Document 4GwrMMeZYQwNgKzYgKb6XKXV
1
iI AUDIT FORM
DATE 5April 5. 1991 SYSTEM BEING AUDITED: Batch Water Strippers AUDIT MO. :______________________________________ AUDITORS I Lee Childers, Steve Wilkes, Debbie Johnson
Go tslk to s&fsty to see wh&t ids&s thsy h&ve About the system and what things you should look for in your audit.
Find existing documentation about the system:
Found (
Not Not Found
A Process Flow Diagram X (file 2.53.0)
B P & I Diagrams Class "A" Design
X (and PCD) ** PT- 3&S-^2'1 " D
CMS -
- (- bj
X (file 2.53.0)
D. Operating Procedures X
E. Maintenance Procedures
Mechanical Design & Construction Files
X (drafting room)
Plant Location Lists
X
Plot Plans
X (file 2.53.0)
EPA Rules
X
OSHA Rules
X
Vista Standards
X (part of procedures)
Previous Audits
X
VAB.0001128877
Interview three people separately who
familiar with the
system you're auditing. Learn from them how the system works
and their concerns about the system.
Interviewed Darnell Perry (O.M. Lead Operator), Rodger Collins (Vinyl Shift Supervisor), and Lee Childers (O.M. Lead Operator)
There was general concensus that the system was operated In a safe manner, but there were a few concerns that dealt mainly with performance. These are listed In the Brainstorm section (#6).
Is it operated as the operating procedures (design, etc.) say it is supposed to be operated? If no, what's different?
No. Changes In operation are indicated on the attached operating procedures.
Is it used per the appropriate OSHA, EPA, or Vista Standards? Yes/No
YES
VAB.0001128878
6. Brainstorm possible problems with the system. Attach the brainstorm list.
1. Insulate all hot lines for personnel protection 2. Leaky valves (steam and VCM-containing lines) 3. Wasting steam by feeding it to the stripper in two places during
dump 4. Cannot dump in "DUMP" mode (which is automatic) - -have to dump in
manual mode because pressure setpoint is not adjusted correctly. This is especially a problem on the south stripper. If the BWS is allowed to empty completely and VCM is fed to the hot stripper, the VCM may flash in the tank. In the "DUMP" mode, the stripper level is interlocked with the dump valve so that the dump valve closes at 10-12% liquid level, so to prevent flashing.
7. Do any of the problems identified in your brainstorming list make it unsafe?
Yes. Uninsulated lines can cause burns. VCM can flash in a hot, empty stripper.
VAB.0001128879
.8 What needs to be done as follow-up to this audit? What changes need to be made?
1. Hake sure that hot lines are insulated, particularly the sample
lines - w.o. written.
2. Evaluate the following items to see if changes should be made:
a. replacing leaky valves, especially steam valves, during shutdown;
b. increasing hold time to 1 hour from 30 minutes; c. installing auto block valves on both sides of the 3-way inlet
valve, to prevent VCM from going into a stripper while the other stripper is filling. Make necessary system changes so that strippers can be dumped in automatic (i.e. "DUMP" mode) instead of manual. The dump valve on the stripper is interlocked with the BWS pressure. The pressure setpoint is so low that the dump valve will close during the dump. In addition, if the operator forgets to stop the dump at 10% (of liquid level in the stripper), the BWS will empty completely. When he begins to fill the hot, empty stripper VCM may flash in the tank.
9. When should this be audited again? Why?
In one year (after VCSM has been running for a while), to see if the safety items have been done.
VAB.0001128880
PROPOSED 12/24/75 PROMULGATED 10/20/76
PLANT OPERATED UNDER A WAIVER OF COMPLIANCE UNTIL SYSTEMS COULD
8E INSTALLED TO MEET THE SITANOARD 9/1/78.
- STRIP SLURRY T0^, 400 PiPM VCM
- REACTOR OPENING LOSS 4 20 PPM VCM
- NO MANUAL VENTING OF VCM
- NO RELIEF VALVE DISCHARGES OF VCM
- MINIMIZE FUGITIVE VCM EMISSIONS
0 RAILCAR UNLOADING LINES
0 DOUBLE MECHANICAL SEAL ON ROTATING PUMPS AND COMPRESSORS ANO
AGITATORS
0 REDUCE VCM IN EQUIPMENT BEFORE OPENING TO ATMOSPHERE 0 SAMPLES
0 REQUIRED LEAK DETECTION ANO ELIMINATION PLAN
CONTINUOUS MONITORS
PORTABLE MONITORS
0 IN-PROCESS WASTEWATER STRIPPED TO LESS THAN 0 EXHAUST GASES REDUCED TO ^10 PPM VCM
EMISSION TESTS
VCM
EMISSION MONITORING OF INCINERATOR OFFGAS
REPORTING
RECORDKEEPING
VAB.0001128881
OPERATING MANUAL BATCH WATER STRIPPERS ABERDEEN CHEMICAL PLANT
JUNE Vfr. 1981
Work By:
D, C,
D. Chris Wing ^
Process Engineer
j
Reviewed By:
Veldon E. Messick Senior Process Engineer
Approved By:
\*cl
R. A. Frohreich Chief Process Engineer
#
VAB.0001128882
OPERATING MANUAL BAWATER STRIPPERS ABERDEEN CH^icAL PLANT
TABLE OF CONTENTS
1. 1NTRODUCT1 ON
11. PROCESS DESCRIPTION
III. OPERATING PROCEDURES
IV. INTERLOCKS AND ALARMS
V. EQUIPMENT INDEX
VI. INSTRUMENT INDEX
VI 1. DRAWINGS
A. INSTRUMENT LAYOUT B. ANNUNCIATOR LAYOUT C. PUSH BUTTON LAYOUT D. P6 I DIAGRAMS
1. BATCH WATER STRIPPING - OLD MODULE 2. BATCH WATER STRIPPING - NEW MODULE
HHW mmmmm
mm
mup
mm
mm
VAB. OOO1128883
MANUAL CAL PLANT
A
. INTRODUCTION
The purpose of this system is to safely and practically treat the plant's process wastewater prior to draining it to the sewer The EPA standard requires that before any wastewater stream con
vert) be released to the
aooppb
. Several wastewater streams throughout the plant are contain In^ted with VCM and require treatment
reduces the VCM concentrat ion by jsteam is then rffumpSh to thefsewed and flows
wastewater st he wastewater
bducXftus W Pi Ifars
Cooh\A
p^r^ed. +1rxra&j^OK<L of C- La-5 Vrv ffc
*
VAB.0001128884
OPERATING MANUAL
BAT
shippers
LANT
II. PROCESS DESCRIPTION
This system serves as a central collection point for all of the contaminated wastewater streams, which include water drains from the V-l l receivers, water from the emfssion recovery system, water from the CRD area, and water from the|contaminated drains. The streams from the V-lt area are routed|directly to one of two parallel stripping tanks, 1*5-801 or 45-302. The wastewater from the CRD area is collected In the existing blowdowtrdrum, 45-746, and pumped to 45-801 or 45-802 to be stripped.
Each new tank is used as both a collector and a stripper. While one tank serves* as a collection vessej, the other is being stripped with steam. These vessels will alternate duties to provide continuous wastewater collecting.
n
The batch water strippers are controlled by a process computer (the Mod icon) which provides interlocks and valve sequencing.
There are three modes of operation, (1) Fill (2) strip and (3) dump.
When one tank is in the fill mode the other tank is either in the strip or dump mode. When one tank, say 45-801, is ready to be stripped, the panel operator routes thje process water to the other stripping tank, 45-802, by placing thalt tank in the fill mode. This is done from the control room by pressing the "mode adv" button until the "fill" light for 45-802 is on and pressing the "open button" for
the inlet control valves for 45-802, CV-952 and CV-962. These inlet
valves on 45-802 are interlocked with the inlet valves to 45-801 so
that when CV-952 and CV-962 open, CV-951 and CV-96I close. 45-801
is now ready for stripping. The panel operator presses the "mode adv" button until 45-801 is in the "strip" mode. The 45-801 recovery
valves, CV-953 and CV-965 and the stripping steam inlet valve, CV-959,
automatically open while the VCM bleed valve, CV-955, automatically closes. Steam is then injected into 45--801 at 5,500 pounds per hour.
Vapors from 45-801 are routed to the emission recovery system. The pressure in 45--801 and the suction of the emission recovery compressors soon equalize at 9 psia which corresponds to a stripping temperature of 190 F. When the temperature of 45-801 reaches tL90bFX a timer attached
totthe temperature controller TR-95I is activated Thirty minutes later,
the timer will activate an alarm on thb board, close vapor recovery valves, CV-953 and 965, and open CV-963, the pressurizing steam valve.
Once the pressure of 45-801 reaches 6 psig, the operator will place
45-801 into the "dump" mode and open the water outlet valve, CV-957.
VAB.0001128885
I
OPERATING MANUAL
At
II. PROCESS DESCRIPTION (Cont.)
CV-957 will close when the liquid level in 45-801 drops below LSL-951, the low level switch. This switch will also close the stripping and pressurizing steam valves, CV-959 apd CV-963, and open the pressure
bleed and vapor outlet valves, CV-9*j5 and CV-965. Tank 45-801 will
then automatically advance into the i"fII1" mode. This completes one cycle and 45-801 is now prepared to col 1act blowdown water.
*
During the collecting process, the stripping tank pressure is maintained at 2 psig. PIC-953 vents vapors from the stripping tank to the emission recovery system if the tank pressures exceeds 2 psig.
In the new module the dxisting blowdpwn tank, 45-746 is used to store collected liquids. The water is reciirculated through 45-746 by the transfer pump, 72-974, or its spare 72-979. When the liquid level in
45-746 reaches the high level switchj, LSH-740, CV-968 on the recirculation
line will close and CV-967 on the transfer line to the batch water strippers will open. At a ,1ow liquid level, C|f-967 will close and CV-968 will open allowing recirculation. The controls for the transfer pumps are located in the new module recovery section in the vinyl control room.
*
VAB.0001128886
OPERA! MANUAL
OPERATING PROCEDURES
Automatic Operation
Determine If the batch water tank being filled is ready
-
to be stripped* A tank Is ready to^J^stripped if the level ^
in the tank is 6*-feet or higher, (worscairon the panel
mounted level indicators). Thje level of the tank may be deter
mined by checking the level indicators on the main control panel
or looking at the liquid level sight glass mounted on each tank.
A high level alarm (LAH-953 fojr 45-801 or LAH-954 for 45-802)
sounds at a liquid level of 7-ifeet, 2-inches (80S of scale on
panel mounted level Indicators!).
B. If the tank being filled is ready to be stripped, the other
batch water tank must be ready; to receive the water from the
collecting headers. The tank jls ready to receive the water if
it is in the "fill" mode (noted by the "fill" light being lighted). If the tank is in the "fill1* mode, the vapor outlet and pressure
bleed valves (CV-965 and CV-955 for 45-801 or CV-966 and CV-956
for 45-802) will be open.
C. Place the tank that is ready to be filled into the fill position
by opening either CV-951 and CV-96I for 45-801 or CV-952 and
CV-962 for 45-802. This will automatically close the corresponding set of valves on the ready to be stripped tank and 1ine up the
three-way valves, CV-969, such that VCM from the double block and
bleed on the VCM charge headers is draining to the tank being filled.
NOTE:
When both tanks are in the fill mode, the inlet valves
to both strippers can be closed. The operator must be sure that this never happens by opening the valves on tbe tank to be filled instead of closing valves on the tank to be stripped.
D. Place the ready to be stripped tank into the "strip** mode by
pressing the mode advance button for that tank until the "strip" light is on. This will automatically:
1. Close the pressure bleed valve (either CV-955 for 45-801 or CV-956 for 45-802).
' 2. Open the vapor outlet valves (CV-953 and CV-965 for 45-801 or CV-954 and CV-966 for 45-802).
3. Open the stripping steam valve (either CV-959 for 45-801 or
CV-96O for 45-802).
VAB.0001128887
OPERATING MANUAL
BATCH
STRIPPERS
PLANT
III. OPERATING PROCEDURES (Cont.)
Automatic Operation
After the temperature of the tank reaches or exceedsu90oFJ a timer in the Mod Icon starts. When 30 minutes have elapsed:
1. The ready to dump alarm, TAH-951/952, is activated.
2. The recovery valves are closed.
3. The pressurizing steam valve (CV-963 for 45-801 or CV-964 for 45*802) is opened.
E. When the tank pressure reaches 6 psig, as read on panel pressure indicators, PI*951 or PI*952, the mode advance button should be pressed to advance into the "dump11 mode and the water outlet valve (CV-957 for 45*801 or CV-958 for 45-802) should be opened.
The level in the tank drops until the level reaches the set point for the low level switch (LSL-951 for 45-801 or LSL-952 for 45*802). This is approximate \2% on the level indicator.
The low level switch on the tank does the following at low level.
1. Closes the water outlet valve.
2. Closes the stripping steam valve.
3. Closes the- pressurizing steam valve.
4. Opens the pressure bleed valve.
t
5. Opens the vapor outlet valve.
6. Advances the tank into the "fill'1 mode.
This completes a cycle for the batch water strippers. The operator will then wait until the other tank is ready to be stripped and start the sequence again.
Manual Operation
Ih automatic operation one of the indicators (fill, strip, dump) will be lighted. In manual operation the mode indicators will be off and the manual push button/light will be illuminated. Switching from automatic to manual mode will cause al1 valves to go to their fail safe positions and all interlocks and Mod icon control will be bypassed. The transfer of water from 45*746 ih the new reactor module to the batch water strippers is unaffected by a mode switch since there is a separate local manual take-over swtich for the new module.
VAB.0001128888
mitrnmimmwim
4*
MANUAL PPING
III. OPERATING PROCEDURES (Cont.)
Manual Operation
To operate
In
the manual
m._ode v#
r - --ww
,,,,,,
raw
iriU f
U
mode
. __ _ --^
indicator
^ jI
lights
will
----
go
out
and....t.h..e......'.'m...a..n..*w1 ill
A11 of the go on The
upcrator can tnen manua 11y operate the valves from the control boa
Follow the sequence as described in the automatic operation secti
the major---------------^------------ d- i.f.fe. wre. nce being i l%J that the panel operator must open and
close each valve. When CV-969, will automat
in
the manual mode, line up to drain
the three-way valve, to the south tank,
45*801. To fill the north tank this valve must 45-802 by operating the switch on the board.
be
I ined
up with
Power /raa1: |lure
Mod power so' operation of the batch
V,VCS 9no?'a De unaffec*ed by power failure. Upon
1s
.P^ssure to the control valves, all will fail in the posit ion.
)
1 .................. ..
VAB.0001128889
A
IV. INTERLOCKS AND ALARMS
The following interlocks are provided for on-off control valves to prevent discharging VCH contaminated water to the sewer. The interlocks are maintained by a process computer, the Hod icon 584. The interlocks are bypassed when the mode selection is off. Items in parenthesis correspond with 45*802 operations. 1. 45-801 (45*802) water inlet valves; CV-951 and CV-961
(CV-952 and CV-962) can be opened only in the "fill" mode. Both tanks may be in the "fill*1 mope simultaneously but only one set of inlet valves may be open as stated in item 2. 2. Opening the 45*801 (45*802) water inlet valves CV-951 and CV-961 (CV-952 and CV-962), automat leally; closes the 45*802 (45*801) water inlet valves, CV-952 and CV-962 (CV-951 and CV-961). 3. In the "dump" mode 45*801 (45*802), the water inlet valves, CV-951 and CV-961 (CV-952 and CV-9|62); the vapor outlet valves,
CV-953 (tv-954) and CV-965 (CV-966); and the pressure bleed
valve, CV-955 (CV-956) are all closed automatically and locked out of manual operation. 4. In the "strip" mode, advancement of mode cannot be made until the 30 minute timer in the Hod icon has timed out. See Operating Procedures, item D.
Alarms
Below are listed alarms and possible conditions that could cause these alarms.
LAH-953/954 - High water level in batch water tank (7 feet, 2 inches) 45*801/802
1. Indicates that batch water tank is full and ready to be placed in "strip " mode.
LAL-955/956 - Low water level in batch water tank ( i feet) 45-801/802
1. Indicates that batch water tank has low level.
LAH-957 - High water level in new module collection tank, 45*746
1. Indicates that 45*746 is full. Possible malfunction in level switch of control valves.
m mm*
mmmrnmmmmmmmmmmmmmmmfmm#
VAB.0001128890
mm
mm
##*** t
i
INTERLOCKS AMD ALARMS (Cont.)
Alarms (cont.)
*
pah-951/952 - High Pressure In batch water tanks (40 psig)
1. Bleed - back pressure controller (PIC-953) could be malfunctioning.
2. Steam blowdown pressure regulator failure (PIC-954).
3: Vapor outlet valves (CV-965/953 or CV-966/951*) closed durinq
"stripping".
3
'** bleed valves (CV-965/955 or CV-966/956) closed during
"fill".
PAL-951/952 - Low pressure (below 2 psig) in batch water tanks.
*
1. Water outlet valve (CV-957 or CV-958) open when tank is empty
of liquid.
r
AA-951/952 - Control valves operated out of sequence.
1. Mod I con problems 2. Bad solenoid on a control valve.
1
VAB.0001128891
A
EQUIPMENT INDEX A. Tanks
1. Blowdown drum - 45-801 - 45-802 a. Purpose
Vessel to collect and recover various VCM containing vapor vents and waste waters.
b. Description
Horizontal - mounted, 26 foot 0 inch straight wall, 10 foot 0 inch I.D., carbon steel construction.
c. Norma 1 ~
~ ....
Ambient temperature to 190^F and pressures from 10 inches Hg vacuum to 10 psig.
d. ~ ' -------
350F and full vacuum to 150 psig. B. Filters
1. Suction Strainers FD-951. FD-951S a. Purpose
Strainer to remove PVC particles from the 45-746 liquid outlet to the transfer pump.
b. Descript ion
Four inch Andale type 105 simplex strainer with 3/8 inch perforated stainless steel basket and carbon steel body.
c. Normal Operating Conditions
i
0 psig and 130F at 75 GPM.
d. Design Conditions
150 psig
VAB.0001128892
OPERATING MANUAL
BATCH
PP1NG
PLANT
V. EQUIPMENT INDEX (Cont.) 6. EIters (cont.) 2. Flush Water Filters a. Purpose
To remove dirt and scale from the seal flush filters b. Descript Ion
Filterite high pressure filter, 3/** 3A HP, cartridge type, particle si
with a polypropylene filter element core.
inch, model LM010Sretention ten microns
with a stainless steel
Norma 1 rat Conditions 220 psig at 100F
d Design Conditions
500 psig and ambient temp C.
1. Transfer Pump 72-97**, 72-979 a. Purpose
lowdown water strippers,
b. Description
batch
Centrifugal type, Gould's model 3196, 1 x 1 50-8
.0 HP, 3500 RPH. impel ler is 6.25 Inches
c* Normal Operati Condit ions Rated for 75 GPM at 173 feet of differential head
i
VAB.0001128893
OPERATING MANUAL BATCH WATER ^TRIPPERS
CAL PLANT
VI. INSTRUMENT INDEX Flow Instruments
Tag No.
Service
FIC-951
Stripping steam
FI-956
Seal Flush
FI-957
Seal Flush
Pressure 1nstruments
Tag No.
Service
PI-951
45-801
PI-952
45-802
PIC-953 PIC-954
45-801/802 Vapor Exit
45-801/802 Steam
Level Instruments
Li-951
45-801 Level
LI-952
i
45-802 Level
TYPe
Setpoint
Foxboro Spec-200 Indicating controller
Brooks 3604c Rctameters Normal 0.25 GPM (Loca1)
Brook 36o4C Rotameters (Loca1)
Normal 0.25 GPh
type
Setpoint
Foxboro Spec 200 Pressure Indicator
Foxboro Spec 200 Pressure Indicator
Foxboro 43AP-FA47C (Loca 1) 2 psig
Foxboro Spec 200 Steam Control
Foxboro Spec 200/dp Cell Foxboro Spec 200/dp cell
VAB.0001128894
OPERATING ANUA L BATCH WATER TRIPPER ABERDEEN CHEMICAL PLANT
VI. INSTRUMENT INDEX (Cont.)
Temperature Instruments
Tag No.
Service
TR-951
45-801 Temperature
TR-952
45-802 Temperature
Type
Setpoint
Foxboro Spec 200 Temperature
190F
Foxboro Spec 200
Temperature Indicator With Alarm
190F
TR-95I and TR-952 to be connected to a timer and a switch to control (on/off) stripper outlet control valve CV-953 (or CV-954).
VAB.0001128895
OPERATING MANUAL BATCH WATER STRIPPERS ABERDEEN CHEMICAL PLANT
VII. DRAWINGS
A. INSTRUMENT LAYOUT
B. ANNUNCIATOR LAYOUT
C. PUSHBUTTON LAYOUT
D. P I DIAGRAMS 1. Batch Water Stripping Old Module 2. Batch Water Stripping New Module
*
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m Winl|rtJ*l|d*fc
VAB.0001128896
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VAI/S OUT
OP OR OER
LAH-955 SOUTH WATER
STPtPPER HfGH L
LAH - "5"*? SJORTh WATER
S TR/PPER H/fiH L E\tl
LAl'SSS SOUTH WATER
STRIPPER.
LOW LEVEL
LAH - 9~6 ;JCR TH 7/A TER
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; Y CKD APO
CONOCO CHEMICALS
ABERDEEN
MISSISSIPPI
annunciator LAYOUT
OPERATl NG MANUAL
BATCH WATER STRIPPERS
SCALE
appo:
oate:
No
1128897
ISU DATE ________DCSCSIFTION
Ss^A
u|
BY CKD ! APD
VAB.0001128898
i_ OC AT 0 iM
CLOUOEO A
OH iKSTRU^eMT LAYOUT ORA>*JlW6,
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mmm
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?
The function of the batch water strippers is to remove VCM residu
als from process wastewater before the water la released to the
wastewater treatment ponds* This Is completed by Injecting steam
through spargers located In the strippers, while pulling a vacuum
on the tanks with the emission recovery system* A thirty minute
timer is actIvatM^ when the {water in the stripper reaches the set
temperature oi 215F. This {temperature has to be maintained during
the 30 minute held period jor the batch will not be able to be
An alam sounds when the batch has been held for thirty
minutes above the set temperature. During this thirty minute
interval pressure
are critical* If vacuum la loet on
the the performance of the strippers la
A batch stripped when this occurs may or
may not be tith
level j of 10 ppm required by KM regulation. of tjha temperature/pressure recorder, the
operator now what jthp pressure and temperature did during
the It something unusual happens and vacuum Is
loet on the
the, operator can restrlp the batch and
prevent a violation of EPA regulations.
The normal temperature andj pressure operating ranges are listed below:
Mode Fill Strip
Dump
T--r.ture 100o-150F 215 F Set Temp*
215F
Pressure
Slight Vacuum (0-51n Hg) Vacuum During Entire 30 min* Hold Period (0-10in Hg) Slight Pressure (0-5psi)
VAB.0001128900
BATCH WATER STRIPPERS STRIPPING REPORT
Batch No.: Date:
4
North or South S tripper: Shif t:__________________________
Comment*
Time: Operator:
VAB.0001128901
fMf rnmmmmm
VAB. mo1128902
VAB.0001128903
BATCH WATER STRIPPING
BATCH WATER STRIPPING