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4 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT MARCH 8, 1985 Work By: Frank 6. Jeanaon Process Engineer Reviewed By: i Vernon L. Thornhill Senior Process Engineer 0 Approved By: R. A, Frohreich Chief Process Engineer VAB.0001106584 ft V VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT Table of Contents I. Purpose of Design II. Process Description III. Equipment and Instrument Specifications IV. Process Piping Schedule V. Work List VI. P&I Diagram A t VAB.0001106585 VCM GAS MONITORING SYSTEM RAILCAR UNLOADING AREA ABERDEEN CHEMICAL PLANT I. Purpose of Design The purpose of this design is to provide the VCM railcar unloading area with an additional gas monitoring system to detect serious VCM releases. Presently, there are six fixed point monitor locations that are tied into one of the plant's Honeywell GC's. These monitor locations are listed below: 1. Sphere (grade level). 2. Compressor shed (grade level). 3. Between railcar unloading stations number 1 and 6 (Top of railcar level). 4. Between railcar unloading stations number 2 and 7 (Top of railcar level). 5. Between railcar unloading stations number 3 and 8 (Top of railcar level) 6. Between railcar unloading stations number 4 and 9 (Top of railcar level). These existing monitors do not provide immediate response and are not distributed throughout the entire VCM tank farm area. Also, since this area is not monitored by plant personnel the majority of the time and since it has the potential for a serious release, additional protec tion is needed. In addition to the gas monitoring system, this design will provide a pressurization blower for the fire pump houses near the VCM tank farm. The purpose of this blower is to prevent VCM from entering the build ings in the event of a serious VCM leak. This design will also provide for Item 84-6 of the Underwriter's In surance Company recommendations. This item recommended Installing vapor detectors for the sphere's VCM transfer pumps to the old and new module. A mW VAB.0001106586 A VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT Process Description * This design will provide for the Installation of ten VCM gas sen sors , AT-101 through AT-110, in the VCM tank farm area (see P&I dia gram for locations). These sensors will be tied into dual channel combustible gas monitors, AI-121 through 125. Each monitor will accept signals from two sensors and display the higher of the two readings. The monitors will Indicate the percent of the lower ex plosive limit (LEL) of VCM gas in the air. The monitors will be tied into alarms in the vinyl control room. The first alarm will be set at 25% LEL and the second alarm will be set at 45% LEL. Should any of the monitors Indicate a low level (25% LEL) of VCM gas in the air, the panel operator will notify the yard operator of the situation. If the monitors indicate a high level (45% LEL) of VCM gas in the air, the panel operator will then notify the yard operator to shut down any transfer or unloading equipment that is being used. When this equipment is off, the panel operator will isolate the sphere by pushing the sphere control valve override switch. This switch will close the following valves: (1) The valve on the vapor line to/from the compressors. (2) The valve on the liquid line from the compressors. (3) The valve on the liquid line to the VCM transfer pumps. (4) The valve on the liquid recirculation line from the VCM transfer pumps. The monitors will be equipped with relay connections to tie into the existing sphere isolation control valve override switch. However, the relay connection will not be tied into this switch until the REMOTE OPERATING VALVES project is installed. When this project is installed, additional equipment and valves will be shut off by the sphere isolation control valve override switch. This includes: (1) The valve on the liquid return line from the VCM vapor line knockout pot. (2) The five VCM compressors in the VCM tank farm. (3) The two VCM transfer pumps. After Installation of this project, the relay connections from the gas monitors will be tred into the sphere control valve override switch. Should the monitors Indicate a high level (45% LEL) of VCM gas in the air, the sphere control valve override switch will automatically shut off all the valves ahd equipment mentioned above. When the isolation switch is used, it will override the motor con trols and shut down the units should they be in service. VAB.0001106587 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT II. Process Description - Continued In addition to the vapor monitors, a pressurization blower, F-150, will be installed for the fire pump houses. This blower will pro vide air to pressurize fire pump houses #1, #2, #3, and #4. Pressurizing the fire pump houses will prevent any VCM from entering the buildings in the event of a serious VCM leak. The blower's controls will be tied into the 25% LEL alarm in the con trol room so that when this alarm goes off, the blower starts. The blower was sized to maintain a 0.25 inch of water pressure in the buildings while providing enough air to the diesel engines for combustion. This blower will be equipped with an extended inlet stack to provide VCM free air in the event of a serious release. A * VAB.0001106588 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT hi. Equipment and Instrument Specifications Item No. Description AI-121 AI-122 AI-123 AI-124 AI-125 VCM transfer pumps gas monitor South unloading stations gas mointor Middle unloading stations gas monitor North unloading stations gas monitor Compressor shed gas monitor AT-101 AT-102 AT-103 AT-104 AT-105 AT-106 AT-107 AT-108 AT-109 AT-110 Gas sensor north of VCM transfer pumps Gas sensor east of actuated valves Gas sensor south of unloading stations Gas sensor between #1 and #6 unloading stations Gas sensor between #2 and #7 unloading stations Gas sensor between #3 and #8 unloading stations Gas sensor between #4 and #9 unloading stations Gas sensor north of unloading stations Gas sensor north of compressor shed Gas sensor north of VCM sphere F-150 Fire pump house pressurization blower HS-130 Handswltch for F-150 A VAB.0001106589 m A t __ La__ ii Od -g*>c r Po-ve & 3^ ^\Ol/V,^ _<5%,, 1 X A *>X gv^A ia /\ c ; ^ ref '* WH^*H --AB^90i4G^|90 J T ^v;: _ J.' -rrV r*sSL. vf v * -K S'< ' -a* t 1. * I- i 'X1* : ,* '-- 5 * f- MONITOM. INC 3037 ENTERPRISE STREET COSTA MESA, CALIFORNIA 02626 PHONE: 1714) 540-4896 TWX 678-372 TO: Mr. Frank Jenson Vista Polymers Box 91 Aberdeen, MS Your Reference: Verbal est of 30 January 1985. DESCRIPTION Date: 30 January 1985 GMI QUOTATION NO 6150 QUANTITY Please Reference GMI Quote No On All Correspondence. UNIT PRICE EXT. PRICE Model 580 System to include one Dual Channel 2 ea Sensor P/N 10001-1, 2 ea Sensor Housing P/M 10007 and 1 ea Instruction Manual Standard Belay Configuration. *Common Alarm 6 ea Alternate System Model 610 System to include one Four Channel Monitor, 4 ea Sensor P/M 10001-1, 4 ea Sensor Housing P/N 10007 and 1 ea Instruction Manual Standard Relay Configuration. ^Common alarm relays for all Four Channels. Common alarm set point adjustment. 3 ea Note alarm relays (Malfunction Low and High) for each. channel plus discrete alarm set point adjustment add $470.00 to unit price of item #1A. lb. Alternate System Model 4800 system to include one16 Channel Monitor, 1 ea Extender Card for Channel Card and one for relay card and one Instruction Manual. Blank Panels included at M/C for inactive channels. Each active channel to include one each channel control card. Belay $1,764.00 $10,584.00 $2,973.00 $ 8,919.00 Signature: Name/Title Sheet No. j Of P Sheet* Local Representative------------------------------------------------------------------------------------------------Phone ................ Address_________________ _ . ____________________________________________________________ VAD.0001106591 GMI /9-R4 A .> r-y-L --. *+ *1+ r- GENERAL MONITORS itow Description General Monitors' Model 580 is a compact, highly-versatile system for contin uously monitoring combustible gas concen trations in two locations. The system consists of two remote sensing assemblies and a solid-state controller For safety, reliability, and ease of calibration, sensor outputs are not summed. Each channel is completely independent and has its own constant current sensor drive circuit. Sensors are available to meet various service requirements for most gases. The Model 580 independently moni tors two locations. The controller automati cally displays the higher reading channel on an analog meter, scaled from 0-100% LEL (Lower Explosive Limit) Manual over ride switching permits readout of the low channel at any time. Low and high alarm set-points are common to both channels. Calibration of each channel is done inde pendently, and an alarm override switch disables the alarms during the calibration mode. A 45 second time delay also disables the alarms on start-up. Customers mav select from a wide variety of relay options, such as normally energized or de-energized high and low alarms, and latching or non-latching high and low alarms. The malfunction relay circuitry ts normally energized and monitors both channels. Features G Peak Picking" Circuitry Automatically displays highest reading channel G Compact Packaging Dimensions: 2"W x 7"H x11.5"D (51 mm W x178 mm H x 292 mm D) low Power Consumption Analog Meter Standard ndependent 3 AMP/117 VAC DPDT High and Low Alarm Relays 3 AMP/117 VAC SPDT Malfunction Alarm Relay Variety of Relay Options Normally energized or de-energized high and low alarm Latching or non-latching high and low alarm Remote Reset Superior Reliability Two week factory burn-in of system Single PC board Solid-state circuitry Proven catalytic sensor Malfunction alarm circuitry Positive contact field terminals Time delay Constant current supply to sensor CtXHUilWi US MMTM CHANNEL Safe, Easy Calibration Fully accessible calibration adjustments Alarm relays automatically disabled while in calibration mode Low Cable Costs 40 ohm loop resistance, e g. 3000 ft (910 meters) one way of #18 AWC cable 7600 ft. (2320 meters) one wav of #14 AWG cable G User Protection Two year warranty CSA approved Applications -- Protection from hazardous combustible gases in: Fuel Loading Facilities G Compressor Stations LNG Processing and Storage C Oil Well Logging G Sewage Plants G Gas Turbine Enclosures G Drilling and Production Platforms G Solvent Vapors Sensor Elements General Monitors' sensors are designed for reliable performance and long life Each sensor must undergo extensive burn-in and rigid quality control procedures before shipment The sensors consist of two catalytic bead elements in a balanced Wheatstone bridge circuit (See Principle of Operation). These low temperature catalytic bead sensing elements require minimal sensor excitation current, greatly increasing sensor life. Principle of Operation A catalytically treated ceramic active bead and a passivated ceramic reference bead form two legs of a Wheatstone bridge circuit. Combustible gases diffuse through a flame arrestor and oxidize on the catalytically treated active bead, causing an increase in its temperature and electrical resistance This results in an unbalancing of the Wheatstone bridge circuit The reference bead, inert to combustible gases, compen sates for ambient temperature, humidity and pressure changes The difference in resistance of the active and reference beads is converted into a sensor signal which is amplified in the controller, sent to the indicator and alarm circuits, and displaved on an analog meter The meter is scaled in percent of the Lower Explosive Limit (% LEL) In the Model 580 the two sensor inputs are continuously compared, the higher signal being displayed on the meter Two adjustable electronic alarm circuits may be field-set for any alarm level up to100% LEL The low alarm signal indicates potentially hazardous gas accumu lations at low concentrations, allowing time for corrective action. The high alarm signal indicates immediate danger A flashing malfunction LED will indicate low input power, sensor removal or damage, "CAL mode, severed cable or current failure Two LED channel indicators are provided to indicate the higher channel A variety of alarm relay options provides contacts for high, low and malfunction alarms to be wired to auxiliary lamps, horns, fans or shut-down equipment VAB ii I \ i 4tl &\o.'j<zr 1 Cs) P- ^ / mm Am gj > eA___ a .r/ n . _^p _ -j i /vV-o ? '-4 c l.ju e rere* i \ K<^\d WHIM - L_aJ_ / _ <J ^ _*_ l_O - v J k. \ Uji >-0^\ Ci i o '>1 t * ..1 , c* / ** VAB.000110 94 J IPf v SIZES 125 and 155--BELT DRIVEN MAXIMUM TEMPERATURE: 200F. fT ^ DIMENSIONS [INCHES] Six* WdlltaM. l araOaustlqa.t ft A B c DE F G H JK 125 121/4 .86 17 10 12% 13% 7% 13 103/8 27% 1% 3 155 15 ___L22_ 17 12 15% 16% 93/4 15% 123/4 30 1% 3 Siza R s TV 125 6% 155 7% 12% 12% 9% 8% 9% 1 8% 1 * Discharge dimensions * * . see page 5. w 10% 10% Y a* b* % 11% 16% % 1 14% j 193/4 e* 12% 153/4 d* 9% 11% Shaft 1 1 L 13% 163/4 M 9% 11% N 17 17 Kayway %X% %X% Bata holes ^16 $16 SIZE 125 Capacities based on air density of .075 lbs. per cu. ft. Maximum safe speed at 70F.: 1715 RPM i r 1 CFM SP '* SP SP *4 SP 1 SP llz SP 2 SP 2*/*" SP OV RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 10JI \m H75 m1200 120 09 498 12 638 20 29 MOO 464 13 535 .17 658 25 777 34 893 44 1600 509 19 575 23 688 31 793 41 896 51 1547 i;io 1891 1800 2000 2200 557 26 616 .30 723 39 818 49 910 .59 1094 84 608 34 660 39 760 .48 850 .59 934 70 1100 95 1262 1 23 653 44 706 49 801 .60 884 71 963 83 1116 1.08 1266 1 37 1412 1 68 2063 2235 ?4o; 25/9 2/61 2923 3095 2400 2600 2800 3000 32U0 3400 3600 711 7W 819 873 927 982 1038 56 72 88 1 07 1.29 1 54 1 82 752 801 852 903 954 1007 1060 61 76 93 t 12 1 34 1 59 1 87 842 884 928 972 1019 1066 1114 73 .88 1.05 1 26 1 48 1 73 2 01 922 961 1002 85 t 02 1 20 1044 1086 1130 1174 1 40 1.63 1.88 2 18 997 1032 1071 1109 1150 1192 1234 .98 114 1 33 L54 1.79 2.06 2.35 1137 1166 1197 I 23 1 42 1.62 1230 1267 1305 1343 1 85 2 10 2 39 2,70 1276 1293 1317 1 53 1 71 1.92 1345 1375 1409 1445 2.17 2.43 2.73 3.06 1413 1421 1436 l 85 204 2.25 1456 1482 1511 1542 2 50 2 78 3 09 3 43 NOTE Performance shown is for Junior Fans with outlet duct and with or without inlet duct. 0HP shown does not include belt drive loss, but does include bearing drag. r.------ ) Tinted capacities indicate BHP requirements which may exceed maximum motor limitations . . . see below. SIZE 155 Capacities based on air density of .075 lbs. per cu. ft. Maximum safe speed at 70F.: 1400 RPM CFM SP SP l2 SP V SP 1 SP l V* SP 2 SP 2Kz SP OV RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 1535 1791 2047 2303 ?559 2815 3071 ii?7 1583 3839 4095 4JM 460/ 1200 1400 1600 1800 2000 2200 2400 26U0 2800 3000 3200 3400 3600 342 13 401 380 .19 433 418 27 467 17 510 24 529 32 554 26 609 .33 619 44 637 36 .44 704 55 715 56 67 858 93 459 37 503 43 584 55 658 .67 731 80 866 I 08 991 1.39 500 48 540 55 615 .69 685 82 751 96 8/8 1 26 997 1 58 1106 1 92 542 63 579 .71 649 86 714 100 776 1 16 895 t 46 1007 1.80 1113 2 15 584 81 620 89 685 1 05 745 1 20 803 i 37 914 1/0 1020 2 05 1122 2 42 628 l 01 660 1 09 721 1 21 780 1 45 833 1 62 939 1 97 1039 2.34 1135 27? 672 1 24 702 I 33 7f>9 l 52 . 814 l 72 865 t 90 964 2.27 1060 2.66 1 ISO 3.06 715 1 51 743 1 61 798 1 8? 850 2 02 899 2 21 993 2 61 1083 3 01 1170 3.44 759 i 81 / 85 1 93 838 2.14 887 2 36 934 2 57 1023 2 99 1109 3.41 8U4 2.16 828 2 28 8/7 2 51 924 2 73 970 2 9/ 1056 3.41 * 848 2 55 872 2 67 918 2 91 963 3 16 1006 3.40 NOTE: Performance shown is for Junior Fans with outlet duct and with or without inlet duct. BHP shown does not include belt drive loss, but does include bearing drag. i_ 1..1 Tinted capacities indicate BHP requirements which may exceed maximum motor limitations . . . see below. COMPLETE PACKAGE MODEL NUMBERS Junior Model No. 125GD 125GB 125HB 125IB 125JB 125KB 125LB 125MB Motor HP RPM v3 1150 Va 1725 Vz 1725 % 1725 1 1750 1 Vz 1750 2 1750 3 1750 Adj, drive RPM range - 420 640 630 960 630.960 730/1110 84a 1240 920/1380 1040-T430 1190/1540 COMPLETE PACKAGE MODEL NUMBERS Junior Model No. Motor HP RPM Adj. drive RPM range 155G0 155HB 155IB 155JB v3 xh % 1 155KB-1 155KB-2 155LB 155M8 1 Vz 1 Vz 2 3 1150 1725 1725 1750 1750 1750 1750 1750 315/540 470715 550,830 590/870 650*900 720-980 740/1110 830/1150 MAXIMUM MOTOR LIMITATIONS Maximum motor frame4 Open TE ML dimension maximum overall motor length 182T 182T 14 3 4" Fiann* vary m length with mol nr niamifavtur^r. Ohr*.k NtMA dimension against ML dimension above if specific make ol motor is required. MINIMUM/MAXIMUM V-BELT DRIVE CENTER DISTANCES Motor frame size Minimummaiimum centers in inches 48 56, 143T. 145T 182T 7.75/10.75 7.25/10.25 8.25/9.75 VAB.OOOl106595 TH! 11 paof 7 m A VAB.0001K >6596 A VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHMEICAL PLANT IV. Process Piping Schedule The following piping schedule uses a system of numbers and letters as a line designation. This system denotes the following information: line size, service, line number, insulation requirements, and piping specifications. Sample Line Designation 8 - AV - 001 - N - A52 - 1 _Piping Specifications _ Insulation Requirement .Line Number .Service Nominal Size, Inches Sample Piping Designation A 52 - 1 First Specification of A52 Group i Piping Material Nominal Pressure Rating Designation AV Insulation Requirement N Nominal Pressure Rating A Piping Material 52 Service Ventilation Air None 150 Pound Class Galvanized Steel Duct VAB.0001106597 * I * PROCESS PIPING SCHEDULE Date -2- -/3- &5"~ Made By PROCESS ENGINEERING DEPARTMENT Project VCA\ i1 > * A Plant f 1 ft iJ S4 r r. > I *i V%V 4 * sm 3 41 1 f1 i*i f j*th *i jf) *j v c 4 t T. t i * VAB.0001106598 < ' own. fc' VAB.0001106599