Document 208Ok5386w9dQmkJVYE5XBRr

INTRODUCTION The purpose of this manual is to provide the auxiliary operator with information and training materials that will enable him/her to work in an efficient and safe manner. This is not a detailed guide to all procedures. The format is general and can be easily revised. If you have comments or would like to change the manual, please feel free to contact supervision. This is a highly skilled job. This unit is optimized and operated based on information supplied by you. Do not take short cuts. There is a reason for everything you do. If you have any questions about why you do a particular task, ask your lead operator. Try to learn as much as possible about the other jobs in the control room. It will make you appreciate your job. THINK SAFETY 020653 SL _____ . jfjjK .J -- 'V-. _' --**'. *-- * .> - -,- ^ -- ^ a'f* ^"chemicals 9~ ^ fS INTEROFFICE / LAKE-CHARLES 1 TO INDUSTRIES Distribution DATE ` CpWF'lDEHTIAt,: Subject to -rrotpctive Orde of 14th. Judi.cial Distrirct Cc June 30, 1980 ; - NgL 91-1145" , FROM R. G. Corley SUBJECT Emergency Squad Response \ c The response of- the plant Emergency Squad into Plant VB** has been reviewed and discussed with Operations personnel and the Fire Chief-- A revised plan for response has been-developed ;and outlined below. -1 . ; .` *. . , . : :'V* "s-*" *- ; General Points: ' - ' --* 1. The Squad will respond to every call, no matter who initiates it. (This is often not known, anyway.) _ . . _' 2. Strobe lights will be respected at all times. Not even the ambulance will drive through one--except by specific permission . from the Shift Supervisor or: the Shift Superintendent. . -- ' Specific Procedure: V-. -- '. 1. Emergency Squad members will respond to the scene of an emergency in the plant as In the past, in all areas. except Plant ''B11, Squad members will assemble at the '" Fire Department pickup truck. If possible. Otherwise, - .** they will respond directly to the Injury or fire by getting directions'from personnel in the area^ - 2.r In Plant "B", Emergency Squad v;ill respond only to one ... ' of four designated assembly points, depending on-the location of the emergency. Assembly points ares ..-v;\. a) west end of Organics Road at the strobe light-'. - b)-'east end of Organics Road at the strobe light c) Tri-Ethane II Control Room - .. * . - d) vcm ii shop ;:; ;. ' ? 3. . For emergencies located in Plant "B1*, the Fire Chief/Shift Coordinator will respond to one of the four designated locations. The Fire Department pickup will be parked at L the-location with engine off, but radio and emergency lights on. . * . `- . - *' li. Squad members will congregate at the truck and monitor the radio for instructions. * 020654 5. -Fire Chief/Shift Coordinator will have proceeded into the\ operational area on foot to size up the situation by visualinspection and contact with an Operations representative. Fire Chief/Shift Coordinator will contact the assembly point * val!<Te ^nd direct Sciuad members where to respond. Emergency Squad Response June 30 , 1980 . Page 2 Subject 'tcy.A?rot e e t'ive- Grjte?.; Of 14th -Judicial bistri'ct-ppurt * 80V 91^1145*.-'-7- 6. Fire Trucks or any other engine powered vehicles will cross a flashing strobe light only on specific directions from the . Fire Chief/Shift Coordinator. He will not issue these instructions without agreement from the production representative This representative will be tfte ranking person at the scene who* .'represents operations. -` - In th&absence of any operations representati as might occur in a large-scale disaster), the Fire Chief will make the decision based on the information available to him- ' . *- v4t-/v . 4 7.: Ambulances will not cross strobe'1 ights without specific'directions from the Fire Chief/Shift Coordinator. Again, Shift Supervisor - approval is required. Pending that permission, ambulance attendants will respond into the unit on foot to render preliminary first aid- The driver will remain inthe unit and monitor the radio.- 4 *#.' .8 As a tactical philosophy, the foam pumper will be committed into the unit only on direction from the Fire Chief/Shift Coordinator ; ; . .after the situation Is sized up. ` ; - M V,- i` V;!--.. The dry chemical truck is not a first strike unit.1-"It will ;:'r normally be mcved into position and operated after water streams have been placed to copl structures and a coordinated .water-chemical attack can be set up. : ; ... . 9. for vehicle response, the order of preference is as follows: . .-- V"" .v` ' * a; Fire Department pickup b) Dry Chemical unit . . . ` c). Foam pumper ` \: = ''.V-'i-'s-: ., - . :-y.` . ' 1.. ' _ 7Z 9 llur-'N-V^ v The foam pumper will be cranked, pulled out of the garage,`and. held on standby until dispatched by the Fire Chief/ Shift V Coordinator. . -` 10. Due to.the congested nature of some plant areas, and the .** Z- potential for personnel injury, emergency response-vehicles will observe a 35 mph speed limit- _ - * v-v* .' . * - wt In addition to training Emergency Squad and Safety Department personnel orj this procedure, medical and security personnel will also require ' briefing- Vt '.-** Also, the Plant 'B'1 Operations Superintendent group must be briefed on ' the importance of providing a representative to meet the emergency^response group at battery limits to provide information and assistance. In the absence of such a person, emergency response personnel must act as thetr judgment dictates. . -SL 020655 _ .;. SAFETY The following is not meant to be a general discussion of safety in the Lake Charles Plant, but is meant to present a more defined discussion of safety in the Per-Tri Plant. CONFIDENTIALt Subject to Protective Personal Protective Equipment: 14th Judicial District v. No. 91-1145 The personal protective equipment that will be required in your routine duties at Per-Tri will be a hard hat, safety shoes, respirator, safety goggles, and gloves. The hard hat is to be worn at all times in Plant B except inside the control room or in any office. Safety shoes, with steel toes, are to be worn by any person who works in the process areas of the plant. The respirator, which is an activated carbon filter used to filter out low levels of chlorine and many of the organics found in Plant B, is to be on the person at all times. Safety goggles are to be worn whenever outside in the unit or in the plant lab. - Gloves are to be worn when catching samples. The laboratory exhaust fan should be left running whenever you are working in the lab. Canister Masks: In low level concentrations of contaminating gases where the oxygen level is at least 19.5 percent, canister-type gas masks are to be used. These gas masks are kept on the wall in the control room. These masks offer full face protection, but, as with the pocket respirator, they merely filter the air, they do not provide oxygen. Scott Air Packs: In cases where there is less than 19.5 percent oxygen present or if there are impurities present which are not filtered out by activated carbon, SL 020656 CONFIDENTIAL: Scott air packs are to be used. These air pac^^gc%tog:idpcrobetntor*hOr<Ifir of 14th Judicial District Cour wall in the control room. Scott air packs are 30-minuteNQl-teift^3ied units offering full face protection. An alarm is present on the pack which goes off when there is approximately 5 minutes of air left. These air packs are not filters but are self-contained units which do provide a source of air. Air-Line Masks: In cases of emergency, there is a station in the control room equipped with six self-contained escape units connected to compressed air cylinders. The purpose of this station is to provide air to those persons who are required to remain in the control room once it has been contaminated and provide them with enough air to allow them to escape. These units are connected to four air cylinders by 50 ft. of tubing. This length of tubing is to allow the person to maneuver throughout the control room while drawing air from four large cylinders of compressed air. Each unit has a small 5-minute bottle that is strapped around the waist. For escape, the 50-ft. tubing is to be removed from the unit and the person begins breathing out of his 5-minute escape bottle. Only one of the four air cylinders is open to the manifold. In case of emergency, open the other three cylinders. Safety Showers: There are thirty safety showers scattered throughout'the Per-Tri area. These showers are placed in strategic places so that a shower is easily accessible from almost any area within the plant. It is a very good idea whenever performing a duty in the plant, such as catching a sample, to SL 020657 locate the nearest shower. This way, if something happens, you will know exactly where to go. If you have material splashed on your clothing, don't hesitate to remove them. Paper coveralls are in the orange tubes attached to each shower. Do not put back on your chemical laden clothes. Also, under each shower is a short piece of hose. This can act as an eyewash should , you splash something in your eye. Fire Extinguishers: Scattered throughout the plant are dry-chemical fire extinguishers. These dry-chemical fire extinguishers are recommended for electrical and chemical fires. Again, you should look for and know the position of these fire extinguishers. Red Phone System: Per-Tri's red phoneys located on the north end of the center table in the control room. The red phone system is part of the regular phone system and is used in situations where different control rooms must communicate closely and also during emergency situations. The various stations in the Red Telephone System have been assigned to three different groups with some locations being in more than one group. The system is to be used for alerting various stations as a group in an emergency. In order for a station to make a group alerting call, he can either pick up the handset or push the on button on the speaker phone and then dial the group master number. The groups and their master numbers are as follows: order Cto Protect^ Colirt oiSf43thC3 SL 020658 Group 1 Master Number: 3101 Liquefaction Cell Bridge Caustic "A: PH "A" Switchboard PH "A: Boiler Board Riverside Powerhouse "C" Shift Supervisor "A" Shift Superintendent Mercury Cell Group 2 Master Number: 3102 EDC Per-Tri EC-VC-HC1 Shift Supervisor "B" Liquefaction Cell Bridge Shift Superintendent OHC Powerhouse A Switchboard Powerhouse A Boiler Board Riverside Powerhouse "C" Silica Pigments Furnace Group 3 Master Number: 3103 Chlorine Control Room/, Caustic Control Room "Tr Powerhouse "C" Powerhouse A Switchboard Powerhouse A Boiler Board Riverside EDC Liquefaction Shift Supervisor "C" Shift Superintendent Silica Pigments Furnace Master number for all stations: 3100 Reporting an Emergency: In case of a fire or first aid emergency, go to any phone, dial 2700, state what kind of emergency exists, and your location (Per-Tri is in Zone 17). This phone number should be glued to every phone throughout the plant. Once notified, the guards will send the plant's fire fighting equipment or the ambulance, as is required, along with members of the emergency squad. Plant B Evacuation: There are four different warning devices that you will be concerned with: the Per-Tri siren, the reactor startup light, the roadway lights, and the Plant B horn. The Per-Tri siren can be activated by a switch located on the south face of the center pillar in the control room. This siren is activated when a dangerous situation occurs. When it is on, all non-Operations personnel are to evacuate The area. All Operations personnel are to return to their control room where they may be needed. SL 020659 Cos0*fliU ot",;; to Cu~ o 14th ( The reactor startup light is located just north of the acid pit. This light is activated by a switch located on an I-beam north of the old OHC con trol room. This light will be activated by OHC or Per-Tri operators whenever a reactor is being started. When this light is on, a potentially dangerous situation exists and all Operations personnel should remain in their control rooms. The,roadway lights axe located at the entrance to Plant B. These lights are on to indicate that a dangerous situation exists and all non-Operations personnel should evacuate and remain outside Plant B. If you are in a vehicle, you should pull over to the side of the road, shut' it off, and proceed to the control room where you may be needed. The Plant B evacuation horn can be activated by a switch located on the east face of the center pillar in the control room. The horn it activates is the shift-change horn. This horn is activated only under potentially dlsasterous situations and calls for the evacuation of Plant B for all nonessential persons. Emergency Flashlight: Although the lighting system in the control room can be powered from two sources; the normal bus and an auxiliary bus, there may be cases where lighting is lost to the control room. In these cases, light will be supplied by a battery-operated light located on the north wall in the control room. Sprinkler System: In the Per-Tri process area, the reactors, cooling towers, and stabilizer building have been equipped with their own automatic water deluge systems irlDB^^VLe Orfer piotective ^"ourt Suabb11ecCctt, ta0ieia1 SL 020660 for fire protection. An automatic deluge valve is installed at each of these locations throughout each area, heat activated devices (HAD) have been strategically placed and will trip the deluge valve in the event of fire, causing the area to be sprayed with water through a system of sprinklers. The automatic deluge valve can be manually activated in each of the red fire water houses and also from behind the control board. Dowtherm Furnace Shutdown Switch: The Dowtherm furnace is equipped with a shutdown switch located in the control room. The furnace also has an organic vapor detector which will shut down the furnace should it detect any organic vapors. This shutdown system is installed so that in cases where there may be a dangerous level of vapors near the furnace, the furnace will not ignite. Air-N2 Alarm Light: The process control instruments used in the control room are normally run on instrument air from VC, but are capable of being run on nitrogen. The 02-N2 light, located on the south face of the center pillar in the control room, indicates whether we are using instrument air (02 light is on) or nitrogen (N2 light is on). When nitrogen is being used, the doors of the control room are left open to ensure an adequate supply of breathing oxygen. As a precaution, an Oa sensor and alarm is located behind the control room board. If the 02 level falls below 19.5 percent, the alarm is sounded as a warning of low level 02. Permit Procedures: There are three types of permits used in the plant. A vehicle entry permit, a burning or welding permit, and a tank-entry permit. A sample of each of these permits is at. the end of this section. A vehicle entry permit must be issued for all vehicles brought into the unit's area. The vehicle entry permit is given by either an Operations supervisor or the lead operator. This permit is good for eight hours or less. ptttK, The ped*permit is the burning or welding permit. A burning or welding permit must be obtained for any burning, welding, or sandblasting in the area. These permits must be signed by an Operations supervisor and a Maintenance or Construction foreman. Prior to the permit's issuance, an inspection of the area must be made to make sure that all valves are closed and tagged, all bleed valves are opened and tagged, all connections have been blinded, all circuits are pulled and tagged, and that the process materials and area in general are free of explosive gases. This permit is good for a maximum of four hours. The orange permit is the tank entry permit. This permit must be signed by an Operations supervisor and a Maintenance or Construction foreman. The tank must be cleaned and have all process lines to and from the tank removed or blinded. The tank should be tested for flammable vapors and for oxygen. A life line is to be worn inside the tank, unless the line would not contri bute to the safety of the job (i.e., a vessel with manways on the bottom). A fresh air mask is to be used in a vessel where there is a chance of being suddenly surrounded by gas. A.manway watch is required at all times that someone is in the tank. nL: , - r0WFlDl^r Vwe order Su^ecVio CUlt *BVt SL 020662 Housekeeping: Housekeeping is a very important part of safety. The following are the main areas of responsibility: 1. The lab. It should be kept clean and orderly at all times. 2. You and the "C" operator should frequently clean the stabilizer building. 3. Wash down organics after catching samples. This is a potential fire and health hazard. 4. Wash down catalyst after adding to reactors. 5. Always roll up hoses and put away tools after using them. Tank Farm: Per-Tri's tank farm is located northwest of the control room and con sists of twenty-three tanks. Of these twenty-three tanks$ six are Tri stabi- * lizing tanks, six are Per stabilizing tanks, ten are auxiliary still line feed tanks, and one is a Tri rework tank. Figure 1 shows the location of these tanks and the use of each tank. Figure 2 is a sketch showing the Per-Tri dock tanks located at the docks. After a certain batch of regular grade Per or -Tri has been stabilized and cleared by the main lab, it will normally be transferred to these tanks. It is from these tanks that barges or ships are loaded. After a dock tank has been filled, -or If nnrnT<nt l-s* needed befege a tank io filled, the main lab must run another set of analyses on the dock tank before the material is cleared for shipmentjfly uatK.. Table III shows what each of the tanks in Per-Tri's tank farm is used for. st 20663 Sublet to o 14th ord Court Oi.strict 91-1145 A PERMIT MUST BE ISSUED BEFORE ANY WELDING OR BURNING CAN BE DONE IN THE PLANT. PERMITS ARE ISSUED BY A SUPERVISOR. E & L ASSOCIATES 59-572-0060 WELDING, BURNING, OR OPEN FLAME PERMIT Date---------------------------------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 Yes Does Not Apply 4. Electric circuit breakers pulled/tagged 5. Sufficient O, for test. Meter in calibration. Free of process materials & gases. % explosive. (This portion to be filled in by Maint/Constr) X 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 Permit Start Time Expiration Time------------------------------------------ Maximum Duration: Four Hours CONFIDENTIAL: New Permit required after job interruptions such as evacuation, safety meeting, or process upset. For other ct to Protective Ord quiring revalidation, the Operations Foreman's signature is reqOifbdli4Lh Judicial District C reverse side of field copy. No. 91-1145 Operations Maint/Constr Foreman t 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 SL 020664 CONTROL ROOM COPY c SL 020665 4-> Li a (V O TJ U O 4J o C>J -H 'M M< -p irt 'H .*< ej a -< i Ha fi. & <3 01 H o* 3C o o 0 4J -r-) tl a 0 2 4-> O o *<rui4xj: -0 vr 3^ to o IGNITION SOURCE PERMITS MUST BE GIVEN ON POSSIBLE SPARK OR HEAT IGNITION SOURCES SUCH AS TOWMOTORS,WELDING MACHINES, AIR COMPRESSORS,MANLIFTS,OR SUBSTATIONS IN THE PLANT. E&L S9-&72-0165Rev. 9-15-86 IGNITION SOURCE PERMIT Date Unit Location in Unit_________________________________ _ Job Description__________________________________ Description of Tools or Equipment Covered by Permit Checklist (to be filled in by Issuing Operations Supervisor) 1. Sewer openings sealed ___ 2. Fire extinguisher accessible ___ 3. Job area free of process materials and gases __ _ 4. JSI given ___ 5. Shutdown point (switch, etc.) of ignition source noted by Issuing Supervisor __ Permit Start Time_.. Expiration Time __________________- Maximum Duration: Eight Hours New permit required after job interruptions such as process upset, area siren, or plant evacuation. Permit must be revalidated by Operations following lunch break or shift change. (See Reverse Side) Permit Requested by: Permit Issued by: Maintenance Foreman/Fteid Engineer Operations Supervisor/Lead Operator Job Completed Maintenance Foreman/Fwld Engineer 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. CONTROL ROOM COPY SL 020666 c INDUSTRIES TANK ENTRY PERMIT AM Date____ Time of Issue. ___ PM Permit. Duration. Form 43A-SD-25 PPG ID # 59-572-0030 Rev. 6/82 Firs. (8 Hrs Max.) Tank Description __________ Prior Contents. Job Description________________ ________ __________ Tank Cleaned __________ ' Previously Purged with: Air N? Burning or Welding Required: Yes No Process Lines to Tank Tagged and Blinded (or Removed) Power Sources Locked and Tagged _____________________________ Breathing Air Required' Yes [j No / Mask Required Yes No External Ventilation Required: Yes No / Air Horn [j Electric [j Life Line Required_____ Wristlets Safety Belts ^ Electrical Equipment Required: Yes No Low Voltage Lights 110 Volt Lights with Ground Fault Breaker , 110 Volt Tools or Inspection Devices with Ground Fault Breakers Q Ladder Required: Yes [l1 No Manway Watch Assigned_______ Communication Device Provided Checked for Toxic Material (See Back of Card). Yes [Z No ^ Comments______________ ,............................................................................ Type Protective Clotnina To Be Used ______________________ Tank Atmosphere Checked % 0.- _________ % Flammable___________ (19 5 Minimum) (10% of Lower Flammable Limit Max) Supervisor Approvals Operations Maintenance Construction Job Completed ____________________ _ i (Maintenance-Construction Supervisor) Definition of Tanks The term "tank1 includes tanks, mixers, sewer manholes heaters, boilers, electric manholes, fume tunnels, large pipelines, small vaults cooling tower oasms tin special casesl and similar confined areas with restricted access di(- ficult rescue where any of tns following hazards may be encountered' toxic or liammaDle gases or vapors- mechanical hazards such as moving agitator blaoes, acids or caustics: plant inert gas or oxygen deficiency This Permit Form Must Be Hung Near the Tank Manway or Entrv Point I i 1 \ I I CONTROL ROOM COPY COW1UO*1TM"' , - x. p-ot-active Order ;i District COW Su^0^cia^-5 0t HO. SL 020669 PITTSBURGH PLATE GLASS lUftPANY LAgV. CHARLES. " ' - : LOUISIANA R ANT ARTA fi ~ ^ CRITICAL ' BLOCK VAl. -PIPING: > ,- . UJCAIIQNS. Z r_-f_*>_r_--_--_--_- r`*/oo'-a MlcPMfimu ^Rf4*W,,0)!VG, Nc52A-aDQ0lf INTRODUCTION TO MAJOR RESPONSIBILITIES What you will read in the following pages may sound complicated to you, but do not worry about it. After you complete your training, you will have a better understanding of what your part is. Basically what is happening; we put some chemicals into a vessel and mix them or heat them to form another chemical. This mixing does not turn out a pure product, so we then put the chemicals through a series of clean up steps. The end result is a saleable or usable product. You will be involved in this manufacturing of chemical products. The name Per-Tri is a shortened form for this unit's products, Perchloroethylene (Per) and Trichloroethylene (Tri). As you can see, it is much easier to use the term Per-Tri. These liquid products are used as either liquid or vapor degreasers. Per-Tri is divided into two major operating areas. These areas are the Reactors and Still Line. The Reactors make the product and the Still Line purifies it. Feeds for the Per-Tri reactors are gaseous oxygen (C^), gaseous chlorine (Clg) and liquid organics. These organics are of varying composition and must be vaporized before being fed to the Per-Tri reactors. The comes from an out of plant supplier. Chlorine comes to the Per-Tri unit from the Liquefaction Area in Plant "A". Organics for the reactors come from the Tetra Unit and some is liquid impurities COSFIDWTI^: Qraer recycled from the Still line. Subject to S&rict Court 7 SL 020670 These feeds are fed to the Per-Tri reactors. They react in the reactor tubes in the presence of a copper chloride and potassium chloride catalyst. The catalyst is fluidized in the tubes. This fluidization causes the catalyst to boil like water in a pot. Fluidization in the reactor tubes is caused by the feeds coming into the bottom of the tubes. By being fluidized, the catalyst can serve its two major functions. They are to promote the reaction and to transfer the heat from the reaction. Since the Per-Tri reaction is heat producing (exothermic), a means is provided to cool the reactor. Dowtherm, a heat transfer liquid, surrounds the reactor tubes and serves as a coolant. The crude Per and Tri leave the reactor as a gaseous mixture through the vapor line. This gaseous crude goes into a condensing system where it is liquified. After being cooled and condensed, the crude is put into a tank. The Per-Tri reactors make water as a waste. The following word equation shows, in a simplified form, the reaction in the Per-tri reactors. Oxygen + Chlorine + Organics catalYg*-- Perchloroethylene + Trichloroethylene + water. This water is removed from the crude with a Dehydration Still (DH). Moisture in excess of 50 ppm should not be allowed beyond the DH Still. This moisture could result in corrosion damage-to-the-Still Line;-- The dried liquid crude is then fed to a series of distillation columns called stills. Separation of the Per and Tri occur first in the Per-Tri Still. Tri and lighter material leave the top of the Per-Tri Still as a SL 0206?1 gas. CONFIDENTIAL* Subject to Protective Order of I4tii Judicial District Court No. 91-1145 The Per and heavier material leave the bottom of the Per-Tri Still as a liquid. It will now be necessary to follow one stream to completion and then take the other. Please keep in mind that in the Still Line there are two major streams. One is the Tri stream and the other is the Per stream. In addition to these will be impurity streams such as recycle and bottoms. The Tri leaves the top of the Per-Tri Still, is condensed to a liquid and goes to the Tri Stills. Here the impurities lighter than Tri are removed, as a gas, at the top of the Tri Stills. Sometimes the Tri must go through the Topping STill. In this still, heavier than Tri impurities are removed at the bottom as a liquid while the Tri leaves the top as a gas. Thegaseous Tri is condensed to a liquid. After the distillation process is completed in the Tri Stills and Topping Still, the Tri passes through a neutralizer to remove other impurities. The final purification step for the Tri is a set of driers to remove moisture. Dried Tri is then stored for sales. Coming off the bottom of--the-PerrTri Still is the Perchloroethylene and heavier material. This stream goes to a Heavies Still where the heavier than Per impuritiies are removed in a liquid state at the bottom. The gaseous Per and lighter material exits through the vapor line of the Heavies Still. The Per and lighter material is condensed, liquified and fed to the Per Stills. In the Per Stills, the Per is separated from the lighter materials. Per leaves the bottom of the Per Stills as a liquid. The lighter than Per material leaves the top as a gas. The Per is neutralized to remove other impuriteies. Driers then remove moisture from the purified Per product before it is stored for sales. SL 020672 9 This is a brief explanation of what happens in the Per-Tri Unit. There are other flows and equipment not mentioned. This general idea will be useful in understanding what is happening around you on the Per-Tri "D" job. A safe and efficient operation of the Per-Tri Unit will depend a great deal on your performance. You will- be responsible for process analyses and assisting when needed in the units. The Per-Tri Unit will be operated largely on your sample analyses. To a great extent, the operation of the unit is dependent upon your job performance. Your job is important. This is a big responsibility. Your training and ability will enable you to fulfill this important respon sibility. As you gain experience, your job will become easier. CONFIDENTIAL: subject to i a + u .indiciaI court 020673 SL 10 PER-TRI PLANT DESCRIPTION The Per-Tri Plant is designed to produce high purity Perchloroethylene (Per) and Trichloroethylene (Tri) simultaneously from a feed stock of chlorine, oxygen, 1,1,2-Trichloroethane (TCE), 1,1,2,2-Tetrachloroethane (Sym>, 1,1,1,2-Tetrachloroethane (Unsym), and other chlorinated hydrocarbons. Per and Tri are formed by a series of successive chlorination and cracking reactions in which HCl is cracked off of the chlorinated organic molecules at high temperatures. These reactions are carried out, under low pressure, in a tubular reactor containing catalyst. The chlorinated hydrocarbons (hereafter referred to as TCE), chlorine, and oxygen, all in the vapor state, are fed into the bottom of the reactor and flow up through the fluidized bed of solid catalyst particles where the'gases are reacted into Per, Tri, water, HCl, and other chlorinated hydrocarbons. Host of the reactions involved are exothermic and the excess heat must be removed. The heat is removed from the reactor by the boiling of liquid Dowtherm which surrounds the outer walls of the reactor tubes. The boiling rate of the liquid Dowtherm is controlled s as to keep the reactor tubes at a constant temperature. Basically, the Per-Tri Plant consists of reactors, a system to remove water and HCl, and a purification system for removal of unwanted chlorinated organics from both end products. Associated with each of the five reactors is a vaporizer and two reactor condensers. The water and HCl removal system consists of three phase separator tanks and two drying stills, and the organics purification system, called the distillation train, consists of seven distillation columns and their associated condensers and tanks. Following the distillation train, there is a product neutralizer and dryers for both Per and Tri. The Per-Tri storage consists of twenty-thi-gt tanks in a tank farm adjacent to the process area and six dock area storage tanks. Of the twenty-three tanks in the tank farm, are Tri stabilizing tanks, 1 are Per stabilizing tanks, ten are auxiliary still line feed tanks, and one is a Tri rework tank. In the dock area, three tanks are Tri and thr e are Per storage pJtu** Pju. a A. The Per-Tri reactors are large shell and tube type exchangers with the reactants in the tubes and the heat transfer medium on the shell side. The reactor tubes are actually fluidized beds filled with catalyst. The TCE and chlorine are first vaporized, then mixed together and fed into the bottom of the reactor tubes. The oxygen is fed into the tubes through a separate line. These gases, as they travel up the catalyst-filled tubes, react and give off a large amount of heat. This heat is absorbed by the liquid.Dowtherm on the shell side. The Dowtherm is vaporized, leaves the top of the reactor as a vapor, is condensed, and is returned to the reactor shell as a liquid. The Per and Tri leave the top of the reactor as a vapor along with HCl, water, and other undesirable by-products. The vapor stream from the reactor flows first to a water-cooled condenser and then to a chilled brine condenser where the organics and the water are condensed. From these condensers, the con densed organics and water flow to a degasser tank which removes some of the CONFIDENTIAL: Subject to Protective Ordei Of 14th Judicial District Court No. 91-1145 SL 020674 -2 diss lved gases and seals the reactor pressure. The organics and wat r Is then fed to the drying still feed tanks. These feed tanks also serve as a phase separator, sending the acidic aqueous phase to the acid pit and pumping the heavier organic phase to the drying stills for the removal of the dissolved water and HC1. The water and the HC1 leave the top of the drying still as a vapor, flow through two condensers.where the vapors are con densed, and fall into the drying still reflux drum. In the reflux drum, the water, which has absorbed the HC1, separates from the organic phase and is discarded to the acid pit. The organic phase left in the drum is refluxed to the drying still. Dry organics leave the bottom of the drying still and are pumped to the still line feed tank. From the still line feed tank, the crude process stream is pumped to the still line, consisting of seven stills, where the unwanted organic compounds are separated from the Per and Tri. The first still in the chain, called the Per-Tri still, makes the split between Per and Tri, the remaining six stills remove the light and heavy impurities from each of the two products. The light impurities are removed in the overhead of two Tri stills and are sent to the Tetra Plant. The heavy impurities are removed in the bottoms from the heavies still and are sent to the Bottoms Plant. In the first still, the Per-Tri still, the Tri is separated from the Per with the Tri and other light impurities going overhead and the Per and heavier compounds leaving the bottom. The overhead stream is condensed and sent to two Tri stills where the Tri is separated from the lighter components. Part of these lights is recycled to the still, and the remainder goes to the Tetra Plant or to the recycle tank. The Tri still bottoms are pumped to the Tri topping still where heavies are removed at the bottom and recycled to the reactor and pure Tri is taken off the top and condensed. The Per stream is taken off of the bottom of the Per-Tri still, pumped to the heavies still feed tank,and then to the heavies still. The Per leaves the top of the heavies still, is condensed, and is pumped to the two Per stills. The heavies still bottoms are sent to the Bottoms Plant. The lights leaving the Per stills are condensed, part is sent back to the still as reflux, and the remainder is sent to the reactor recycle tank. The pure Per product is drawn off the bottom of the Per still. v* After distillation, the pure Per and Tri streams are fed to the neutraliz rs, where they are first treated with ammonia, then washed with water, and from here flow to alumina dryers where the water is removed. After drying, th y are pumped to stabilizing tanks where stabilizing chemicals are added , after analysis, are transferred to storage. In the Per-Tri process area, the reactors, cooling towers, and stabilizer building have been equipped with their own automatic water deluge systems for fire protection. An automatic deluge valve is installed at each of these locations and throughout each of these areas, heat activated devices have 020675 SL CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 -3- been strategically placed such that they will detect fire and activate the deluge system. These heat activated devices (HAD) will trip the deluge valve in the event of fire and the area will be sprayed with water through a system of sprinklers. For each of the three deluge valves in the process area, there is a set of sprinklers that cover its particular area. In addition to the automatic sprinklers, there are carbon dioxide and dry chemical fire extinguishers, and five hose houses located throughout the plant. For protection against over-pressurization in the process, vessels are equipped with rupture discs. In the Per-Tri Plant, flammable materials are present in some areas, and, for this reason, special precautions are taken regarding electrical equipment and grounding. In the control building area, the still area, and the product storage area, all motors are TEFC, and lighting is vapor tight. The control building is pressurized to prevent any vapors from entering. In the reactor and Dowtherm areas, and in the stabilizer building, all motors are TEFC, lighting is vapor tight, and all arcing devices are explosion-proof and s aled. All motors and other electrical devices in the plant are grounded and the ground is contained in the conduit supplying the device. Due to the static charges produced in the handling of hydrocarbons, all vessels and pumps are grounded, and flanges are equipped with jumpers and as a result, any static charge buildup is eliminated. The plant is equipped with an alarm system that warns operating personnel of any abnormality in the plant, telling them where the abnormal condition is located and whether it is above or below the normal operating condition. All variables in the plant that can cause serious trouble or operating difficulties, such as levels, flows, temperatures, pressures, pH's etc., are equipped with alarms. When an abnormal condition occurs, alarm horns will sound in the control building and a light will flash on the graphic panel board showing the exact location of the trouble. The lights on the panel board are gre n under normal conditions, but if a high flow, pressure, temperature, level, etc., occurs, the alarm horns will sound and the light will flash red; if a low condition occurs, the horns will sound and the light will flash yellow. The horns will continue to sound and the lights flash until the acknowledgment button is pushed. Pumps and otherelectric motors also connected to the alarm system. When a motor is running, a green light shows on the panel board, but if the motor should stop for any reason, the horn will sound and a red light flashes on the board. CONFIDENTIAL: Subject to Protective Ord.^ of th Ju&?;i-u4s SL 020676 SL 020677 PER-TRI. PLOW SHELT K pSg/T12l dTZffUNP fCjQP klATPHLlN&.SSE: ^RP3. | OF^ ^ 2 OF3 <^?N^|2E?T& gg. 4 ^vAY w f o to a O-vl' vo > Q? 2*s> <si-<s4 ^<Sx.\&e\o o m 11 -saiQ o $ *C cF^b r-*f ooQ* H- *3 H VC & 3 w o V- P A H P> vn > & rf <rr i~- ?* rS_... I H-1344 I H- o (+ on O r- ; '; 11-1343 11-134& 1 C* go-ie^a 1 i i. UNB p pUMP3 <&SsMIH1 -, 00-410? <Z2?-I 5y-N OVo 0^0 ocOO-Pl&& G0-4A.&*1 <-<22*463 4 11-020^ 11-&I6 ni-cSM & ih3&3>ii-i36o^ 1H354 ^"11-1351 m-^!<s ?-A&A - (^?HK PLASM&G2 C>-A<SS> - TCI "RPPPIMC3 SpLU (2BFUJX. QI2UM ?-A&<=\ - #2 pee STILL 23FLUX C?[2UM 0.410 - TCI STILL P5FLUX. P12UM 0-4*11 - P/T II H >40S - t^NPEHSAre SJOPASS 0-1133 - #2 TF2I STILL (23FUjy P2UM 0-1130 -H.S. 23FLUK C*2UM 0-13^0 -V&HT HBAP3I2 BSTp SBp O-ie!0 - LevVl S <OlL SBpAlZATDpOeqvi. MIPPLB*) 0- \<=\&e -4* I STILL [2&FLUX Q2UM 1- I -4*2 pSI2 *STI LL 1-2 - 4* l T21 I* 1-3 1-4- - p/r still -*fc| P&I2 STILL I-io TKI -notTPlMG STILL 01-04 - HOL A3302332 01-32 -*2TCI STILL 01-e> - HEAviBS "SJlLL 1I-B4cS - T-2 FB|2, 3TlLL ESe*PI LB12 *2 11-3^- M: || || II #1 11-ocpi - fri "nsi still eeeoiLBe -ri 11-003 - PBI2TCI STILL Q2B>OILEe-*l 11-005 - #1 P5-I2 STILL SSESOILLB. 1|-OI<=T " #1 -T&l M M #=-2. 11-020 - H n **2. 11-1343 - SOUTH BV^R?AT2?2 11-1344 - H<P|STH OIL CO&\je& 1I-I34&-NHS C0rt&(TOp\A\VO\J& m-iOA^ -ooHoe^eatb flash ooHc? 11-1300? -HEAVIES STILL 1256301L6B*-*2 1I-I3SI - H i| H 4=1 1M3E?3-#2TSt n ti * ! i 2HP pLOOfc BA6f SlPp PpSTAIPVAy' 5 1l-ISSg> gM456. 13- *3 P* ^g(5. VApK>{2 ppUM - *r I u il H n - #z u u u ii !3 - #4 11 1 I* -4-**& a H ii ii ^4-<Fl (2* OtG^e&tZ. ?6>_42 II II *&-*3 it i| . ,. &-tfg? II H io - #4 ii * .51- P5(2 VASH SEpApATPP- #2 - #-2 pPB still -# I 'Tig'Ll -P&^T fP - *1 FE-fZ 3p- I - F5IZ./TCI lE&AcTTC- !3F*2 - 11 ii si-s> _ #i psp H^JT <S1-S - PH ScJ|ZUB&e-|2 11-1320 -p^e/TCI STILL <^?np. 11-1331 -TGI ecTT<5VS CO0\Jc& <&*1-1 - **2 p&[2 sl&U*TT 11-1332 - pZPH&AT&'E <2>1-|P - TI2l TAPING ^q*lLL 1I-134P -F/T S*pLL gPTTCkl^ <sn-i3 - TCi - M&UT- 1I-ISI4 - ^MTA^T <^pHC'^Ne.&f2 SI-02 - # -2 TCI, STILL 1HSS2 - H2 SI-03 _ HEAV7I3S STILL 11-1431 -H.S. CA&&XV3 &MO. si-un - w&rtsuz EesewfegATioNS^BSw IMF30 - il ii I' 10-2>4S-ML PlZIM. PNP. 11-2^41 -H^L A 33 e5PNPA/PN0 11-523 -#l F5I2- PPfcQJCT GOCM& H-3FI - TGI T^PPINS STILL CO^\Ol (2epLA^5P 11-342 11-1333 -#2 pep. &GTTCMS CCOV3& -ii-e?4<2> -a-.-s pep still cpmr 3F-3 - P&2/TI2I I2eAeTC?2- -- 4fc | TCI `I *' 34-G - il H ni-Se?2 - # I P3I2 II II 34-1 (P - II n 11-1321 -#*2 TCI 11 " 34-23 - *i H o CO JD O O') o cn I *11-2P4<S -11-&40 pgg/TTgl .: ihsas me ni-iai .11-1326 11-615 1I-63P 1H*M2 11-^45 o w * C *. tr 3* (0 a c/i f a o * Cj & a h* ot-" ft _ o *0 ao a ,!S"J1 j o o to o O' hkOS i ^a It--- Dr-- fu! g js. a) rt > CO yi <T H- r* rlr(*- <(5 O rt jO-s o a* o fl> c tt n rt 11-12*12 II-644 li-cca "11-1324 11-515 , <2OA0\& - *M p.M. ^TIUL I26FUUK PPUM 6P-II41 - #2 M II II H tf(4n - RH. PHASE. <sn-*i -#-i rh.-still <S"1-P - 1-2 II II <2r\-e>4 -pw.veNt ec^ue?e?E^2 Kwp^-^jy-pwr c?,H. *^till eee>^it-e.e 11-|3?e>-#2 II * II 1I-2*1<-W^L f^iMApY ^2HR H-2P^n-N^L A& ^<2. tf3PHC7. I 6&-A&4 -4T3 12k I22VTH3I2M VfcNT CdKiV. VfcC. 60-/n*?- fr I i H ii H n ^-41<-#2 I II II ^-5>I8 -p&Nfc H&AP TANK <<?-B*2P-#l P(2UM --42 B H N II ^.&T1 _44 (2k RWjH&gM VtNy <^ING 2&S ^-nei -43 R&jm &a--\34 - 4F e> 12k tfca.VTU&(2M V&NT <SPNR (262 a*?-\3*u-A&z>. car\& b>nt e&p n-e^e*-#! i2x a&a r?nr H-^a -43 i *11-012 -RM. ejlLL S. V&NT RRlSR 11*013 --41= I IZX CK\VTH&|2M <PrSG 11-014 -42 ii M 'I t<aie> --*2 ex. ee^<7HPAev' shr -it /6"*2n* -_tt--tf1p-, STILL paiMAEv' r?v Pr? u'-i a r^v/ /^AsJn II fc t 11*034 ~ 2* OCWjWb'foA V^Hr <2?Nl2 1 1-043 - # 4 (2X ptZlMAi^ 40NR # I 11-044-43 H II H #'2 ll-fi'sjfl-frfi 12k QRyTH(2M V^NT^RNE 'I H COtAQ. . 11-131 - 44 i e>U&tt9A&{ il "11-133 _ 44 2k P2IMAI2/ 02NR 42 11-141 -#4- H tfps/rU&pM #NR 11-142-42 i' ll-^42--4? (2k !|.*I4I -#4 it. 11 il n v/^NT^RNR NiP. VBNT^NR li-*l42-43 ii F^IMA(2V 0RNG. #2 11-^43 -#& ii e>tCCWA&( H 11-12^2-43 H pR-lHAlZv' ii ft5 I 11-1324-- 4 I il II 11 11-132*b-42 il nu ll-l32<S-42 RH.eTlLU p&MAf^ CO^^. -iui/^oo_4f i C?u nayrruc-PM \ /cpMT" vjnIo n o a ( nil AREA. TANKAGE (Continued) S;.te No. 60427 523, 823, 1142 1137, 1138 13.39, 1140, 1216 649, 650, 652 423 522, 824, 1141 1143 528 Service Per Shipping Tank Per Dock Tanks Nos. 1, 2, 3 Per Stab. Tanks Nos. 1, 2 Tri Stab. Tanks Nos. 1, 2, 3 Tri H.P. Stab. Tanks, Nos. 1, 2, 3 Tri Shipping Tank Tri Dock Tanks Nos. 1, 2, 3 TCE Storage Tank NHa Storage Tank 505 BLM Storage Tank 647 EPN Storage Tank 506 oi NPL' Storage Tank f 486 o(O Dowthcrm Storage O Tank O' 488 u Condensate Storage Tank CONFiMteTIAL: Subject to I^BIectivs Order Of 14th Judicial district Court No, 91-1145 Normal Max. Cap. 24,500 Dia. 12' Side Height 30' Roof Type Umbrella 430,000 48* 32' Umbrella 65,000 20* 30' Umbrella 65,000 13,500 2O' 30' Umbrella 12' 17'6" Umbrella 24,500 430,000 102,060 13,000 6,000 4,100 6,000 8,700 10,500 12' 30' Umbrella 1 48' 32' Umbrella 24' 30' Umbrella 9' 33'2" Dished/ 700 gal. 9' 13' Umbrella 9' 9' Umbrella 9 1 13' Umbrella 10' 13' Horizontal 10' 18' Horizontal Page 2 Bottoms Type Plat Gallons Ft. 840.10 6" Crown 13,506.13 Flat 2,345.18 Flat Flat 2,345.18 840.10 Flat Flat Flat Dished/ 700 gal. Flat Flat Flat Dished Heads Dished Heads 840.10 13,506.13 3,372.13 471.46 471.46 471.46 471.46 - - I J PER-TRI AREA TANKAGE Qi i4tu uo - 9V ae* ,, CouP ^ .vie K'o. 60- Service 477 Recycle Tank 1424, 1425 Oil Feed Tanks Nos. 1, 2 Dll Feed Tank No. 3 463, 472~ Still Line Feed Tanks Nos. 1, 2 450, 491, 492, 493, 494, 495, 496, 499, 500, 651 ASLFT No. 1 - No. 10 497 Wash Tank 859 P/T Feed Tank No. 1 at 0HC 503 Heavies Still Feed Tank 586 Bottoms Plant Feed Tank No, 1 630 Bottoms Plant Feed Tank No. 2 483, 484, 498, 501 Per Deg. Stab. Tank Nos. 1, 2, 3, 4 Normal Max. Cap. 20,000 7,500 12,100 20,000 13,500 13,500 39,660 20,000 20,000 11,250 13,500 Dia. 12* .8' 12' 12' 12' f Side ( Height r- Iloriz. 15' 24' 17'6" Roof Type Umbrella Dished Heads Bottoms Type Flat - Dished Heads Flat Umbrella Flat Unbrella Flat Gallons Ft. 840.10 - 840.10 840.10 840.10 12' 17'6 Umbrella Flat 1 840.10 15' 30' Umbrella Flat 1,314.49 12' 24' Umbrella Flat 840.10 12' 24* Umbrella Flat 840.10 12' 14' Umbrella Flat 840.10 12' 17'6' Umbrella Flat 840.10 020684