Document 2bb879eQV2JOOnvJ21dbqDVN
ABD00230093
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Work bv: Douglas E. Knittig Process Engineer
ifc. I4JI--
Approved by: Steve C. Hillman Sr. Process Engineer
ABD00230094
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Table of Contents
Introduction Design Basis Process Description Impact Statements Instrument List Work List Drawing List
1 3 3 4 5 17 17
ABD00230095
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Introduction
Project Description
This project will install remotely actuated isolation valves at the VCM railcar unloading stations to comply with the Department of Transportation requirements. The valves will isolate the railcar liquid and vapor lines and the VCM storage area in the event that a VCM leak is detected.
Two additional gas mixture monitors will be added to improve the ability to detect a leak at the railcars. The monitors will be connected to the existing leak detection and isolation system at the tank farm.
Problem Definition
This project addresses the DOT Unloading Requirements under 49CFR174.67(i) by providing "attended" immediate shutoff of the process and railcar in the event of an unloading malfunction. The project will?
1) Add two additional VCM lower explosion limit sensors.
2) Add emergency shutoff valves on all the railcars. 3) Add emergency shutoff valves or ball check valves to
isolate the process. 4) Change the monitoring of VCM in the area by placing
two of the fixed point monitors on a different gas chromatograph.
These additions address the plant(s need, based on DOT regulations,to attend the railcar through non-human monitoring during unloading and provides for immediate shutoff. The requirements for non-human monitoring are?
1) equipment used must provide surveillance capability at least equal to that of a human observer on-site or at a remote location?
1
A
ABD00230096
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
2) equipment used should be designed to provide immediate notification of malfunction to a person responsible for unloading, but if not so designed, equipment must be checked at least once every hour for proper functioning?
3) in the event of known equipment malfunction, human observation of the unloading, as described above, must be instituted immediately; and
4) the person responsible for unloading must have the capability to halt the flow of product immediately.
Economic Evaluation
There are no economics associated with this Safety and Health project.
Alternatives Considered
1) Use of a camera for observation and automated
valves.
This was not considered to be the most
effective way to "attend" the railcar. VCM leaks would
be difficult to detect through a camera.
2) Addition of more yard personnel. costly.
This was too
3) Addition of process isolation valves only with railcar monitoring. This did not provide for shutoff of the railcar.
4) Automated valves for emergency shutoff of the process. The additional valves, 16 in all, were costly and the ball check valve provides a emergency shutoff in this clean service.
A
2
ABD00230097
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Design Basis
This design addresses DOT regulation 49 CFR 174.67(i)
concerning the unloading of hazardous waste.
The
regulation states that "throughout the entire period of
unloading ... the car must be attended by the unloader."
The %LEL sensors and the emergency shutoff valves will
provide "attended" immediate shutoff in case of an
unloading malfunction.
Process Description
When a railcar is being prepared for unloading the new emergency shutoff valves, HV-101 and HV-102 will be added to the vapor and liquid railcar valves by the operator. The unloading hose will be hammer locked on the shutoff valves and the manual valves, both process and railcar, opened. The quick connect air connection will be hooked up. When the manual air valve is opened the railcar and process^ emergency shutoff valves, HV101, HV-102, and HV-122 will open.
In an emergency, the railcar will be isolated by HV-101 and HV-102. The process will be isolated with HV-122 on the vapor line and the new ball check valve on the liquid line. Check valves could not be added to the vapor line because flow must travel in both directions.
The spare liquid lines will require ball check valves to comply in the case of an excess flow valve checking and the railcar being unloaded through the spare liquid line.
To disconnect the railcar the emergency shutoff valves are closed by closing the manual valve in the air line to the valves and disconnecting the quick connect. The railcar is valved off and the emergency shutoff valves removed(*)
(*) Typical for each of eight unloading stations
3
A
ABD00230098
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Two additional sensors, AT-113 and AT-114, will satisfy the non-human monitoring part of the "attended" definition. The sensors will be located in the two gaps in the circle of %LEL sensors around the VCM railcar unloading stations.(See Drawing No.l.) These sensors will signal the %LEL monitor, AI-127. The monitor will be tied into the existing %LEL alarms in the control room.
Two of the four fixed point monitors at the unloading site will be modified to be monitored from a different GC. Currently if one GC is out of service all the fixed point monitors at the unloading stations would be out of service. By moving two points to another GC, two GCs will service the unloading stations instead of one. (See Drawing No.l.)
The emergency shutoff valves for both the railcar and process will be tied in to the VCM sphere emergency isolation switch, HS-103, the 20% LEL VCM storage alarm, XAH-601, the VCM unloading deluge system, CV-9901, and PSL-101, the low pressure switch on the air line. If any of the four are activated the emergency shutoff valves will close. HS-101 will allow the system bleed valve, SOV-101 to be de-activated while maintenance is performed on the interlocking systems.
Impact Statements
This project will greatly reduce the possibility of a massive VCM release by providing emergency shutoff valves at the railcar and to the process. By providing immediate remote shutoff valves the probability of VCM exposure to the operators in an emergency situation is reduced.
A
4
ABD00230099
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Instrument List
AI-127
%LEL Gas Monitor
AT-113
Gas Monitor Sensor
AT-114
Gas Monitor Sensor
HS-101
S0V-101 Isolation Switch
HV-101 HV-102 HV-103 HV-104 HV-105 HV--106 HV-107 HV-108 HV-109 HV-110 HV-111 HV-112 HV-113 HV-114 HV-115 HV-116
2" VCM Railcar Liquid Emergency Shutoff Valve 2M VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve 2" VCM Railcar Liquid Emergency Shutoff Valve 2" VCM Railcar Vapor Emergency Shutoff Valve
5
ABD00230100
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
HV-122 HV-124 HV-126 HV--128 HV-130 HV-132 HV-134 HV-136
PAL-101
PSL-101
SOV-101
1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve 1 1/2" VCM Process Liquid Emergency Shutoff Valve
Low Pressure Alarm Activated by PSL-101
Low Pressure Switch on Air to Emergency Valves
Solenoid for Air Bleed on System
A
6
ABD00230101
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ABD00230108
TYPE N560 EMERGENCY SHUTOFF VALVES
the body, preventing wear or damage when connect ing or disconnecting. A 1/4" FNPT opening in the hex portion can be used to install a bleed valve.
Type N560-26
Series N560 Snappy Joe ESVs are designed expressly for attachment to the shutoff valves on railroad tank cars, see installation drawing. Usually three N560s will be used, two on the liquid lines and one on the vapor line. NFPA 58 regulations call for ESV protec tion on both sides of the transfer hose or piping.
While conventional ESVs intended for bulkhead in stallations could be used on tank car service, they are generally unsatisfactory for this application, being too bulky and cumbersome for easy Handling on top of a tank car.
The N560 series is pneumatically opened and closed at the valve by means of a standard quick-disconnect coupling (furnished with the valve). Depending upon pressure in the tank car, approximately 20 to 45 psig is needed to open the valve. Remote closure from one or more points, such as the unloading riser and another remote location, is ac complished by exhausting pressure from the N560's piston chamber with a pneumatic control valve.
No External Moving Parts -- All moving parts are inside the N560 series to help minimize damage from rough handling. Should the quick-disconnect nipple be damaged, replacements are widely available through air supply outlets.
Hardened Threads -- The 2" MNPT threads on the nipple portion of N560s are of hardened stainless steel which holds up against repeated connection and disconnection to the shutoff valves on the tank car.
Excess Flow Valve -- Poppet design is similar to Fisher's internal valve series, making possible the incorporation on an excess flow spring. The spring has a closing flow of 200 gpm (other closing flows available on special order).
Fuse Plug -- Thermal protection is furnished by a steel cased fuse plug which melts if exposed to 212 F. When the plug melts, pressure can escape from the piston chamber, closing the valve.
Dual Service -- Since the body and internal parts are of either stainless steel or plated steel, the N560 series can be used on NH3 service as well as propane gas.
FEATURES
Light Weight -- N560 ESVs weigh only about 14 pounds, making them easy to handle at an unloading riser. In addi tion, the valve is shaped like an elon gated pipe fitting to facilitate connec tion to the tank car shutoff valves.
Different Nipple Lengths -- Type N560 comes with a long nipple (5.15") to allow the valve to be connected through various size tank car dome openings. The N561 has a shorter nipple (1.30") for use where the tank car dome opening does not present a connection problem.
Wrenching Hex -- To further ease at tachment, a wrenching hex is built-in to
Installation schematic of N560 and related equipment on unloading riser
ORDERING INFORMATION
TYPE NUMBER
NIPPLE LENGTH
SHUTOFF VALVE
CONNECTION
HOSE CONNECTION
N560-26 N 561-26
5.15" 1.30"
2" MNPT 3'A" M. Acme
4 14
ABD00230109
TYPE N560 EMERGENCY SHUTOFF VALVES
HARDENED STAINLESS STEEL
PIPE THREADS
EXCESS FLOW SPRING
A
QUICK DISCONNECT
NIPPLE
EXTENDED NIPPLE (N560 Only)
PILOT VALVE
SEAT DISC PISTON
FUSE PLUG
.WRENCHING HEX
PNEUMATIC CLOSURE ACCESSORIES
Pneumatic controls and fittings are needed to re motely close the N560 series and the N550/P327A (page 2 and 3). Fisher does not manufacture these items, and a handling and stocking charge would have to be added if they were offered. Since these accessories are readily available from a number of sources, it was felt that the end user could obtain the equipment himself, thus saving money.
A listing of pneumatic accessories that appear to be suitable follows. Fisher has not extensively tested any of this equipment and cannot guarantee these com ponents will function satisfactorily under all condi tions.
Model #18002-112-0102 -- Mac Valves, Wixom, Michigan
1/4 " NPT connections. This is a 4-way valve, but port number 2 could be plugged. Largest of the three valves.
Model #382-0602 Air Pal -- Airmatic/ Beckett-Harcum, Wilmington, Ohio
1/4" NPT connections. O-ring seats and no spe cial dirt seals.
FITTINGS
Available in 1/8" and 1/4" NPT sizes, tees and elbows are needed to connect tubing to the control valves.
CONTROL VALVES
The push-to-close button type (using the palm of your hand) of pneumatic control valve appears to make the best choice as a remote closure valve. It is usually easy to see if the valve is open or closed, and it's also easy to close the valve quickly in an emergency situation. All valves are the three-way type unless noted.
Model #01DPBA3-R -- Numatics, Inc., Highland, Michigan
1/4" NPT connections. Compact and reasonably priced, seems to have good weatherproofing. Lapped metal seats (not affected by contamin ants).
Model #PC52A -- Mead, Chicago, Illinois
1/8" NPT connections. Very compact, but not too well sealed against dirt. NOTE: Do not use Model #PC52 because it is spring returned.
Imperial Eastman--"Poly-Flo" fittings in brass or plastic, compression type connector.
Legris, Inc., Rochester, N.Y. -- LF3000 fittings with wide range of push-in tubing connectors.
TUBING
Plastic tubing (1/4" size) is the easiest to install and is widely available. Black tubing is more resistant to sun light.
Type 44P "Poly-Flo Black" -- Black poly ethylene tubing that is flexible and has a low melting point. Type 44-NF "Nylo-Seal Black" -- Black nylon tubing, stiffer than "Poly-Flo" and more chemi cally resistant with high melting point.
Both of the above are manufactured by Imperial Eastman.
is 5
ABD00230110
INCOItQIAtlD
3094 CONNAHBROOK . MEMPHIS, TENNESSEE 38110
FACSIMILE MESSAGE FORM
FACSIMILE MACHINE NUMBER 901-346-1790 NUMBER OF PAGES ( INCLUDING THIS PAGE) FACSIMILE NUMBER OF RECEIVING MACHINE
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ACKNOWLEDGMENT REQUIRED BY RE0ARDsf:^Q^S^Oa^J
SQUIBB-TAYLOR INC. FAX NO. 901-346-1790
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STRICTLY CONFIDENTIAL
ABD00230111
DOT UNLOADING REGULATIONS COMPLIANCE PROJECT Aberdeen Plant
November 7, 1990
Work List
1. Install additional LEL monitor AI-127 in Old Module old control room.
2. Install additional sensors AT-113 and AT-114. 3. Tie AI-127 outputs to the existing %LEL alarms in
the control room. 4. Install SOV-101 and PSL-101 in the air supply line. 5. Use existing spare alarm for PAL-101 in control
room. 6. Install process emergency shutoff and ball check
valves, HV-122 and others. 7. Prepare railcar emergency shutoff valves HV-101 and
HV-102 by added nipples and fittings for railcar usage. 8. Install storage baskets on the unloading booms for railcar emergency shutoff valves. 9. Add quick connects and flex hose on the booms to the railcar emergency shutoff valves. 10. Tie-in the SOV-101 to HS-101, HS-103, CV-9901, and XAH-601. 11. Rotate fixed point monitors such that two are on one GC and the other two are on another.
Drawing List
Drawing No. 1 Drawing No. 2
Additional VCM LEL Monitors PI and D Diagram - DOT Unloading
A
17
ABD00230112
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