHe AMT (KW TMCEVCC FLOW mi mm f. tests SfO-*ssos ts Mome MOtM fro- imm 77O-tSM00 MTor HEW WHOt ear j*^ s*wr <d10 tts /noso to *t ss*r js-jtsV s> <z 0 UnSMHS ... ZT'&tf ?, OWW t-MW IN struwiL i(W M-(# n;^w rr--------- lvr L-i 3 OO ruc U O XJ V D -H * > 1-3 -H 4-J (j < +j t; - M O -m r ttf t*re*s JO * Z X> 1 j___________________________________________________________________ j______________:_____________________________________________________ O Li (0 c t J. l H (X -H j-l 0 . Z O -H < 0 -p *0 ; orsso c>4 **** "C S u b je c t o f 1 4 th Ju L sro -/ass* ik JL STO JOSS sre ms* c9 X 3 J0 i stove (9 S70./000! A S70-J000* ____ 1________ oe ses J JJYOSS i j X C j-A-OY - SL 000087 MMC sto-tsoos SJOjcocs tts jvroso St X-SM ____1_______________________________________________ X, tts utosc flT x-tstr xr/x.*acto S70/SS04 tts arose j*ft iw x-*tr -- T io 0 A 1C T|? IlNIAJjIKlAL US CHEMICAL DIVISION MUM LUX OVJU5. LOUSUNA CFN7RAI DHC STFAM STRIPPER PlPtK jiwjM^l!S3r>t|,| pftuMr^Tt Zm-------------n57D -- KX321.1 APPENDIX 6 CAL-VAC RUPTURE DISC SL 000088 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 -*'t *i the revolutionary Continental ft A 1 sT&T'AiO l'SE"'TM *TM p,iJ * E0ZU.Z-3IT ^i B J^ VjTvA^ ,. ISO*-. L PotZT POU. Port RUPTURE DISC... An ntlrely new and better way to protect processing and storag tanks from collapsing when too much vacuum is pulled. At the same time it provides protection against damage from sudden buildups of positive overpressure. The CAL-VAC rupture disc is NOT just another vacuum breaker. It's a fail-safe, non-mechanical device designed to provide both vacuum and positive pressure relief at standard pre-determined settings. (See.table on back page for standard sizes and settings). Although the unit is designed for insert-type installation, standard sanitary ittings are available on request. SOME TYPICAL APPLICATIONS Beverage processing and storage tanks Liquid chemical, petrochemical and gasoline storage tanks Bulk liquid transportation . equipment # Co 1S77 CONTINENTAL CKSC CORPORATION, Riverside. Missouri CONFIDENTIAL: Subject to Prot^ptive Order Of 14th Judicial district Court No. 01-1145 // \ design features of the \ CAL*VA. /* I* :l RUPTURE DISC... i I . f It* *. r ti ?p: V.' r`j f*1' $ i; h & c V VACUUM GIRDLE DESIGN determines standard mini/maxvacuum settings, allows system to operate within one inch water column of minimum vacuum pressure rated setting. Patents pending. TOP SECTION will give positive pressure relief as calculated per standard flow relief... either as primary relieving device or as a backup device to an existing safety relief valve. (Suggest disc be rated at 1.2 to 1.5 times primary relief setting). U.S. Patents 3,445,032 and 2,953,279. JPTURE DISC SEAL distributes pressure liformly in both positive and vacuum SL 000090 directions, eliminates both external and internal leakage. FLAT SEAT DESIGN reduces susceptibility to product buildup, promotes easier cleaning to meet FDA requirements. THINNER FLANGES reduce weight and material cost. LOCATING PINS on inlet Safety Crown holder assure proper disc alignment. KNIFE BLADES with PRECISION-HONED EDGES are designed to provide maximum vacuum relief. NO MOVING PARTS eliminate possibility of malfunction, assures a fail-safe operation. CONFIDENTIAL: ' Subject-to Protective- Order Of 14th Judicial `District Court No. 91-1145 SAFETY CROWN HOLDER (Outlet flange) L_TOP SECTION SEAL 1 ;agsBgaS3? SL 000091 VACUUM GIRDLE RING (optional) SAFETY CROWN HOLDER (Inlet flange) with KNIFE BLADE ASSEMBLY standard materials of construction SAFETY CROWN HOLDERS (inlet end outlet flanges) Carbon steel and stainless steel. Other machineable materials available on request. (NOTE: Holders can be furnished with Teflon "S" coating, nickel electroless or tantalum plating.) SIDE-MOUNTED BARS Stainless steel with steel round head cap screws. KNIFE BLADE ASSEMBLY 17-7 PH stainless steel, heat-treated and polished. TOP SECTION and RING Monel, nickel, inconel, 316SS. Other materials available. SEAL and VACUUM GIRDLE: Teflon. Subject to ^ttfstricfcourt o 14th ' * iJ 4* AIMS! BOLTING I (150 LB.) SIZE 3' 4* 6' 8" DIMENSION "A" 5 Y*" 6%8%" 10% - DIMENSION 40M iy<" i%" IVi" i%" A EZC B F-; M SLi v; fc ,9 ij p r Standard Sizes and Settings of CAL-VAC Rupture Discs ; RUPTURE DISC - ; SIZE 3" - .. 4" i 6" 8- - VACUUM PRESSURE REUEP STANDARD VACUUM RELIEF SETTINGS Inch.* of walar column when vacuum inUfl atarta Inch.* of wal.r column when lull vacuum f.li.l 1* reached 1.0 3.0 2.0 4.5 4.0 9.0 5.0 12.0 2.0 7.0 3.0 13.0 4.0 10.0 5.0 12.0 7.0 20.0 1.0 4.0 2D 7.0 3.0 5.0 4.0 8.0 5.0 11D 1.0 5.0 2D 5.0 3.0 10D 5.0 8.0 6.0 12.0 8D 10.0 Approilm.lt Relief Area In vacuum direction Cq. In.) 3.5 5.8 10.5 16.4 POSITIVE PRESSURE REUEP RANGE OF AVAILABLE POSITIVE RELIEF PRESSURES PSIG @ 72s F. Minimum Maximum APPROXIMATE RELIEF AREA IN POSITIVE DIRECTION (aq. In.) 12 150 6.62 10 125 15J90 7 100 33.18 4 75 66.75 TEMPERATURE LIMITATIONS. ALL SIZES: Minimum, 20* F., Maximum, 150 F. H rlr.jf *I-,l' i-i h f3 ly~` ?rirraad Si U.S.A. Disc Replacement VACUUM PRESSURE RELIEF When vacuum relief occurs, normally the seal only needs to be replaced. POSITIVE PRESSURE RELIEF When positive overpressure relief occurs, the . entire rupture disc assembly is replaced. (top section, seal, vacuum girdle and optional ring) *1S--.* CONTINENTAL DISC CORPORATION 4103 West Riverside, Riverside, Missouri 64150 Telephone: (816) 587-8300 Telex: 42273 SL 000092 O*f I144f.thh J7 uad-icial DiedtieOl ffC* No. 91-1145' Bulletin 73-1006 COaHHBilAL DISC COSPOSATIOS c CONFIDENII ATi : . RUPTURE DISC & H HOLDER PR3C3NG % #n Prica Sht CDC 3-77 Subject to Protective Order tE 14th Judicial District Court No. 91-1145 . INSERT FLANGE ASSEMBLY FOR CAL-VAC DISCS SAFETY /L"nDUAWWfKnl AA Klw1ClI FLANGE MATERIAL QUANTITY - PRICE EACH SIZE RATING INLET OUTLET 1 23 45 150 C.S. C.S. 235.00 3" 150 316 C.S. 253.00 ' 150 316 316 271.00 -:^:;i50CL: v*jGS* ^4^C.S. ': -r244.00 V.V. *1 T&150--S ^3l6'4;:^^c:s: "273.00 SrP-150'^U 31*317 * - -\ J>1**" >f[j 16,i-- 302.00 150 C.S. C.S. 265.00 6" 150 316 C.S. 313.00 150 316 316 361.00 ->*? ,150 -Vi?Er316 :^"r.C.S. 299.00 ;377.00 '-150 '^316 `^.V-316 447.00 182.00 203.00 226.00 . 189.00 ' 23s;oo 265.00 217.00 275.00 331.00 258.00 342.00 420.00 162.00 151.00 178.00 168.00 204.00 195.00 >166.00 460.00 -218.00 ^204.00 -242:00 ^235.00 199.00 191.00 261.00 251.00 313.00 301.00 r 240.00 4232.00 -312:00 K302.00 380.00 358,00 141.00 159.00 184.00 -154.00: 191:00: 227.00 184.00 241.00 289.00 " 224.00 - 292:00 341.00 "Different materials or designs will be quoted on request. ' Above prices include knife blades (17-7 SS), alignment pins (SS), pre-assembly clips, and screws (SS). (Does not include the disc). DISC SIZE 3" 6" 8" CAL-VAC DISCS INCLUDES METAL TOP. TEFLON SEAL 8c GIRDLE QUANTITY - PRICE EACH BOTTOM RING TEFLON REPLACEMENT PARTS 1 2 3 4 5-10 (OPTIONAL) SEAL GIRDLE 101.45 91.90 82.35 -$408.90 &&98L65 88.40 167.55 150.54 133.55 t-*?1221.70 r'470.65. -.152.10 82.35 88.40 133.55 152.10 82.35 88.40 133.55 -152.10 5.25 7.50 -;^;i.;-i6.45 7-&9.00 7.85 11.40 14.00 `V-: -?T4.50 25.10 26:90. 31.55 40.80 Metal top or bottom ring material Monel, Nickel, Inconel or 316 Stainless. Other materials quoted on request Disc tags are aluminum. For Stainless Steel tags add S^g.to price of disc. QUANTITY DISCOUNTS FOR IDENTICAL DISCS ORDERED AT THE SAME TIME 1-10-0% SL 000093 11 - 19 - 5% 20 - UP - 10% CONTINENTAL DISC CORPORATION . 4103 WEST RIVERSIDE RIVERSIDE,MISSOURI 64150 PHONE (315) 587S300 TELEX42273 HOW TO INSTALL THE CAL*VAC.. RUPTURE DISC CAUTION! Thu unit n i precision instrument i4 the knife blades are raior sbirp. F*r thfii two reasons, hendle with extreme cerel PRECAUTIONS REQUIRED IN LOCATING UNIT IN THE SYSTEM 1. Before installing this rupture disc unit, make absolutely sure it will be located where people or property will not be exposed to the discharge irt cate ol rupture. 2. H toxic or flammable lumes or liquids win be roleosed upon discharge, be sure they will vent to a sale place. GENERAL PROCEDURE FOR INSTALLING UNIT 1. Chock >11 components to niika sure thoy lino not boon domiged. Hondlo Worn contulty. 2. Asnmbt* rupture dioc cempensntt between hoWm oi shown, 1. Initill numblid unit in piping system using good piping ond Instrumentation tnstatlitlon prectini. Moke sure How arrows point In propot diroctton. Sn blutUiboas >1 right HOW TO PREPARE THE HOLDERS 1. Diuooomblo holdirt by Intoning screws in oullot bongo ond lilt biogd out ol osnmbly dipt. 2. It tbit It l now Itittobolloit. remove kollo Mada shipping pruodor tantuby. bemambar tbo knllo Modao ora ruor ibtrpl DO NOT INSTALL SHIPPING PROTECTOR! S. II tbU to o riplecimint Initillotion, remove rupturod or dd dlte. 4. Clnn ob tonlgn material Iron rupture dlte totting d boin lolot Mid outlet bongos. Chock knllo bltdn lor dimagi. DO NOT INSTALL iho rupture dlte numbly II knift point! art domogod or It Ibaro oro nickt on Ibo cutting edge. CAUTION: Hondlo Modoc with con. They ore extremely thtrpl HOW TO ASSEMBLE THE CAL*VAC RUPTURE DISC UNIT CAUTIOKI Follow procodurt taiotully. Hondo Iho CAL'VAC rupture due with extreme core A rupture disc u o procition instrument. 1. Plied Inlet tlfngo on o ltd tortici with knlto Model tnd locating pint pdnHng upward it mown. II2. It option metallic ring It bdrtg uud. place ring on the locating pin it Mown. 3. Plan vacuum girdle gn locating pin with convex lido up at thowo. 4. Plan Taboo tool ond loo oodtoo d rupture dlte on lontlng phtt wbh canvai tin up at mown. NOTE: In loma coin the ring, vecuum drdlo and mddbc too tocllon ore pormenontty etuchod end may be installed n t tingle unit. ; 5. Lower outlet bongo on locibng pin carefully. Man* euro you do not damega crown nl rupture due. b. Fitttn the complete numbly eocurdy by Hghtodog screws ogikut osumbly dtps'. HOW TO INSTALL THE CAL*VAC RUPTURE DISC ASSEMBLY IN THE SYSTEM 1. Soiling gatkdt are to bo furdshid by tho cuttomor. Plan gatktti batwnn tutht tlangt ond companion tlanga end Inlot bongo and companion tango. 2. Intort CAL'VAC rupture disc leiimMy into lyitsm. CAUTION: 6c turo FLOW ARROWS on nemo piste ore pointing In PROPER VENT DIRECTION -- potnive pretture reliel ond vacuum pleasure rciiel 3. Instill or ra-lnatoll boiling. Torque unb by milntalning prnsuro evenly around tbo penmoter using cress torqua hobmg soquann. Rotor to lorquo tsblo below. SAVE 'TIME AND MONEY BY FOLLOWING SOUND PREVENTIVE MAINTENANCE PRACTICES 1. Replies rupture disc dvety yur b optrtbng coodlttun ire normd. It nvtra conditions oxisl, shorten thi change-dut ptnod as required. 2. When replaclog rupture discs, chock kobo Modoc lor point damoga, nicks and preens media buildup. Do not re-install bit unb b blada odges ire dud or hivt bttn dimtgtd. Ruturn Inlot hddor and knllo bladot to Continoul Otic Corporation lot repltctmant. Be sura tn ssmble CAL'VAC rupture disc catnponbntt In this order CAL'VAC rupture disc property Installed In pressure syitem 3. To avdd I major plant tbutdown, maintain an ImronMry ol three apart bttn lor aock unit In usa. Tour ptrsunal aipariann wih datormino it tbit is adiquats. Ad|ii>t your invuniory accordingly. (sr V9Z-. CONTINENTAL DISC CORPORATION 4103 West Riverside Riverside, Missouri 64150 Telephone: 816-587-8300 TORQUE TABLE SIZE ANSI RATING *"3" ISO 150 8" ISO 1" 150 TDROUE lb. Ibt.) 40 30 40 75 'Patents applied tor SL 000094 No. 91-1145 appendix h SAFETY PERMIT PROCEDURES SL 000095 CONFIDENT At* Subject to Protective OtfVet of 14th Judicial Di-Ptrict Court No. 91-11^5 WELDING, BURNING, OR OPEN FIAME PERMIT When ond Where R quired A Welding, Burning, or Open Flame Permit must be issued prior to beginning "hot work" (welding., burning, or open flame work) anywhere in the plant with the following exceptions: 1 . Permanent designated shop locations, 2. Temporary fabricating areas may be treated as a permanent designated shop location upon mutual agreement of the Construction or Maintenance SPU Lead r and the SPU Leader of the affected operating unit. Note: This exception does not apply in Plants B, the Organics Dock Storage Area, the Organics Shipping Facilities, or the South Terminal Area, When "hot work" is performed on piping, vessels, pumps, or other equipment which contains, or may have contained, process or utility liquids or gases, a Permit shall be required even in th exempt shop locations. Responsibilities Issuance of a Welding, Burning, or Open Flame Permit requires |oint participation of Operations Supervision and the Maintenance Foreman or Field Engineer. Communication must take plac between these individuals concerning scope of the job, other related jobs, possible unfores n occurrences, etc. Specific consideration must be given to all items on the Permit checklist described below. PPG supervisory personnel are responsible for immediate termination of a Permit when a change In conditions warrants such action. Persons working under the protection of a Permit should keep Operations Supervision informed of observed changes in job conditions and/or breaks in job continuity and should request revalidation of the Permit any time there is a question about continued safe working conditions. SL 000096 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Checklist Each item n the Permit checklist (s P rmit Form on Page 6) must be carefully considered. _ A response to each checklist it m Is required. Job Safety Instruction (J5I) Appropriate JSI should take place between the Foreman and the persons on the job each time a WBOF Permit is issued. An explanation of each "Does Not Apply" item on the checklist should be included. PPG employees directly involved in the welding or burning operation covered by the Permit should initial the reverse side of the field copy of the Permit to indicate that JSI has been received. Signatures A Welding, Burning, or Open Flame Permit is not valid unless it contains the signatures of an Operations Supervisor and a Maintenance Foreman or Construction Field Foreman. Duration of Permit A WBOF Permit should only be issued when all preparations have been made and the welding, burning, or open flame work is ready to commence. The Operations Supervisor issuing the Permit specifies the start time and expiration time of the Permit. Depending on the location and nature of the job, he may specify that revalidation of the Permit is required following any break in continuity of the job such as smoke breaks, time spent in shops on fabrication, etc. Additionally, revalidation may be requested by Supervision or the personnel protected by the Permit at any ti,me there is a question about ability to perform the welding or burning op ration safely. A space for revalidation signatures by the Operations Foreman is included on the reverse side of the field copy of the Permit form. The maximum duration of a Permit is four hours, and it may not be revalidated after that time. SL 000097 -2 - f iJth^udiei^rD^^* rtJer No. CoUrt Pistribution of Permit The Welding, Burning, or Open Flame Permit is print d on a two-part form. Wh n filled out and issued, th paper original is posted in th Operations Control Room. Th cardboard c py / (field copy) is posted in a conspicuous place on the job site. The Control Room copy will be used by Operations as a means of keeping informed about field activity and will serve as a checkpoint if necessary to terminate Permits due to process upsets. The field copy is to be returned to the Maintenance Foreman/Field Engineer at the completion of the job. The Maintenance Foreman/Field Engineer shall sign the "Job Completed" blank and return the Permit to the Operations Foreman who attaches the Control Room copy and forwards both to the Senior Safety Supervisor/Engineer. Expired Permits which are replaced by new Permits during the course of the job shall be destroyed. General Rules 1. A WBOF Permit should only be issued when all preparations have been made and the welding or burning operation is ready to commence. (That is, don't issue a Permit at 7:30 a.m., if welding rigs have to be moved, material gathered, etc. Conditions can change in the interim.) 2. A combustible gas test must be made to insure that the work is free of a flammable atmosphere. The explosimeter reading shall be recorded on the Permit. When the possibility of a false reading exists due to Inert gases such as freon or nitrogen being present, an oxygen check should be made to determine if there is a sufficient amount of oxygen present to cause combustion in the explosimeter. It is expected that a meter reading of 0% LEL will be obtained in order for the Permit to be issued. On a special exception basis, readings between 0% and 9.9% LEL will be permitted after consultation SL 000098 3" Subject CNf,iDENTIAI, : 0f l4th JuaiciaTb(Cllve 0r3er No. 91-illlrict Court with a higher ranking Operations Supervisor. In no case will th Permit be issued when combustible gas tests of 10% LEL or greater are obtained. 3. When welding or burning on or around process lines or vess Is which may contain flam mable or explosive material (including well water), closed and tagged valves shall not be considered adequate. Installation of isolating blinds (with tags) is the preferred method of control for such cases, but where removal of spool pieces or other similar procedures provide equivalent protection, these procedures are acceptable. 4. All valves controlling flows to and from the work shall be closed and tagged by an Operations Representative, Maintenance Foreman, and the men performing the work. When contractors are doing the work, only the Operations Representative and the Field Engineer are required to tag. 5. All bleed valves shall be opened and tagged according to Rule No. 4. .6 Presence of blinds must be physically verified and shall not relieve anyone of the responsibility of tagging. Blinds .are considered as control points just as valves are, and must be tagged accordingly. 7. All electrical circuit breakers pertaining to the job should be pulled and tagged according to Rule No. 4. .8 A check should be made with an oxygen meter if necessary to determine if breathing air is needed. 9. A check should be made to determine if a life line, safety belt, etc., is necessary. 10, All sewer openings in Plants B near the "hot work" shall be covered and sealed. Sewer openings in other areas of the plant should be considered jointly by Operations and Maintenance/Construction, and covered if necessary. 11. A fire extinguisher should be accessible while the "hot work" is being performed. SL 000099 -4 - , ject to Pro l4th Judicial ^ . Ve Order NO. Dl-U4~rict CUrt 12,. Fire watch rs shall b r quired in Plants B and in other plant locations where sparks or hot slag from welding operations could precipitate a fire. The person designated as fire watch shall use water to wet the sparks and hot slag ar und welding in such areas. 13. The electrode ground from an electric welding machine must be clamped directly to the metal being welded or as close as possible. 14. Operating personnel shall make use of the Control Room copy of WBOF Permits to keep informed of "hot work" in progress in their area. All vessels, piping, or other operational equipment that has to be opened, vented, etc., should be done only after proper communication with the personnel performing the "hot work". 15. The Permit shall be issued for one job and not to each welder unless the foreman decides that a specific part of the job requires a separate Permit, The Permit shall be displayed in an appropriate place on the job. 16. On weekends and during the night shifts, the Shift Supervisor or Shift Foreman, in conjunction with the Maintenance Foreman, should issue any Permits that are required. SL 000100 -5- CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 WELDING, BURNING, OR OPEN FLAME PERMIT Dat Area Job Description________________ Checklist (This portion to be filled in by Operations) 1. Valves closed/tagged 2. Bleed valves open/tagged 3. Connections blanked or blinded & tagged 4. Electric circuit breakers pulled/tagged 5. Sufficient O2 for test. Meter in calibra tion. Free of process materials & gases. % explosive. (This portion to be filled in by Maint/Constr 1. Fresh air masks & air needed 2. Life line (wristlets,belt-harness) required 3. Sewer line opening sealed 4. Control points checked and tagged 5. JSI given ye$ Does Not Apply X Permit Start Time____________________ Expiration Time Maximum Duration: Four Hours New Permit required after job interruptions such os lunch break, evacuation, safety meeting, or process upset. For other situations requiring revalidation, the Operations Foreman's signature is required on reverse side of field copy. Operations Maint/Constr Foreman Foreman When job is complete. Maintenance Foreman/Field Engineer returns Permit to Operations Foreman who will then forward both copies to the Senior Safety Supervisor/Engineer. Job Completed Maintenance Foreman/Field Engineer This is a two-part, carbonless form. The paper original is to be designated as "Control Room Copy" and the card stock copy is to be labeled "Field Copy". SL 000101 Subject to Protect! -6- of l4th Judicial Diet No. 91-lX Order t Court REVERSE SIDE of Field Copy of Welding, Burning or Open Flame P rmit I have received JSI concerning the |ob covered by this Permit Signatures of PPG employees protected by Permit, The signature of an Operations Foreman is.required below whenever revalidation of the Permit becomes necessary. Request for revalidation may be initiated either by PPG supervision or by personnel protected by the Permit, Operating conditions are stable and the job covered by this Permit may resume. Operations Foreman / Time Operations Foreman / Time Operations Foreman / Time Operations Foreman / Time Operations Foreman / Time Note: Only the Field Copy will have this printed on reverse side. SL 000102 -7- of 14th Judicliaai.l hDi istrict G^Uft No. 91~iia^ IGNITION SOURCE PERMIT (Prior to impl mentation; Purpose An Ignition Source Permit is similar to the Welding, Burning, or Open Flame Permit and is designed to control the use of tools and devices having the potential to provide a spark or source of ignition in areas of the plant where this is a concern. Includ d among the devices covered by an Ignition Source Permit are: 1. Spark ignition vehicles which are to operate for more than 30 minutes within a restricted area. (The Vehicle Entry Permit is only intended for quick-in/ quick-out use.) Cranes, fork trucks, hydroblast rigs, etc., are examples of vehicles requiring an ISP in designated areas. 2. Gasoline drive pumps, air compressors, etc. 3. Electric powered tools, pumps, etc. 4. Heat lamps 5. Hot air blowers 6. Sandblasting nozzles 7. Jack hammers, chipping guns, and similar spark producing tools 8. Electronic transmitters and similar devices having spark potential when being calibrated. Note: This is not intended to be an all inclusive list. When and Where Required An Ignition Source Permit is required when using devices similar to those described above in the following locations: 1. Throughout Plants B operating areas, at the Organics Dock Storage Area, at the Organics Shipping Facilities, and at the South Terminal Ar a. SL 000103 CONFIDENTIAL* Subject to Protective Ordef of 14th Judicial District Court ' *2. At all other locations in the plant when ignition sourc devices are used in work performed on process vessels, proc ss lines, s wers, pumps, or other equipment . having the potential to contain a flammable or explosive liquid or gas. *3. At any plant location where there is the possibility of an explosive atmosphere due to conditions such as a release from a safety relief device, a sewer carrying foreign material due to a process upset, or from any other abnormal conditions. * The affected Operations Supervisor and Maintenance Foreman/Field Engineer are responsible for evaluating the job situation and determining the need for a Permit in these areas. R sponsibllity for Issuing Th Maintenance Foreman/Field Engineer on a job requiring an Ignition Source Permit is responsible for initiating a request for the Permit. For situations where an ISP is required for service contractors or others not working under the supervision of a Maintenance Foreman or Reid Engineer, an Operations Representative of the affected unit shall initiate a Permit request. An Operations Supervisor in the unit is responsible for verifying that the job area is free of flammable or explosive materials and for issuing the Permit. Unlike the Welding, Burning, or Open Flame Permit, the Maintenance Foreman/Field Engineer is not requir d to directly participate in issuance of the Permit unless warranted by unusual circumstances. For certain types of equipment such as compressors or pumps which will not be constantly att nded, the issuing supervisor must see that provision is made for emergency shutdown of the equipment. Resp nsibility for Shutting Down Equipment Operations personnel from the issuing control room are responsible for seeing that ignition sources are shut down when process conditions call for such termination of activity. Ordinarily, an Operations Representative shall inform the person using the ignition source of the hazardous condition and the user shall turn off or shut down the machine or device. For unattended SL 000104 -2 - Of 14th* Irtective Order OI 14th Judicial District Court Wo* 91-1143 equlpm nt, the Operations Repr s ntative shall operate switches, breakers, etc., as required to render the ignition sourc saf . Th Operations Supervisor who issues the Permit should take note of the shutdown point (switch, breaker, etc.) when issuing the Permit and if the point is not readily identifiable, shutdown instructions should be written on the control room copy of the Permit. Duration of Permit Th Operations Supervisor issuing the Ignition Source Permit specifies the start time and expiration time of the Permit. The maximum duration of a Permit is eight hours provided that the Permit is revalidated ay an Operations Supervisor following a lunch break or shift change. The Operations Supervisor is responsible for immediate termination of the Permit wh n a change in conditions warrants such action. For jobs interrupted by process upsets, area sirens, or plant evacuation, a NEW Permit must be issued. Distribution of Permit The Ignition Source Permit is printed on a two-part form. When filled out and issued, th paper original is posted in the Operations Control Room. The cardboard copy (field copy) is posted in a conspicuous place on the job site. Th Control Room copy will be used by Operations as one means of keeping informed about field activity and will serve as.a checkpoint if it becomes necessary to terminate Permits due to process upsets.' The Field copy is to be returned to the Maintenance Foreman/Field Engineer at the completion of the job. The Maintenance Foreman/Field Engineer shall sign the "Job Completed" blank and return the Permit to the Operations Foreman who attaches the Control Room copy and forwards both to the Safety Office. Expired Permits which are replaced by renewed Permits during the course of th job shall be destroy d. SL 000105 -3- CONFIDENTIAL! of ubject to Protective Order i4th Judicial District Codrt Wo. 91-1145 General Rules 1. On-site visual and odor checks should be made to Insur that the work area is fr of flammabl vapors and liquids. A combustible gas test should be mad wh n th visual or odor checks reveal the possible presence of flammables. On those occasions when a combustible gas test is required, it is expected that a meter reading of 0% LEL will be obtained in order for the Permit to be issued. On a special exception basis, readings between 0% and 9.9% LEL will be permitted after consultation with a higher ranking Operations Supervisor, in no case will the Permit be issued when combustible gas tests of 10% LEL or greater are obtained. 2. Operating personnel shall make use of the Control Room copy of the Ignition Source Permits to keep informed of such work in progress in their area. All vessels, piping, and other operational equipment that has to be opened, vented, etc., should be don only after proper communication with the personnel working under the Ignition Source Permit. Supervisory personnel have the prerogative to call fora Permit authorization in specific cases of unusual or upset process conditions, 3. The Permit shall be issued for one job and not to each person on the job unless the foreman decides that a specific part of the job requires a separate Permit. The Permit shall be displayed in an appropriate place on the job. 4. On weekends and during the night shifts, the Shift Supervisor or Shift Foreman should issue any Permits that are required. SL 000106 -4- ** Hth Judicial Diatrictco1" Wo. 9l-n45 Ct U: REVERSE SIDE of Field Copy of Ignition Source Permit This permit is to be revalidated in the space below before resuming work following a lunch break or shift change. Operating conditions are stable and the {ob covered by this permit may resume. /________________________________ Operations Foreman Time /^________________________ Operations Foreman Time SL 000107 -6 - ------------:----- COMF1 DDm'IAL'. Subject to Protective Order Of 14th Judicial District Court No. 91-1145 *f " I IV. EQUIPMENT IN THE CENTRAL OHC STEAM STRIPPER AREA A. PROCESS ID NO. AND SAC NO. INDEX EQUIPMENT PROCESS ID NO. SAC NO. Organic Transfer Pump P-1 57D-55-2967 pump 57D-50-5113 motor P-2 57D-55-2966 pump 57D-50-5114 motor Steam Stripper Feed Pumps P-3 57D-55-2968 pump 57D-50-5115 motor P-4 57D-55-2969 pump 57D-50-5116 motor Sump Pump P-5 57D-55-2970 pump 57D-50-5117 motor Sodium Formate Transfer Pumps P-6 - 57D-55-2971 57D-50-5118 pump motor P-7 57D-55-2972 pump 57D-50-5119 motor Steam Stripper Feed Tanks T-l 57D-60-1902 T-2 57D-60-1905 ^1 Air-Cooled Condenser E-i 57D-71 -2121 ^2 Air-Cooled Condenser E-2 57D-71 -2122 ^1 Steam Stripper Economizers E-3 E-4 57D-71-2123 57D-71-2124 ^2 Steam Stripper Economizers E-5 E-6 57D-71 -2125 57D-71-2126 ^1 Steam Stripper Column C-i 57D-67-172 ^2 Steam Stripper Column SL 000108 C-2 57D-67-173 C,, . CONFIDENTIAL* Of 14thCJudiciI?tDisjV rder o ict Cbair B. EQUIPMENT DESCRIPTIONS 1) STEAM STRIPPER FEED PUMPS; P-3, P-4 (SAC *57D-55-2968, 2969) The steam stripper feed pumps are Durco Mk II standard centrifugaT, horizontal-mount, model 10/94 pumps designed for 200 GPM at 87 ft, discharge head. The pump body is Durcomet 100; ASTM codes A744 and A351, Durco code CD-4M (chrome steel). Impeller diameter is 10 inches; pump seals are Chempro 670. Inlet size is 4 inches; outlet size is 3 inches. A Chempro 670 seal is used in the stuffing box. The pump Is self-priming. Availabl NPSH is 6 ft. Specific gravity of liquid transferred is 1.16, Pump motors are Westinghouse 15-hp motors operating at 1750 RPM; model TBFC, style 680 B655 G43 horizontal-mount. Motors are TEFC, MAC rated as explosion proof. Service is 460 Volts, 3-phase, 60 Hz drawing 19.5 Amps, nominal. Operating temperature range is 40 - 65C ambient. Motor SAC #57D-50-5115, 5116. 2) STEAM STRIPPER FEED TANKS; T-l, T-2 (SAC *57D-6Q-I902, 1905) Steam stripper feed tanks are 12 ft 0 x 20 ft (tangential) upright cylindrical unlined carbon steel tanks. The manufacturer of both tanks was Allied Fabricating and Welding Company, Inc. Both tanks meet API 620 and PPG Spec. P-759-T2,1. Each tank is designed for 10 psig @ 110F and code-stamped for maximum work ing pressure as permitted by API 620 code. All tank welds are continuous and s aled. Tanks have cone-type roofs and flat bottoms Each foot of tank height contains approximat ly ^,^^^13.1 ft3) SL 000109 ive Order triet Cduirt of liquid. Overpressure is relieved by a 3-inch Furan line to the incinerator vent header/ line ^PL260-15-5001; SK-9451 Dual, switchable 4-inch graphite (Cal-Vac) rupture disks with burst pressure of 10 psig are also in place on each tank. Vacuum is relieved by a manually-actuated N2-makeup system when a low tank-pressure alarm sounds. A 3-inch reverse buckling graphite (Cal-Vac) rupture disk with a 2 or. burst pressure also protects each tank from vacuum. Normal aqueous phase analysis should be: 80% H20/ 14% NaCI, 1% NaOH, 1% NaOCo4. Liquid specific gravity is 1.10, The over head condensate inlet nozzles on the tank roof have dip tubes ext nding to four feet from tank bottom. Tank T-l has an empty weight of 12,040 lbs., a full weight of 153,240 lbs., and the capacity is 16,000 gals. Tank T-2 has an empty weight of 13,296 lbs., a full weight of 154,496 lbs., and the capacity is 16,000 gals. 3) STEAM STRIPPER ECONOMIZERS; E-3, E-4 and E-5, E-6 (SAC #57D-712123, 2124, 2125, 2126) Two identical Con-Rad Industries, Inc. horizontal shell-and-tube exchangers are used on each steam stripper. Shells are carbon steel (SA-106B) of thickness 0.375 in. (nominal) with a 1/8 inch corrosion allowance. Shell length is 20 ft. 1/16 inches and shell diamt^fe$Eft:FiAW?rlcin9 Subject to Protective Ordet SL 0001 1fl 0f 14th Judicial District CUJrfe No. 91-1145 4-4 pressur is 200 psi @ 500F (max,). Fixed tubesheets are carbon steel (SA-516-70) of diameter 25 1/4 inches, with nominal thickness 1 7/8 inches, and a 1/4 inch total corrosion allowance. Tubesheets are bolted in place. Floating tubesheets are 23 inches in diameter, of carbon steel (SA-516-70), and 1 7/8 inches thick with total corrosion allowance of 1/4 inch. They are bolted in place. Tubes are carbon steel (SA-214), 5/8 inch OD, with 0.075 inch thick ness for tube walls. There are 619 straight, 20 ft,-long tubes giving 2004 sq. ft. of tube surface area. On the heat exchanger channel side, the concave head is 3/8 -inch thick carbon steel (SA-516-70) with 1/8 inch corrosion allowance, and is installed concave side to pressure. Elliptical ratio of h ad is 2:1. Flathead is 3-inch thick carbon steel (SA-105-N),with Hub-type flanges and 1/8 inch corrosion allowance. Shell-side heads are carbon steel (SA-105); hub-type flange head is 3" thick while ring-type flange head is 3/8" thick. Corrosion allow ance is 1/8" for both heads. All exchangers meet ASME VIII and TEMA-R code requirements. Pre-heated feed service is 80,770 Ib/m (min) to 110,640 Ib/hr (max) SL 000111 No. o ^ ] i , 4-5 for both shell-and tub -sides. Feed temperatur incr ases from 150F to 190F tube-side as stripper bottoms on shell side are cooled from 212F to 172F. Normal heat load is 2.88 M Btu/hr, with max. rated load at 3.95 M Btu/hr. Bundle weight is 6900 lbs. Exchanger weight empty is 11,200 lbs. Wet weight is 15,427 lbs. One pass is made for both shell and tube side flows. 4) SODIUM FORMATE TRANSFER PUMPS; P-6, P-7 (SAC *57P-55-2971; 2972) These pumps are Durco Mk V centrifugal, horizontal-mount pump model 10/94. Pump casing is Durcomet 100 (chrome steel, code CD4M), Pumps are rated for 200 GPM with discharge head of 87 ft. Available NPSH is 1 ft. BHP is 8.14 (12.88 max1.). Inlet size if 4 inches; outlet size is 3 inches. Impeller diameter is 9.5 inches. Pump seals used are Chempro 670. Pump motors are Westlnghouse horizontal, TEFC-MAC, 15-hp, 1755 RPMrated model TBFC, Style 680 B655G43 on Model 245-T frames. Service is 460 volts, 3-phase, 60-Hz drawing 19,5 amps (nominal). Temperature rating is for specific gravity 1.16 @ 40C ambient. Motors are SAC #57D-50-5118, 5119. 5) SUMP PUMP; P-5 (SAC *57P-55-2970) The sump pump is a Gould model 3796 "ST" centrifugal, horizontal- mount pump with 7.62 inch diameter impeller. Rating is 50 GPM with discharge head of 20 ft. Available NPSH is 6 ft. Service is for water, specific gravity 1.00. SL 000112 Inlet size Subject to Protective Ordr of 14th Judicial District Court No. 91-1145 siz is 1.5 inches. Pump casing is cast ductile iron, as is the impeller. The pump motor is a Westinghouse model TBFC, style 680 B655 G68 horizontal-mount motor with TEFC, MAC enclosure. Rating is 1 hp @1180 RPM. Frame is model 145-T. Motor service Is 460 Volt, 3-pha$e, 60 Hz, drawing 2 amps nominally. Motor SAC #57D-50-5117. 6) ORGANIC TRANSFER PUMPS; P-1, P-2 (SAC *57D-55-2966, 2967) These pumps are Gould model 3196 "MT" centrifugal, horizontalmount pumps with cast ductile iron casings. Impeller diameter is 8 inches. Rating is 50 GPM at discharge head of 70 ft. Inlet diameter is 2 inches; outlet diameter is i inch. Service rating is for specific gravity i .36. Available NPSH is 9 ft. Pump motors are Westinghouse model TBFC, style 680 B655 G25 with TEFC, MAC explosion-proof enclosures rated at 5 hp @ 1750 RPM. Temperature rating is 40 - 65 C ambient. Service is 460 Volt, 3phase, 60 Hz,drawing 7.2 amps nominal, (SAC ^57D-50-51l3, 5114). 7) AIR-COOLED CONDENSERS; E-l, E-2 (SAC *57D-71 -2121, 2122) The condenser/coolers were fabricated by Hudson Products Corporation. Their overall dimensions are 8 ft 7/8 in (H) x 2 ft 11 in (W) x 5 ft 9 1/4 in (L). Section sizes are 3 ft x 5 ft x 4 rows. Two passes per section are used with 1442 sq. ft. external surface area and 68 sq. ft. bare tube area per section. Th shell material is 3/4 in thick carbon steel (SA-516-70) with a CONFIDENTIAL: Subject to Protective Order SL 000113 of 14th Judicial District Cotiirfc No. 91-1145 4-/ 1/8 Inch corrosion allowance. H ads are flat, 3 3/4 inches x 7 5/8 inches of carbon steel (SA-516-70). Shell weight is 1025 lbs. Work ing pressure is 75 psig @ 300F (max). Rated heat transfer is 416,300 Btu/hour normally (570,800 Btu/hr max.). The plug-type header is carbozinc ^11. Tubesheets are carbon steel (SA-516-70), 3/4 inch thick, welded, with a 1/8 inch corrosion allowance. There are 52 straight, 5 ft. long carbon steel (SA-214) tubes of 1 inch OD, 0.085 inch nominal thickness per section placed at a 2.5 inch triangular pitch. Tubes are arranged in straight banks. External transfer rate is 6.55 Btu/hr sq ftF, Bare tube surface transfer rate is 138.9 Btu/hr sq ftF in service; 167,1 Btu/hr sq ftF when clean. Tube-side pressure drop is 0.2 psi. Tube-side flow is 1810 Ib/hr (max), 1320 Ib/hr (normally). Two Inlets, 3-inch 150 psi RFWN (SA-105) sch 160 welded on are provided. Two outlets, 3-inch 150 psi pipe (SA-106B) sch 160 welded on are also provided. Normal service is 20% H2O, 37% CHCI3, 43% EDC at 210F inlet temperature, 180F outlet temperature. Cooling is by forced draft, using ambient air (@ 100F) [[directed over tubes byja 32-rinchdiameter, 3-bladed, fixed-pitch propeller driv n by a 1.5 hp, 1160 RPM TEFC, MAC Westinghouse el ctric motor. SL 000114 IAL r - Subject to Protective Oriieir Oi 14th Judicial District Court No. 91-1145 4"t> Motor s rvice Is 460 Volts, 3-phase, 60 Hz. As the air Is h ated to 163F, the vaporized feed is completely condensed. Air to the fan is 8863 ACFM. The air side rate is 8387 SCFM with a 610 SFM face velocity. 8) STEAM STRIPPERS; C-1, C-2 (SAC *57D-67-172, 173) The steam strippers have 0.375 in. thick carbon steel (SA-285-C) shells of dimensions 20 ft, 9 inches tall by 3 ft. diameter. The fabricators are Allied Fabricating and Welding Company, Inc, Empty column weight is 5413 lbs. Support skirts are welded on the bottom of the column. The shell has one (1) 18-Inch manhole. Column heads, both top and bottom, have concave sides to pressure, are 0.375 inch thick carbon steel (SA-285-C) with 0.125 inch cor rosion allowance and have 2.5 inch knuckle radii. lo Two switchable ^3 size SRV*s are located on top of the shell rated (f) for burst pressure of 20 psig. jj Nozzles on the column are all welded onto the shell; none are U3 a) o -u o reinforced. Nozzle Service Vapor out Nctl 1 TVPe Flanged Size (in) 4 Material SA-53B O 4J U CD *-l >u Thickness (in) <i-3 -i-i JJ O 4J in UMT f-* cj a -i E 4-> | 0.337 Steam in Liquid in Level controller P.l. Sight glass T.E. 1 1 2 1 2 1 II II II II II II, 4 II 3 II 3 II 1 II 1 II 1 II 0.337 0.300 0.300 0.25 0.25 0.25 O Z O "! 0 Oiica Vc 4J l-J u 0) JZ r-\ jj w y-i 0 PHS 1 II 1 II 0.25 IDE iPar lo 91 Column internals include a liquid distributor at th top, packing support trays, tie downs, and 15 ft. of 2-inch Kynar Tellerettes as packing. 4 SL 000116 01 Jmcuitcuiv? No- >1-1145^ V. DETAILED PROCESS DESCRIPTION: A. STEAM STRIPPER FEED SYSTEM 1. SOURCES OF STEAM STRIPPER FEED The aqueous effluent streams from OHC-l, OHC-ll and OHC-III (Vinyl) are pH-ad|usted within these units by utilyzing their own mix tanks and cell liquor addition lines. The steam strippers in the OHC-I and OHC-ll areas are to be maintained (mothballed) in operational condition, normally being bypassed by the feed system to the Central OHC Steam Strippers. Steam Stripper feed consists of: (1), reactor phase separator overflow, (2). DH still reflux drum overflows, (3), chloral treatment overflows, (4), Bicarb surge tank purges. No provision for pH adjustment (by cell liquor addition) is made at the central steam stripper feed tanks. A 6" header (1000M-PL4) routes the combined aqueous effluent streams to the two 32 ft. ft x 20 ft. (16,000 gal.) upright carbon steel feed tanks, T-l and T-2. Headers containing pH- adjusted aqueous effluent from the source units have sample points and are monitored for pH, as is the 16" combined effluent header (I000M-PL4) ,,. The 6" tank feed inlet line (I000M PL4) has a pH alarm (alarms to the OHC-l control room) with alarm points set at pH 9.0 for "low pH" alarm and at pH 13.0 for "high pH" alarm. It is necessary to maintain a pH 10 level within the tank SL 000117 of 14th No. ? ] - ? : < , D 0-2 to prevent the deterioration f the carbon ste I proc ss equipment and lines in the unit downstream of the feed tanks. PH control is essential also for the proper operation of the steam strippers since at lower pH problems with corrosion, of the carbon steel process equipment may develop. Monitoring of pH upstream of economizers Is also provided by analyzers and alarm on stripper feed with alarm points of pH 7.0 and pH 13.0 for low and high pH alarms, respectively. 2. FEED TANKS/PHASE SEPARATORS; Each feed tank contains 4 phases: (1), aqueous phase, (2). Indeterminate phase, (3). organic phase, (4). sludge phase - as mentioned earlier. Level indication is provided for the aqueous and organic phases by both level indicating transmitters which indicate a % span of instrument in the OHC-I control room, and a level gauge/sight glass on the tank. Since the level transmitters are at different positions on the tank to correspond to phase location (and overlap in a sense)/ It is possible to monitor the position of the indeterminate phase between the aqueous and organic phases in the tank. This is desirable because it facilitates easy removal of this interface by vacuum truck. Both low and high phase level alarms are provided for the aqueous phase, while a high level alarm only is provided for the organic phase. These alarms in the OHC-I control room are termed total feed tank level and feed tank interface level, with low and high level alarm set-points of 20% span and 80% span for each alarm* respectively. SL 000118 Subject 0< 14th *&&*!*' 0rt,ef , No. ~ *^ -* *-- L F 7 *"* f. , t* The organic phase is pump d down once per shift (one in 8 hours) to the intermediate crude storage tanks (T-iO, T-29) located at OHC-I. One empty feed tank provides a surge capacity of 16,000 gallons or nearly a 2 hour span at normal feed rates of 137 GPM. Note, however, that feed tanks in service are never completely empty. Tank pressure is monitored and high and low pressure alarms provided alarming to the OHC-I control room. High pressure is relieved by one of two swltchable 4-inch, 10^-rated graphite rupture disks. Should one rupture disk relieve, the other may be placed in service while repairs are made on the primary one. No indication is provided in the control room to notify personnel that a rupture disk has relieved, so a visual check is necessary when a high pressure alarm sounds. Low tank pressure is alleviated by addition of makeup N2 via a manuallyactuated 3-way, fuljport, ball valve when a low pressure alarm sounds. In addition, a 3-inch (CAL-VAC) reverse buckling graphite rupture disk with a 2-oz. burst pressure protects each tank from vacuum. Tank vents to the incinerator vent header are regulated by an automatic PCV and a differential pressure transmitter which act to control back pressure on the vent. An emergency bypass with plug valve is provided at the PCV ,station. The feed tanks may be placed in various feed tank/stripper arrangements as described below. The procedures necessary to align the system are SL 000119 CONFIDENTIAL! Subject to Protective grtiw*? Of 14th Judicial Distrief; G@ur-fc No. 91-1145 describ d in Section VI of this manual. Th various arrang ments possible are: (1), feed tank T-l, stripper ^1,(2). feed tank T-2, stripper $2, (3). feed tank 1, stripper $2, (4). feed tank $2, stripper ^1. It is possible to select any of these arrangements under computer control, or any combination of any 2 arrangements, except the one which would place the two strippers in operation at the same time in a "CROSSED" configuration (a combination of (3.) and (4.)). It is intended that one stripper and feed tank pair only be used at one time, with the other pair normally held in reserve. STEAM STRIPPER ECONOMIZERS The aqueous phase fed from the feed tank to the steam strippers normally first passes via pumps (P-3, P-4) through two shell -and - tube heat exchangers in series in which it is preheated from approximately I50F to approximately I90F using steam stripper bottoms at approximately 2I0F. The aqueous phase feed on the tube-side of the economizer is flow-controlled ^to.maintain a.constant aqueous phase level in the feed tank . Normal heat duty is 2.9M BTU/hour for two exchangers in series. This flow to the economizers is analyzed for pH and has pressure indication gauges at pump discharges. Either pump may be used to feed either column from either feed tank through various valving arrangements of the economizers. See mechanical flowsheet ^2 of 2, DWG 57D-I0004, for details. Stripper bottoms used to preheat the stripper feed are cooled from approximat ly 2I0F to I72F and are either sent back the feed tanks or to the formate destructi n unit depending on th ir total chlorinated organics content. SL 000120 CO'NT'TDENTlM.t Subject to ^otective Orf|Jrt . w.h Judicial DiCtlicu 14th "io. 91-1145 5-5 Both pressur ond temperature gauges are provided on the tub -side of all four economizers (two pairs E-3 and E-4, and E-5 and E-6) to allow their performance to be evaluated. While one economizer can handle the normal heat load at reudced rates, using both In series reduces the load on each and so reduces maintenance requirem nts. Either economizer may be isolated while the other remains in service should maintenance be necessary. Economizers have carbon steel shells, heads, and tube bundles. Each exchanger contains 6T9 straight 5/8 inch OD tubes which provide 2004 sq. ft. of heat transfer area on the removable tube bundle. The economizer shells contain horizontal baffles which serve to maintain turbulent flow for better heat-transfer. Adequate steam is available to operate one stripper without economizers at normal feed rates, but the economizers must belin service if both strippers are used or if maximum feed rates are used on one stripper. C. STEAM STRIPPERS The two steam strippers are identical 20' tall x 2' diameter, carbon steel columns. Aqueous phase feed to the column is introduced at the top of the column under flowcontrol. Feed temperature and flowrate are monitored at the column. The stripp rs contain 2" Kynar Tellerette packing to a depth of I5; ft. through which the aqu ous feed flows down the column as it is contacted by upward-moving steam which vaporizes the organics and carries them ovehead. At normal operating temperatures of 208 - 210 overhead temperature, all organics are removed when 3% by volume of stripper feed is vaporized overhead, A liquid distributor at the top of the stripper, CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 SL 000121 5-6 packing supports and hold-downs, and the packing itself are the only column internals. Fifteen (T5) feet of 2-in. Kynar Tellerettes are used. Live 50 lb. steam is inj ct d directly into the column under flow-control; no sparger is used for steam distribution. The direct injection of steam allows the omission of steam traps at the stripper, ther by -reducing. : maintenance since steam condensate simply drains into the column. While the steam flowrate is normally flow-controlled under computer control (via a calculated heat balance based on feed rate), a manual override with pressure indication is also provided. This option is' used if computer control fails. An alarm indicates a 20% deviation in steam feed rate. Both overhead and bottoms temperatures are monitored in the steam strippers on the CRT control screen. Both high and low temperature alarms are provided on each of these; for bottoms, 230F and 205F respectively; for overheads, 220F and 200F respectively are the alarm setpoints. Column pressure is also monitored by a high pressure alarm provided with an alarm point of 15 psig. Should over-pressure occur, the column is protected by two (switchable) 3-Inch, 20-lb,-rated graphite rupture disks. Each rupture disk serves to spare the other, although^ no indication is given that one has relieved and they must be manually switched after it is observed that one has failed. Iripper pot level is monitored by both a sight glass on the column and through svel transmitter output in the control room. Both high and low bottoms lev l al arms e provided with setpoints of 80% and 20% span of instruments respectively. L vel controlled in the pot by a lev l control valve (LCV) in the bottoms flow stream ! CONFIDENTIAL: ` ^uhiect to protective Ordet o Hth Judicial District Court c 5-7 through the action of the sodium format transfer pumps. The sodium formate transfer v pumps (P-6/ P-7) route stripper bottoms through the feed economizers to preheat feed, then on to the sodium formate destruction unit. Pump discharge pressure indication is provided on these pumps. Stripper overheads are condensed in an air-cooled condenser before being routed back to the feed tanks where organics will phase out to the lower portion of the tank. D. AIR-COOLED CONDENSERS ' Air cooled condensers (E-l/ E-2) with 1442 sq ft. of external surface area and 68 sq. ft. of bare tube surface area are used to condense the vaporized organics/ cooling them from 2I0F to I80F. The condensate is then re-introduced to the feed tanks (T-!l., T-2). Temperature indication is provided on the vapor inlet and condensat piping of the condenser. An electric fan motor drives a 32-inch/ 3-bladed fan to force ambient air over two sections, each containing 52 straight, 5 ft. long, 1-inch OD carbon steel tubes. Sample points are provided on the tube-side of the condensers. Normal heat transfer is 416,300 BTU/hour with a tube-side heat transfer coefficient of 138.9 BTU/hrs'q. ft *F On service). E. PROCESS SUMP The central OHC steam stripper area process sump collects all pad runoff, seal I aks, rupture disk blowouts, spills, etc. and routes then back into the stripper feed tanks via a level-controlled pump (P-5), The process sump level is not alarmed, so SL 000123 operators must monitor its operation to insure that the pump operates properly. F. RUPTURE DISC SCHEDULE . VESSEL Tank T-l Tank T-2 Stripper C-l Stripper C-2 Tank T-l Tank T-2 TYPE NO. SIZE RATING CAL-VAC 2 4" 10# CAL-VAC 2 4" 10# CAL-VAC 2 3" 20# CAL-VAC 2 3" 20" CAL-VAC 1 3" 2 oz. (reverse buckling) CAL-VAC 1 3" 2oz. Reverse buckling) CAL-VAC RUPTURE DISCS: The CAL-VAC rupture discs used in the Central OHC Steam Stripper area are a new vessel protection system produced by Continental Disc Corporation, They are fail-safe, non-mechanical devices which provide both vacuum and positive pressure relief at pre-determined settings. In this area they are used with 3" KTM Fig ^E03T62--31T 150-lb full port ball valves and insert-type housings. See Appendix G for further information on CAL-VAC rupture discs. SL 000124 CONFIDENTIAL: Of subject to Protective Or 14th Judicial District dcr Court no. 91=1145 6-1 VI. CENTRAL OHC STEAM STRIPPER OPERATION A. UTILITIES The Central OHC Steam Stripper area is supplied with well water, steam, instrument air, and nitrogen. See Figure 6.1 for a list of lines in utility service in this area. 1 Well Water - Water is supplied via a 1.5 inch supply header in the OHC area. Well water use is limited to safety showers and utility stations in the area. 2. Steam - Fifty pound (50 lb.) steam is supplied to the area by an eight inch (8") insulated line from the desuperheater which serves the Waste Treat ment unit. Live 50 lb. steam is infected directly into the bottom of the steam stripper under flow control via a four inch line. Additional steam for steam tracing is provided by a one inch line branching from the 8" header. Both flow and JJ u 'O0) M p o CJ o 4u-> pressure are monitored on all steam lines. Instrument Air - Instrument air is supplied to the Central OHC Steam Stripper area by a 1.5 inch OHC area header. Inside the area, a one inch line supplies instruments and utility stations. vP M ESH w UaM, >H jOj -<PD o h Hp co -QH pH ra uH ir> i----(i rHI Cl z O o -p 'CH. sO V JJ <u1) r- X1 p n *43J* 4. Nitrogen Nitrogen is supplied via a 1.5 inch OHC area wp header. Inside the area a 3/4 in. line supplies Nitrogen (N2) to utility stations and a 1/2 in. line supplies N2 to pad f ed tanks for vacuum relief. SL 000125 6-2 FIGURE 6.1: CENTRAL OHC STEAM STRIPPER AREA UTILITIES UTILITY Well Water Steam Instrument Air Nitrogen HEADER 1.5"-P723-3159-PL9 AREA LINE NO. 1"-3002-PL9 1"-3008-PL9 1"-3009-PL9 1,5"-3001-PL9 1,5"-3003-PL9 1,5"-3004-PL9 1,5"-3005-PL9 1.5"-3006-PL9 1,5"-3007-PL9 8"-PLl4-31-312 8"-6001M-PL14 4"-6002-PLl4 - 4"-6003-PM4 1"-6006-PL14 1.5"-P723-3162-PL139 1 "-4001-PL139 _ 1"-4002-PL139 1"-4003-PL139 1"-4004-PL139 1"-4005-PL139 1.5"-P723-3105-PL79 3/4"-5001-PL79 3/4"-5004-PL79 l/2"-5002-PL79 l/2"-5003-PL79 SERVICE Utility Station II II Safety Shower II II II II II Area Header Steam Stripp r ^2 Steam Stripper Steam Tracing Utility Station II II II Instrument Air N2 Service Station II Tank Padding ^2 Tank Padding SL 000126 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District court No. 91-1145 o 00 0 F76Kf& &.-Z - CENTRAL OHC STEAM STRIPPER RECIRCULATION CONFIGURATION FIGURE 6> --ohi-- ah o3 *UT3 U O 0) --oHU ** > i-l <J --hU jj 01 in M O -H r-i 2^ oi -P qh I WO IOh <I-D< Or-S! CO CMh CLi -oH O2+JO'U*HSSO O 40CJJ) P33 .n *XrI^-4srj 3 *-l CO liliil IQPS INDUSTRIAL CHEMICAL DIVISION ^nociss.. -7f I.1* ._______ *- - DWG - - START-UP PROCEDURE The Central OHC Steam Strippers are started-up in the manual control mode in a cold recirculation configuration. Only one steam stripper is normally operated (or started up) at any one time and only one feed tank is normally used (full). Start-up is done with a partiafly-full feed tank into which effluent streams from OHC-I, OHC-ll, and OHC-III areas flow. In the manual control mode, a constant level is maintained in the feed tanks by varying feed flowrate to the stripper under temperature control and by varying steam flowrates to the column. For reference in start-up and other situations, a complete area line list is provided in Appendix F, A general procedure is outlined for normal start-ups and an area-by-area checklist is provided for use with the stepwise procedure. See Figure 6.2 for the recirculation configuration. START-UP PROCEDURE 1. The checklist should be followed to insure that all valves in the pipeline system are properly aligned to establish the recirculation configuration desired for start-up. Start-up is done in the manual control mode. 2. Once the system is aligned for recirculation, the condenser fan motor should be started. 3. Proper levels of liquid for start-up should be present in the feed tank and a proper pH 10 observed for contents. If necessary, effluent from OHC-I, II, and III may be fed directly into the feed tank during start-up if the pH analyzers on this tank fe d ar placed in service. CONFIDENTIAL: Subject to Protective Ortlejr SL 000128 of 14th Judicial District Court No. 91-1115 6-4 4. All utilities should b available and in service to control valves, transmitters, etc, 5. All indicating transmitters for pressure, temperature, level, etc, should be operating properly and proper valves for all monitored variables should be recorded on the CRT display. 6. Feed flow of aqueous phase to the stripper should be started slowly with FCV in manual control mode to build up bottoms level in the column, 7. LCV on stripper bottoms is now partially opened. When bottoms reach operating levels in the column, the LCV on stripper bottoms should be manually adjusted after flow through the pumps is es tablished, 8. The system should now be aligned and liquid flow established ?n the recirculation configuration under manual control. See Figure 6.2. At this time, leak checks should be carried out on all lines and vessels. 9. The pH analyzers on stripper feed pumps should now be placed in service. 10. Stripper pressure and temperature are monitored on the CRT display and should be closely watched as steam is introduced slowly to the stripper under manual control (FCV on steam in manual mode) until the steam line reaches equilibrium temperature. The system will tend to pressuriz until all inerts a^'jf5\l SL 000129 Subject to Protective Order1 of 14th Judicial District Court No. 91-1145 6-5 hammer will occur if this step is not don slowly. When normal overhead temperature (210F) is achieved, the stripper is ready to be placed in the computer control mode. 11. The steam stripper should now be operating in the recirculation configuration under manual control, with overheads and bottoms returning to the feed tanks. At this time, bottoms samples should be taken and analyzed for total organic content. If the stripper bottoms contain less than 20 ppm chlorinated organics, they may be routed to the formate destruction unit, 12. The steam stripper is now operating normally under manual control and may be switched to computer control (and brought to full rates under computer control). Feed rate adjustments by the computer (about the base feed rate) to maintain tank levels will cause computer-aided adjustments of steam flowrate. This will alleviate the need for manual steam adjustments since the computer can perform a heat balance on the feed/steam requirements and make any necessary adjustment to steam rate as feed is adjusted. *Note: Any one manual loading station set to "M" for manual control for each stripper invalidates computer control over all process variables controlled, so switch all manual loading stations to "C" for computer control at the same time. SL 000130 SuhJi^ni.C0^F-I-DE^TiAr th VQ *-der No. 91-iArllct cour 6-6 C. START-UP CHECKLIST 1. Steam Header Block all downstream block valves on stripper. Close all header vent valves. Condensate purged into column is recirculated with feed through economizer/ feed tank, and column. No steam traps at the column are used. The steam header should be allowed to come to equilibrium temperature slowly. Check that steam traps are operating properly (on the header). .2 Feed Pumps _____ Activate switch gear _____ Close drain and sample valves _____ Check oil level Open suction valve to one pump and check position of feed bypass block valve _____ Crack discharge on same pump _____ Push start button _____ Check pump rotation and discharge pressure _____ Open pH analyzer sample valve to place the analyzer in service on feed stream 3. Feed FCV on Stripper _____ Close bleed valve Close bypass valves Stroke valv SL 000131 CONFIDENTIAL: Of SlhAr\ t? 4th Judicial Order D'.r.hrict Cbhrt to. ~1 i 6-7 Open FCV block valv s, also one valve downstream at stripper should be partially open Leave FCV partially open, in normal control mode 4. Condenser Start fan motor _____ Open block valves isolating the condenser _____ Close bleed valves _____ Check to see if vent PCV is in service 5. Economizers _____ Close stripper feed and bottoms bypass valves _____ Close sample valves and bleed valves Open process stream valves to place economizers in series (E-3, E-4); (E-5,, E-6) _____ Check tube-side PI gauge valves & Tl gauge to monitor operation of economizers 6. Stripper _____ Close level transmitter (LT) drain valves. Open block valves. _____ Close sight glass ble&d valves Open block valves on sight glass Place LCV (on manual control) in a slightly open position The feed block valve on stripper should be opened now The overhead block valve on stripper is also opened now 7. Sodium Formate Transfer Pump (Stripper Bottoms Pumps) _____ Activate switch gear Close drain and sampl -------- SL 000132 valv s CONFIDENTIAL: , Subject to Protective Orcjer of 14th Judicial District Court No. 91^1143 Check oil level Close valve to Formate Destruction unit; open valve to feed tank Open suction valve on pump The discharge on pump should be closed; crack open now Push start button Check pump rotation and discharge pressure .8 Stripper Bottoms Level Control Valve (LCV) Close bypass and bleed valves on LCV Stroke valve _____ Open LCV block valves Leave partially open on manual control 9. Phase Separator/Feed Tank _____ A feed tank's feed line block valves may be open (or closed) during start-up Open valve to incinerator vent header _____ Close valves to intermediate crude storage tanks _____ Close sight glass clean out valves Open sight glass block valves _____ Close condensate return block valve bypass and open block valves on return line to tank (2 valves) from condenser Bleed valves closed, block valves open on level and pressure transmitters on tank 10. Process Sump Pump Activat switch g ar SL 000133 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 o-y _____ Close drain and sampl valves _____ Ch ck oil level Open suction valve on pump _____ Crack discharge valve on pump Push start button _____ Check pump rotation and discharge pressure 11. jack Pressure Regulator Valve on Vent to Incinerator from Feed Tank Close bypass valves Open valve on tank vent to incinerator vent header _____ Check valve operation and flow to incinerator header Differential pressure transmitter sample valves should be open .12 Nitrogen Make-Up System on Feed Tanks Block valves on each tank should be closed unless N2 is needed N2 line should be unblocked at the header _____ Check pressure regulator for proper operation *Note: N2 need not be used during start-up unless, a low tank pressure condition exists. D. SHUT-DOWN PROCEDURE Shut-down of the Central OHC Steam Stripper is essentially the reverse of the start-up procedure with the notable exception of changes in the recirculation configuration achieved on a stripper being removed from service. Shut-down is normally carried out In the manual control mod . SL 000134 CONFIDENTIALt Subject to Protective Order ^ ^ 14th Judicial nislricf 0-1U SHUT-DOWN PROCEDURE An appropriate decision concerning tank feed status should be made from the choices below: a. If the stripper is to be removed from service due to lack of feed from the OHC-I, OHC-II, and OHC-III areas, the tank feed lines from these sources may be blocked off. b. If the stripper is to be removed from service for maintenance (other than on the feed tank) and tank feed sources exist, then tank feed should be maintained on the feed tank currently in service (or switched to the other feed tank if desirable). c. If maintenance work involves the feed tank currently in service, then tank feed should be switched to the other feed tank (not in service) to fill it In anticipation of switch ing over to it for either continued feed to the operating stripper or for start-up of the other stripper. The sump pump discharge from the process sump should be switched to the appropriate feed tank now. The feed tank vents to the incinerator vent header should remain open during shut-down. 2. It is desirable to reduce the aqueous phase level in the feed tank to be removed from service, as in cases (a) and (c) above. This is done by removing tank feed and continuing normal stripper operation under manual control. Manual control is used since SL 000135 active Order district Court 6-n changes in aqueous phase f ed level cause corresponding changes in stripper feed rate under computer-directed control. Normally this would serve to maintain a constant desired aqueous phase level in the tank, but in this case computer control would prevent the emptying of the feed tank by continuing to reduce feed rates as level falls. 3. Tlie level of ffie aqueous/phase in the feed tank should be moni tored as., it.,is. reduced. To reduce tank levels it is necessary to 1 continue to route stripper bottoms to the formate destruction unit. This may be done as long as 3% by volume of stripper feed is vaporized overhead, as indicated by normal overhead temperatures (210F) in the column. Stripper bottoms containing greater than 20 ppm organics should not be routed to the sodium formate destruction unit. An alarm will sound when the 20% span point on aqueous phase level is reached. Overheads may still be routed to the same in-service feed tank during shut-down. 4. When the aqueous phase level is reduced to its minimum operating level (20% span) with the stripper on manual control, reduce steam flow and stop routing stripper bottoms to the formate destruction unit. For case (a), there will be no further accumulation of liquid in the feed tank when bottoms are routed back to it. For case (b), stripp r bottoms are routed to the appropriate in-service feed tank. For case (c), stripper bottoms are routed to the oth r feed tank and h Ip SL 000136 o-\z to fill it for operation. 5. Reducing steam rates to the column will depressurize the system and cause organics to no longer be vaporized overhead. Steam should be completely removed from the column and the steam line FCV closed in the manual mode and blocked off. A liquid recirculation configuration now exists between the stripper and the appropriate feed tank as in cases (a), (b), and (c). 6. The feed line pH analyzers may now be blocked off and removed from service. 7. Reducing feed rates to the stripper further, close block-valve on feed pump discharge and remove the pump from service. Block off the feed pump. 8. Close the FCV in manual mode on the feed line to the stripper and block it off. 9. If desirable, drain the column by allowing the stripper bottoms to drain to the appropriate feed tank via the sodium formate transfer pump (stripper bottoms pump). Should stripper bottoms spill on the process pad, they will drain to the process sump and be pumped to the appropriate feed tank. 10. If desirable, reduce the out-of-service tank's total level by pumping phased-out organics to the intermediate crude storage tanks and vacuuming off the indeterminate phase. 11. All control valves should be closed in the manual mode and blocked off. All proc ss v ssels should be blocked off. All proc ss pumps should be blocked off. SL 000137 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 o-lo Only the tank vent to the incin rator header should remain open on an "isolated" out-of-service tank. E. SPECIAL PROCEDURES 1. Switching Feed Tanks while Stripper is Operating a. Switch to manual control mode. b. Reduce feed rate to the stripper from tank to be removed from service and switch tank feed to the tank to be placed in service. This action allows time to fill the "new" tank to a safe start-up level while maintaining stripper feed from the "old" tank and lowering the aqueous phase level in the "old" tank. Rate reductions under manual control must be based on tank feed rates in order not to exhaust stripper feed before the "new" tank is ready. Manual control over the stripper feed FCV is necessary to allow the reduction of aqueous phase level in the "old" tank. The falling level would normally, under computer control, cause a computer-directed cutback of stripper feed rote; thereby never allowing the aqueous phase level to be sufficiently lowered. c. Continue routing phased-out organics in the feed tank to the intermediate crude storage tanks to further reduce the tank level. SL 000138 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 6-14 d. The sump pump discharge should be routed to th "new" feed tank to hasten its filling. e. Valves on both tanks to the incinerator vent header should be open. f. When a sufficient level is obtained in the "new" tank, switch the feed tanks by opening the suction line on the operating feed pump to the "new" tank via the bypass line (4"-l006-P14y block valve. g. Close the suction line to the f,o1d" tank and isolate the "old" tank. h. Overhead from the stripper should now be switched to the "new" (in-service) feed tank via a block valve on bypass line (3"-1017-PL4). i. Switch the tank outlet valves on line (2"-2001-PLi40) to o> <T> route phased-out organics from the in-service feed tank to CD CD CD the intermediate crude storage tanks. CO {. Remove the indeterminate and sludge phases from the how out-of service feed tank via auziliary nozzles on the tank for vacuum truck service. 2. Switching Strippers while Operating p . QjUDOu 'Ou u tJ* OQ-)>h-4jJHoJjj in <M 4UJ"VH) rr a. Open block valve on line($) (3 -1020, 1021-PL4) to establish h a) a --i 2 aW -P hO icsn|t a liquid recirculation loop for stripper bottoms back to feed H Si-iM CH U 2 O -H o tank on the stripper not in service. Be sure the line to UO+J-3DZ JJ V) u formate destruction unit containing stripper bottoms is blocked 0) JZ r-)jj 3 rH off and stripper bottoms are not routed to formate destruction CO 4J o 6-15 b. Plac the operating stripper (to be taken out of service) on manual control, c. Switch feed to stripper to be placed in service by using bypass valves at stripper feed pumps. This places the "new" stripper in a recirculation Configuration. Both strippers are now in the recirculation .^configuration. d. Follow normal start-up procedure from Step ^8 for stripper to be placed in service. e. Follow normal shut-down procedure from Step $5 for stripper to be removed from service. F. EMERGENCY SHUTDOWNS 1 loss of Electrical Power a,, Results of Power Loss Loss of computer control Loss of pressure, temperature, level transmitters and analyzers Loss of electric pump motors and condenser fan motors b. Response of Power Loss Go to manual control Restart condenser fan motor , W3 TU5 Coj O 4J X3 C >QJ P -PHo -W CO vLO t"? --I O' Q rH Z -U | ____ Open block valve on line (3"-i020, I021-PL4) routing hh O U It} stripper bottoms to feed tanks; close block valve on line to formate destruction unit. AVOID DEADHEAD- di -h fc, o u o -p 4J o rs C3J . zc (J a) jz Qr~o 4wJ ING PUMPS I W3 4M SL 000140 o 0-10 Restart pumps with stripper stil! in the recirculation configuration. Switch to computer control once stripper temperature profile is normal, analyze stripper bottoms for total organics and if organic content is less than or equal to 20 ppm, route bottoms to formate destruction and close recirculation block valve* c. Response, to Long-Term Power Loss _____ Go to manual control. All control valves must be manually closed so they will not reopen if power should be unexpectedly restored. _____ Close FCV on steam. (It should FAIL CLOSE auto matically.) _____ Close block valve on line (3"-10i8-PL4) carrying bottoms to the formate destruction unit. Remove all pumps from service and block them off. Follow normal shut-down procedure from Step ^5. jj 'aQ) uO O 4oJ 0) *H tj -->i 4IJ* m 7<MEM?"->. 4-pCaO-)1) -aru<)t H M1 CI--I Cu -iaH m SUj Q O <Q* O + z 'Z U3 JJ rj u nSiii SC3Oi -W"sr U-t O 2. Loss of Steam a. Results of Steam Loss Organics present in stripper bottoms as stripper fails -- could 4J t? % oo O 4J a -0 go to formate destruction. b. Response to Steam Loss _____ Go to manual control mode SL oooui Establish r circulation of bottoms to feed tanks _____ Close block valve on line (3"-1018-PL4) carrying c. b a.' c ... b o -: .i: ;; r\ u r 4J COJ Jr'-w 3 r~t CO O o-t/ b ttoms to the formate destruction unit. If steam is recovered, restart the stripper for start-up Step ^8, If steam is not recovered, shut down the stripper from shut-down Step ^5. _____ Identify reason for steam loss, (if possible). 3. Instrument Air Loss a. Results of Air Loss _____ Control valves on feeds (aqueous phase and steam) to stripper should FAIL CLOSED, but steam FCV should be manually closed. It should not reopen unexpectedly if instrument air is restored. b. Response to Instrument Air Loss _____ Go to manual'control. Close all valves under manual control. _____ Close block valve on line (3M-1018-PL4) carrying stripper bottoms to formate destruction unit. _____ Shut down pumps, close block valves on both feed and bottoms lines; but level control valve (LCV) on bottoms should remain open. Open valves to establish recirculation of bottoms to feed tank. If instrument air is restored, restart stripper from Step ^8 of start-up procedure. If instrum nt air is not restored, maintain stripper in the SL 000142 Q) ^ ^ CO w O recirculation configuration until a d cision to shut down (if necessary) or restart stripper is made. 6-18 SL 000143 CONFIDENTIAL? Subject to Protective Order of 14 th Judicial District Court No . ^ I " -- ' _> G. OPERATIONAL CHARTS, GRAPHS, TABLES: SL 000144 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District CoLirt No. 91-1145 VII. PROCESS CONTROL AND INSTRUMENTATION A. General Discussion of Control The Central OHC Steam Stripper area operates under control by a microcomputer through six (6) manual loading stations. The controlled variables are: (1) aqueous phase level in the feed tank - via stripper feed flowrate adjustment, (2) steom fe d rate - by a heat balance performed by the computer, and (3) stripper bottoms I v Iby a level control valve. 1. Steam Flow Control The objective of the steam stripper is to remove soluble organics from th bottoms stream, but there is no continuous measure of the organics in the bottom stream; therefore, no "feedback" control scheme could be employed. No adjustment could be made in the steam flow based on a deviation from * a desired organics content allowed in the bottoms stream. A "feedforward" control scheme ?s therefore employed instead. From operating experience it is known that if 3% by volume of the feed to the steam stripper is vaporized and driven overhead that nearly all of the organics in the feed will be driven overhead, leaving the bottoms stream with less than 20 ppm organics. This guideline was established at OHC-II. Adjustments to this guideline may be made after the Central OHC Steam Stripper is placed in service. The microcomputer monitors the feed temperature and feed rate of aqueous phase feed going to the stripper. The heat requirement (BTU's required from associated steam flow) to bring the total feed stream to the boiling point and to vaporize 3% by volume of the feed stream is then calculated. The microcomput r then adjusts the steam FCV to cause the actual steam SL 000146 CONPIomiALt Subject to Protective Of 14th Judicial nietri Order NO. i r; ct Court flow to the stripper to match th required steam flow. A further adjustment is made to the steam flow based on variations of the stripper temperature from the desired stripper temperature. This variation is caused by heat loss from the surface of the steam stripper when the ambient temperature changes. 2. Feed Tank level Control The aqueous phase level is controlled in the feed tank with the objective that the tank not overflow or be emptied completely. The surge capacity of the feed tank is however utilized to its full advantage. To maintain the level within the feed tank at the desired point, the feed rate of aqueous phase to the steam stripper is adjusted. To avoid unnecessary adjustments in stripper feed rate, the level in the feed tank is allowed to drift near the 50% span point of the level transmitters used to monitor its position. The relationship of feed rate adjustment to level changes is proportional to the square of the deviation of the level from the 50% span point of the lev I transmitter. Therefore, any adjustments to feed rate caused by variations in phase level will be insignificant when the level is near the 50% span point, and very significant when the phase level is near the top or bottom of the feed tank (far from the 50% span point of the level transmitter). 3. Steam Stripper Level Control The pot level of the steam stripper bottoms is controlled by adjustments to the level control valve in the bottoms stream. SL 000147 CONFIDENTIAL: o S1u4btjhecJt utdoicPiarlotDecistivtreicOt rCdeorurt No, 91-1145 B. Impl mentation of Control Th Centro I OHC Steam Strippers operate under two (2) modes of control: (1) computer control of valves to maintain process variables within desired valu s, and (2) manual control of valves. There are six (6) manual loading stations b tw en the computer output and the input to the control valves. These are: (1) Stripper ' ' Feed Flow, (2) Steam Flow, (3)'^1 Level, (4) ^2 Stripper feed Flaw, (5) ^2 Steam Flow and (6) ^2 Level. The manual loading stations have the following functions: 1.) To display process variables continuously 2.) Upon depression of the "OUT" switch, to display the control valve position 3.) As a two-position manual/computer control selector switch "C" and "M"; a.) with the selector switch set to manual ("M"), the operator will be controlling the valve position b.) with the selector switch set to computer control ("C"), the computer will be controlling the valve position. In this mode the manual loading station receives a signal from the computer and converts it into a 4-20 ma signal to the valve. A green light on the front of the manual loading station will be illuminated while in the computer control ("C") mode. 4.) To indicate to the computer that the manual loading station is in computer control ("C") status via a switch. In order to attain computer control on either stripper, all manual loading stations assigned to that stripper must be set to "computer" control ("C"). A single station set to "manual" control ("M")will prevent computer control on all variables for that stripper. SL 000148 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 If the Feed Tank is feeding the *1 Stripper and the ^2 Feed Tank is f eding the ^2 Stripper, both st am strippers can be placed on comput r control. If the ^1 Feed Tank is feeding to the ^2 Stripper and the ^2 Feed Tank is feeding to the ^1 Stripper, only one (1) stripper can be placed under computer control. An attempt to place both steam strippers under computer control in this "cross-fed" configuration will cause all controllers to go into a "hold" state with no computer control or manual control being accomplished. In addition, an alarm messag "FEED CROSSED" will be printed. Under these conditions the operator must sel ct the steam stripper that is to be placed under computer control and place the oth r stripper on manual control. Should electrical power be lost to the control system or a "reset" of the computer be executed, all manual loading stations should be set to the manual ("M") control mode. After having accomplished this, the steam stripper(s) that should hav computer control must have their manual loading stations set to computer control ("C") mode. Failure to follow this procedure causes all control action to go into a "hold" state with no computer control being accomplished even though the manual loading stations indicate "computer" control ("C") mode is operating. Color Graphics Display (CRT) A color graphic representation of the process flowsheet is provided to display information pertaining to the 1_7 variables associated with each steam stripper, and the one common variable on tank feed. A total of 35 variables in all ar monitored. These variables are listed in the Appendix D and shown labeled in the proper positions as they appear "on scr en" in Figure 7.1 . CONFIDENTIAL: Subject to Protective Order SL 000149 of 14th Judicial District Court No. 91-1145 OVERHEAD TEMPERATURE (F) _L_L AIR-C COLEI CONDENSES '1 --[XH AIR-COOLEE1 CONDENSEdj- #2 FIGURE M OVERHEAD TEMPERATURE (*F> STEAM STRIPPER #1 PRESSURE | FEED TEMPERATURE ("F) FEED TEMPERATyRt f PRESSURE 45# STEAM EAM RATE ' 1 b/m) FCV ' 'EAM RE5SURE (pjig) rE* TEMPERATURE (f) (p9) FEED RATE r~i rr FEED RATE (piig) (GPM) LIQUID PHASE JXJFAN MOTOR1 SIAIUS. ("OFF") temperatl|re -FEED pH / FEED TANK #1 FORMATE (F) FEED RATE SETPOINT (GfM) TANK PRESSURE (wig> QHC f TANK PRESSURE (p.ig> FAN MOTOR STATUS ("OFF") FEED pH (GPM) FEED RATE SETPOINT LIQUID PHASE TEMPERA TlIrE (F> 45# STEAM BOTTOMS LEVELS(%: TOTAL TANK LEVEl (%) 1 TOTAL TANK LEVE'. <%) #2 ECONOMIZM5- (GPM) BOTTOMS LEVELS(%) STEAM RATE (lb, - 0-) 7 FCV BOTTOMS I SETfjciNT V LCV FCV FROM TK 1 (OR 2) SODIUM FORMATE TRANSFER PUMP FEED PUMP STATUS ("OFF") ^--M------------------------- ^ --M--- FEED PUMP STATUS ("OFF") " &* LC^ ____________ b BOTTOMS LEVEL SET-* POINT STEAM PRESSUR1 (psig> STEAM TEMPERATURE SODIUM FORMATE TRANSFER PUMP TREND VARIABLE #1 TREND VARIABLE #2 TREND VARIABLE #3 (YELLOW) (RE^ (BLUE). *) v<D o n Q) -H >1 C 4J v-t O E-i Qj 2W C Oi Hf EL, OC2J 0, (UNITS) TREND VARIABLE #4 (YELLOW) (UNITS) (UNITS) TREfcJQ_yARIABLE #5 TREND-VARIABLE #6 (RED) (BljUE)' LD (UNITS) (UNITS) (UNITS) CO Chvr-rc *ON s)ot - , - c OTpnf 43 T 3 :7VIXNaaiJN03 TREND VARIABLE #4 (YELLOW) TREND VARIABLE #5 (RED) TREND VARIABLE #6 (BLUE) INDUSTRIAL CHEMICAL DIVISION LAKE CHARLES LOUISIANA MTB Jti J rmc CENTRAL QHC STM STRIPm^l^S, i>>ao uOtJ0 mrit CHAMC ^&SK 10102 _________ CRT DISPLAY MIT su. it iniran SHEET, _OF_ fU>St*am Rate t >lam f tenure (11) item Temp. (40) I I t* rSpsniTq-TX6(?T'co-Hxpnr tnvt JO OpJO sax 33930,1a 03 qoafqog ."iviiwaaiJNOD ?g INDUSTRIAL CHEMICAL DIVISION !SS! LAKE CHARLES LOUISIANA &2Tine CENTRAL OHC SIM STRIPPER 1MWHUKWCUWWBvIifVir MTV mu OUMUIOU& tSx SK 10(03 CRT DISPLAY POINT INDEX SHOT . OF 7-5 Labels shown identifying variables' positions do not appear on the actual screen. In addition to the graphics display, the color CRT will provide 3.5 hours of trend display of any six (6) variables selected from the 35 variables monitored. The "trend" display consists of two (2) grids onto which are overlayed historical data of three (3) variables on each grid. Associated scales, time, labels, and engineering units are displayed. Updating of "trend" variables is done every 30 seconds with the oldest data being deleted from the left side of the screen and the newest data being added on the right side of the screen. A request to change one of the vari ables being trended will cause a loss of the history of the variable being replaced. The newly added "trend" variable will have no history. The history of the "new" trend variable will begin at the time of the request. The display provides valid information on monitored variables in both tb manual and computer control modes of operation. D. Keyboard Functions From the keyboard, an operator may request various functions and input information to change operating conditions. This is accomplished by means of an instruction set of 4-character keycodes. Each function may have two (2) parts: Part I - the 4 character function code, and Part II and optional structured sequence of data. A list of user instructions is provided with explanations of their use and functions in this section. CONFIDENTIAL: u rL o> c u j-i O 4J G) -r- U 1-1 r<~Ui JZ jj 4Q nr W3 i--t o An index of monitored process variable and th ir corresponding point numbers is included in Appendix D. Also see Figure 7.2 for a positional guide to the t r rder Cou tO c rei No. 91-1145 tsi tv ci t oD p l CONFIDENTIAL: /-o point numbers to be used with these instructions. The procedure for entering a request from the keyboard is : (1) type function nam , (2) hit RETURN key, (3) enter associated data, separated by commas if required, (4) hit RETURN key if required after data. For functions not requiring any data entry, only steps (i) and (2) apply. To clear or cancel a request depress the control"CTRL" key and while depressing it, hit the "C" key. When requests are made too frequently, or more than one pending request is current, the message "RQ BUSY" is printed. USER INSTRUCTION SET: 1. Keycode: "TANK" (RETURN) 1 (or 2) (RETURN) The operator enters a "1" or a "2" to designate which feed tank is on stripper . By default, the other feed tank is on stripper ^2. If a "1" was entered, the computer prints "NORMAL*'. If a "2" was entered, th computer prints "CROSSED". A "1" indicates that Feed Tank is on stripper and Feed Tank ^2 is on stripper ^2 - "NORMAL". A "2" indicates Feed Tank on stripper ^2 and Feed Tank ^2 is on stripper "CROSSED". In the event that the feed tanks and steam strippers are "CROSSED", only one stripper can be on computer control. Attempting to place both strippers on computer control when feeds are crossed will cause a "hold" on all control action. If both stripper feed pumps are operating, crossed feed cannot b specifi d. If eith r stripper is on SL 000153 Pr c ia i to ud ct J S ubje 14th f o /-/ computer control, a change In feed configuration cannot b specified. 2. "PLOT" (RETURN) point number, pen number (RETURN) The operator enters o monitored variable's point number and the pen number to change the variable being plotted on the CRT display. Th correct entry format is a two digit number (1-36) for variable point number, followed by a comma, then a single digit (1-6) for pen number, followed by a "RETURN". Any value out of range for either pen number (1-6) or point value (1-36) will cause the request to be aborted. u4-J Example; Enter "PLOT" (RETURN) 17, 2 (RETURN) replaces a o ----------- current trend variable at pen position ^2 with the ^ "new" variable corresponding to "point number" 17 tj on the CRT display. .. > *-5 -p in Pen Definitions; Pen Position ri o-hh E- G) Q r-| TOP GRID BOTTOM GRID 2 3 4 5 6 Top Yellow Top Red Top Blue Bottom Yellow Bottom Red Bottom Blue Q 14 ru cn H O) -n| 4J -*>Qmu--I4vjJs 3 r-4 CO 44 o A list of monitored process variables and associated point numbers is given in Appendix D. Also see Figure 7.2 for the correct point numbers and pen positions to be entered as data. 3. "TIME" (RETURN) MO, DAY, YR, HR, MIN (RETURN) The operator enters month, day, year, hour, minute separated by commas and followed by "RETURN". This function allows the operator to nter the present time. The time basis is a 24-hour day. SL 000154 Example 1: Typing "TIME" (RETURN) 10, 2, 80, 14, 23 (RETURN) ... 1 would ent r the time 2:23 PM on Oct. 2, 1980. Example 2; On printed messages the time 8:32 PM would appear as 2032; with the first two digits as the hour of a 24-hr. day and the second two digits as the minutes of the hours. No colon or AM/PM indication is printed. Valid entry values are: Month Day Year Hour Minute month of year day of month two digit year in decade hour in 24-hour day minute in hour (1-12) (1-31) (80-99) (0-23) (0-59) "LOGG" (RETURN) No data is associated with this function. This function causes a printout (hard copy) of the status of all monitored process variables to be produced. Items contained in the log output are: 1, current status of ^1 and ^2 condenser fans (ON/OFF) .2 hours of operation forward since 7:00 AM for strippers #1 and *2 3. feed tank ^1 and ^2 aqueous phase level (% span) 4. feed tank and ^2 indeterminate phase level (% span) f^0J JQ3 'O -U <D vHi ^\* '-*11:1 -v^U .*]>, ^` ` -u ^ ^ I G --* W 5. steam stripper pot level for strippers ^1 and ^2 (% span) -J 3 as 6. feed flow to strippers and ^2 (GPM) o'* 0) .c 7. steam flow to strippers *1 and #2 (Ib/hour) .8 steam header pressure (p$ig) -Q ^3* W3 r-i Uw O r 9. stripper bottoms pressure for strippers *1 and ^2 (psig) .10 feed tank vent pressure for tanks ^1 and ^2 (psig) % 11. stripper bottoms temp ratur for strippers #1 and #2 (F) / -7 12. stripper overh ad t mp rature for ^1 and ^2 (F) 13. stripper feed temperature for ^1 and ^2 (F) 14. feed tank pH for tanks ^1 and ^2 (pH) A sample log sheet printout is contained in Appendix A. 5. "DAYR" (RETURN) No data is associated with this function. This function causes a daily report to be printed. A sample daily report printout is contained in Appendix B. The daily report consists of the following information: 1. steam usage for strippers ^1 and ^2 (Ib/hour) 2. hours of operation of each stripper while forward (hours) 3. feed tank pH for tanks ^1 and ^2 (average value over 24 hrs.; pH) 4. steam stripper overhead temperature for strippers ^1 and ^2 (avg. va lue over 24 hrs.; F) 5. stripper feed temperature for strippers ^1 and ^2 (avg. value over 24 hrs.; F) 6. stripper bottoms temperature for strippers ^1 and ^2 (avg. value over 24 hrs.; F) 7. feed tank pressure for tanks ^1 and *2 (ayg. value over 24 hrs.;, psig) 8. feed flow to strippers and ^2 while forward (avg. value over 24 hours; GPM) 9. stripper bottoms to sodium formate destruction unit (avg. value for for strippers ^1 and ^2 separately over 24 hr.period; GPM) A copy of the daily report is forwarded to the Records Department daily. The jrs forward" in the report are cumulative, starting with a 7:00 AM starting t for the reporting day. SL 000156 CONFIDE...N...TIAL . Su b*ject at.o,.. PPrrootteeoctitveleOt rocoeruirt Of 14th Judicial DisUict /'IV 6. "VALU" (RETURN) point number (RETURN) An operator must enter the "point number" associated with a monitored process variable as required data. This Function causes the value of a process variable to be printed. A list of monitored process variables and corresponding point numbers is included in Appendix D. Also see Figure 7.2 for point numbers' location. 7. "CCRT" (RETURN) This function causes the CRT screen to be "replenished"; the screen is completely cleared and graphics reconstructed in approximately 4 minutes. This instruction is used whenever the trend of variables fails to update. 8. "INSR" (RETURN) point number (RETURN) This function requires the operator to enter a "point number" as data. It causes a monitored process variable that was 'previously taken out-of service to be placed "in-service"; "INSR". See Appendix D or Figure 7.2 for point numbers. 9. "OTSR" (RETURN) point number (RETURN) The operator must enter a "point number" as data. This function causes a process variable to be taken "out-of-service"; "OTSR". A typical reason for using "OTSR" would be to calibrate or replace a transmitter. After maintenance is completed, the variable should be put back in service using the "INSR" function. See Appendix D or Figure 7,2 for point numbers. CAUTION; Care must be taken wh n used in computer SL 000157 Subject to Protective Order of 14th Judicial District Court Mo. 9 1 " 1L1 control in "out-of-service" status. It is recommended that if a control variable is tak n out of s rvice that the associat d stripper be set to II manual" mode. 10. "ALRV" (RETURN) No data is associated with this function. This function causes a printout of all variables exceeding their alarm conditions at the time of the request. The report will indicate whether a variable is high/ low, open (faulty input signal), or out-of-service at the time of the request. The time of the request appears to the left of the message. 11. "LTIM" (RETURN) log time interval (RETURN) The operator must enter a "log interval" in minutes. This instruction allows an operator to change the time interval between periodic log report printouts. The log time interval must be a value of 5 minutes or more. SL 000158 TrrFTTvITri7kJ-j * Subject to Pr 0 14th JucUcio